Cl/OWI': RR/RD 5700 Series

Model No.
_
Cl\OWI' Serial No. _
)
{JQS5 ced~ J3/1

RR/RD 5700 Series
AC Traction
Service & Parts Manual
Crown 2009 PF17419 6109 Printed In U.SA

mown
New Bremen, Ohio 45869 USA
Phone 419/629-2311
crown.com
HOW TO ORDER SERVICE PARTS
To obtain fast, efficient service when ordering repair parts for your Crown Material Handling Equipment, please follow
this simple procedure:
1. Address all orders to your local Crown dealer.
2. Specify model and serial number of truck, which is shown on the serial number plate.
3. List the quantity needed.
4. List the part number and description, as shown in this Service Manual.
5. Show billing and shipping address.
6. Suggest fastest routing.
Your authorized Crown dealer stocks a large number ofstandard service parts. In addition, he has a factory-trained
Service Department to serve you.
Our Local Crown Dealer Is
NAME _
ADDRESS _
CITY _
STATE ZIP _
TELEPHONE _
The information in this manual is the latest available at the time of printing for the unit with which it was shipped.
Should there be any variation due to vendor changes or special options on ycmr unit, contact your Crown Dealer
or Crown at the above address.
Crown 1986 PF7609 Rev. 4101 Printed In U.SA

mawr. Crown Equipment Corporation
New Bremen, OH 45869 USA
Tel 419-629-2311
Fax 419-629-3796
crown.com
WARRANTY
Crown Equipment Corporation ("Crown") warrants to and for the sole benefit of the original purchaser of
material handling equipment sold by Crown, that such equipment is free from defects in material and
workmanship under normal and proper use, operation and maintenance. This warranty shall remain in effect
for a period of one (1) year after delivery of the equipment to the original purchaser with respect to:
• Power Units, Frames, Masts & Uft Structures • Major Electronic Modules & Circuit Boards
• Hydraulic Motors, Valves & Pumps • Motors
• Drive Units • Cylinders
The above warranty will remain in effect with respect to all other parts (including brushes, contactor tips.
and switches) for a period of ninety (90) days after such delivery.
Crown shall provide both the labor and the parts required to repair, or, at Crown's option, Crown shall replace
any part of the equipment which upon examination by Crown is determined by Crown to have been defective
during the applicable warranty period.
Notice of any claimed defect must be promptly given by the original purchaser to Crown or to an authorized
Crown dealer, and the claimed defective part promptly returned to Crown in New Bremen, Ohio, with
transportation charges prepaid.
Crown does not warrant and this warranty does not apply to batteries, chargers, tires or other trade
accessories or attachments not manufactured by Crown which are incorporated in or delivered with the
equipment and which are warranted by their respective manufacturers. Damage or defects from overloading
or other misuse, negligence, abuse, accident, failure to follow instructions, or from other causes having an
origin other than in the manufacture of the equipment are not within the scope of this warranty. Crown
reserves the right to make changes and improvements in the design and construction of its equipment
without thereby being obligated to make corresponding changes and improvements in previously manufactured
equipment.
The term "original purchaser" as used in this warranty means the customer to whom the equipment was
first delivered for use.
The warranty set forth herein is the complete and entire warranty made by Crown, and there are
no other warranties, expressed or implied, whether of merchantability, fitness for particular purpose,
or otherwise, made by Crown. No person is authorized to make any other or additional warranty
on behalf of Crown. The right to repair or replacement, as set forth herein, is the sole and exclusive
remedy for breach of the above warranty, and Crown shall not be liable for any damages, whe~her
direct, incidental, consequential or otherwise, occasioned by any breach of this warranty, or for
any charges or expenses of any nature incurred without Crown's consent, even though Crown has
been negligent. In no event shall Crown's liability under any claim exceed the purchase price of
the equipment in respect of which damages are claimed.
Crown, and the Crown logo are trademarks of Crown Equipment Corporation.
OF1795 Rev 4/10 Pmted In USA

mowr\ Crown Equipment Corporation
New Bremen, OH 45869 USA
Tel 419-629-2311
Fax 419-629-3796
crown.com
Limited Supplemental Warranty

For Crown Models Equipped With Access 123®... Control
Crown Equipment Corporation ("Crown") makes this limited Supplemental Warranty

to Crown's standard warranty for the sole benefit of the original purchaser of Crown
material handling equipment with Access 123@", Control. This limited Supplemental
Warranty shall remain in effect for a period of three (3) years after the date of delivery
to the original purchaser or 6,000 hours of use (whichever occurs first) with respect
to the following Access 123®", Control components:
• Standard and Enhanced Display Module (Access 1)

• Hydraulic Control Module (Access 2)
• Traction Control Module & AC Traction Drive Module (Access 3)
• Vehicle Control Module (Access 4)
• Steering Control Module (Access 5)
• Guidance Control Module (Access 6)
• Accessory Control Module (Access 7)
• Operator Control Module (Access 8)
• On-Demand Cooling Module (Access 9)
Applicable Crown Models:
• RR & RD 5200(S) • SR5285H .

• RR & RD 5700(S) • SH & SHR 5500
• RC 5500 • PC 4500
• TSP 6000 • SC 4500
• PE 4500 • SP 3400
• PR 4500 • SP 3500
• C5 1000 • FC 4500
Crown will provide this limited Supplemental Warranty for no additional charge for
new purchases of Crown models with Access 123®,., Control. Limited Supplemental
Warranty coverage includes Access 123®, .. Control parts and labor for the first year
and Access 123®, .. Control parts only coverage in years two and three up to 6,000
hours. Labor and other charges associated with repairs in years two and three are
the responsibility of the original purchaser.
This Limited Supplemental Warranty incorporates by this reference the terms and
conditions of the Crown standard warranty not in conflict with this Supplemental Warranty.
Crown, the Crown logo, Access 123, Access 123... and Access 3 are trademarks of Crown Equipment Corporation,
OF14276 Rev 4/10 Printed In USA

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Notes:
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TABLE OF CONTENTS
SAFETY PAGE
General Maintenance Instructions 3
Cleaning of Material Handling Equipment 5
Cleaning Methods 5
Control of Hazardous Energy 7
LockoutfTagout 7
Battery 7
Safety Rules 7
Battery Care 7
Charging 7
Battery Removal 8
Battery Installation 8
Lockout - Tagout 8
Capacitance 9
Releasing the Brakes 10
Tow Mode Method 10
Brake Release Service Tool Method 10
Mechanical Brake Release Method 11
Towing Truck 12
Towing by Pulling in Power Unit First Direction 12
Towing by Pulling in the Forks First Direction 12
Towing by Lifting Truck and Pulling in
Power Unit First Direction 12
Towing by Lifting Truck and
Pulling In the Forks First Direction 13
Hydraulic 14
Lifting and Blocking 15
Mast and Fork Carriage 16
Blocking Masts 16
Reach Mechanism 17
Tilt 17
INTRODUCTION PAGE
Introduction 21
Operator Instructions 21
Operator Training 21
Service Training 21
Replacement Parts 21
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LUBRICATION &ADJUSTMENT PAGE
Lubrication and Adjustment .....................•.... 27
Planned Maintenance . • . . . . . . . . . . . . . . 33
Overview 33
Component Access 34
Power Unit Console 34
Contactor Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Floorboard 35
Power Unit Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Left and Right Hand Reservoir Covers 35
Lubrication . . . . . . 35
Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Audible Indicators 54
ALM1 54
ALM2 54
HN 54
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ED1 54
ED2 56
P2 56
Encoders 56
ECR1 56
ECR2 56
ECR3 56
ECR4 58
ECR6 58
ECR7 58
Fans 58
FAN 1 58
FAN3 58
FAN4 60
FAN5 60
Fuses ......................................•...... 60
FU1 60
FU2 60
FU3 60
FU4 62
FU5 62
FU6 62
FU7 62
FU8 62
FU9 (AC Hydraulic Trucks) 62
FU9 (DC Hydraulic Trucks) 64
FU10 64
FU11 64
FU12 64
FU13 66
FU14 66
Lights 66
LGT1 66
LGT2, LGT3 66
LGT4 66
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Miscellaneous
BRK1 ........................•............. 68
LS 68
RES1 68
RES2 68
RES3 68
RES 4' 68
RES5 70
RES6············································ 70
RES8············································ 70
RES9 70
RES10 72
RES11 72
RES13 72
RES14 72
RES15 72
RES19 74
RES22" 74
RES23 74
RES24 74
RPS1 74
RPS2 76
THS4 76
THS5 76
TS1 76
TS2 76
TS4 : 78
Motors' : 78
~~:::::::::::::::::::::::::::::::::::::::::::::
M4... .
:;i
80
Potentlom~t~;s' 80
POT1 80
POT2 80
POT3:: 80
POT4 80
Relays : 82
~ ::::::::::::::::::::::::::::::::::::::::::::: J~
K11 ...........
.. . 82
K12. . 84
Solenold~' 84
PVA 84
PVL :: 84
SCV : 86
SVA 86
SVBY :: :86
SVL ....... 86
SVR ........... 86
............ .
SVS... 88
SVT ... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :::
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Switches 88
BRES1 88
BRES2 88
BRS1 90
DMS1 90
EDS 90
ENS 90
FLS 90
FNS 92
FS 92
HGTRS2 92
HNS 92
KYS 92
LGS1 94
LGS2 94
ORS 94
RS 94
SSS 96
TBS 96
TDS 96
Metric Torque Values 99
Grade 99
Torque Values 103
Grade 103
HYDRAULIC PAGE
Hydraulic System 107
Adding Hydraulic Oil 107
Hydraulic Lines and Fittings 107
Filter 108
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Secondary Lift Pump (P2) Cutout 108
Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Hoist Drift 109
lilt Drift 109
Hydraulic System Contamination 109
Main Lift Cylinder and Carriage Cylinder Contamination 109
Hydraulic Tank Contamination 111
Hydraulic Manifold Block Removal and Flushing 111
Hydraulic Circuits 117
Oil Flow for Hydraulic Steering 117
Hoist Raise, Dual Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Hoist Raise, Single Pump 122
Hoist Raise Stopped 123
Hoist Lower 124
Accessory Hydraulics 126
Hydraulic Schematic Symbols 133
Lift Pump 137
DC Lift Pump Disassembly 138
Parts Inspection 138
Mounting Flange and End Cover 138
Bushings 138
Gears 139
DC Lift Pump Assembly 140
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Load Sensing Flow Control Valve 141
Load Sensing Flow Control Valve Disassembly 141
Load Sensing Flow Control Valve Assembly 141
Initial Start Up Procedure 141
AC Lift Pump Disassembly 142
Parts Inspection 142
AC Lift Pump Assembly 142
Initial Start Up Procedure 143
Manifold Block 145
Relief Valves (RV1 & RV2) Operation 145
Adjustment 145
RV1 145
To adjust RV1 on AC trucks: 146
RV2 146
Proportional Valves (PVA & PVL) 147
Manifold Block O-Ring Replacement 147
Hydraulic Troubleshooting 153
DRIVE UNIT PAGE

Disassembly and Assembly 159
Drive Tire Replacement 159
Drive Unit Lubrication 161
Oil Pump Disassembly 161
Oil Pump Assembly 162
Under Carriage Inspections and Adjustments 163
Articulation Adjustment 164
RRiRD 5700 Series 164
RRiRD 5700S Series 166
Drive Unit Removal 168
Drive Unit Replacement 169
Drive Unit Dowel Pins 172
ELECTRICAL PAGE
Electrical System 175
Wiring Color Codes 175
Power Cables 175
Switches 179
Height Sensor 187
Removal and Disassembly 187
Assembly and Installation 188
Access 1 2 3® Menus 189
Quick Reference Guide 189
Operator Menus 190
User Code 190
Info Screen 190
Timer 190
Timer - Start 191
Timer - Stop 191
Timer - Reset 191
Trip 191
Height 191
Hours 191
Odometer 191
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Speed 191
Weight & Height 191
Model 191
Hour Meters 191
Event Codes 192
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Performance = ............................... 192
User Rack 192
User Rack - Show/Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
User Rack - Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
User Rack - Modify 193
User Rack - Loaded Offset 193
Rack Select 193
Next: LL Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Target: LL Height 193
Raise Only 193
Remote Raise/Lower 193
Rack Select Disabled 193
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Analyzer Access 277
Analyzer Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . 277
Calibration 286
When to Calibrate 286
Calibration Access 286
Calibration Procedures 287
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Features Access 292
Hour Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Hour Meters Access .. 296
Events 297
Events Access 297
Performance 298
Performance Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Utilities Access .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Capacity Data Monitor 305
Camera Setup 309
Keyboard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Standby Mode 310
Horizontal Bars 310
Locking the Keyboard 311
Language and Default Settings 311
Language 311
Default Settings 312
AC Traction Drive 313
Basics of System Operation 313
Control Circuit Operation 313
Power Circuit Operation 314
Contactor 315
Inspection 315
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Coil 315
Component Replacement 316
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Contact Replacement 316
Coil Replacement 316
Torque 316
Multi-Task Control Handle .................•.......... 317
Lubrication 317
Handle Harness Replacement 318
POT1 or POT2 Replacement 318
Battery 321
Safety Rules 321
Checking Battery 321
Battery Care 322
Charging Battery 322
Battery Removal & Installation (S Series Truck Shown) 323
Battery Removal 323
Battery Installation 324
Battery Cleaning 325
Troubleshooting 326
Motors 327
Traction Motor 327
Lift Pump Motor - AC Hydraulics 327
Lift Pump Motor - DC Hydraulics 327
24 V Trucks 327
36 V Trucks 327
Steer Motor 330
DC Motor and Brush Inspection 330
Event Code Introduction 331
Event Codes 333
Event Code 100 337
Event Code 102 337
Event Code 103 338
Event Code 104 339
Event Code 105 340
Event Code 111 340
Event Code 112 340
Event Code 113 340
Event Code 114 340
Event Code 115 341
Event Code 122 341
Event Code 123 342
Event Code 124 343
Event Code 125 344
Event Code 131 345
Event Code 134 345
Event Code 138 ..................•................. 345
Event Code 140 345
Event Code 141 345
Event Code 142 345
Event Code 200 346
Event Codes 201 346
Event Code 205 346
Event Code 221 347
Event Code 222 347
Event Code 223 348
Event Code 224 348
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Event Code 225 . . . . . . . . . . . •. . . . . . . . . . . . . . . . . . •. . 348
Event Code 226 ................................. 349
Event Code 227 ................................. 349
Event Code 228 ............................... 349
Event Code 229 350
Event Code 230 .................. 350
Event Code 231 351
Event Code 232 ....................... 352
Event Code 233 ....................... 353
Event Code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Event Code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Event Code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Event Code 237 ............... 355
Event Code 238 ............... 356
Event Code 239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Event Code 240 Through Event Code 244 356
Event Code 255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 256 .. . .. . . . . . . . . •. . . . . . . . . . . . .. . . . . . 357
Event Code 257 ................................. 357
Event Code 258 ................................. 358
Event Code 259 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Event Code 260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Event Code 261 359
Event Code 264
Event Code 265 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 266
Event Code 267 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 268
Event Code 269 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 270 .
Event Code 271 360
Event Code 272
Event Code 273 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Event Code 274
Event Code 275 360
Event Code 276
Event Code 277 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Event Code 278 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 279
Event Code 280 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 281
Event Code 282 ....................... 361
Event Code 283
Event Code 284 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Event Code 285
Event Code 286 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Event Code 301 363
Event Code 304 . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . 363
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Event Code 305
306 364
Event Code 322 ......••............................ 364
Event Code 323 365
Event Code 324 366
Event Code 325 366
Event Code 326 366
Event Code 327 367
Event Code 328 367
Event Code 329 367
Event Code 330 : 368
Event Code 331 369
Event Code 332 369
Event Code 333 370
Event Code 334 370
Event Code 335 371
Event Code 336 371
Event Code 337 372
Event Code 338 372
Event Code 339 372
Event Code 340 373
Event Code 341 373
Event Code 342 373
Event Code
Event Code 343
344 373
Event Code 345 374
Event Code 346 374
Event Code 347 375
Event Code
Event Code 348
349 375
Event Code 350 375
Event Code 351 376
Event Code 352 376
Event
Event Code
Code 353
354 .
376
Event Code 355 376
Event Code 356 376
Event Code 357 377
Event Code 359 378
Event Code 360 378
Event Code 361 379
Event Code 364 379
Event Code
Event Code 365
366 379
Event Code
Event Code 367
368 .......•............................ 380
Event Code 370

Event Code 369 .•.................................. 380
Event Code 371

Event Code 372 380
Event Code
Event Code 374
373 381
Event Code 375 .................................... 381
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Event Code 376
Event Code 377 381
Event Code 378 381
Event Code 379
Event Code 380 382
Event Code 381
Event Code 382 .. ...... ..... ..... .. 382
Event Code 383
Event Code 384 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Event Code 385
Event Code 386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Event Code 398 ................................•... 383
Event Code 400 .. ...... ..... ..... .. 384
Event Code 401 384
Event Code 402 ........... .. ........ ..... ..... .. 385
Event Code 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 404 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 405 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 406 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 407 386
Event Code 408 ........... ........ ..... ..... .. 386
Event Code 409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Code 410 388
Event Code 411 389
Event Code 415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Event Code 418 ...... .. ... ..... ..... ... ..... .. 391
Event Code 419 392
Event Code 420 ................................. 393
Event Code 421 394
Event Code 422 395
Event Code 423 ......................... 396
Event Code 424 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Event Code 425 ..•..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Event Code 426 . . . . . . . . . . . . . .. 399
Event Code 427 400
Event Code 428 .... 401
Event Code 432 401
Event Code 435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Event Code 436 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Event Code 438 ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Event Code 439 .. . . . .. . . . . . . . . . .. . •. . . . . . . . 404
Event Code 442 405
Event Code 443 405
Event Code 444 ...................................• 406
Event Code 445 406
Event Code 446 407
Event Code 447 407
Event Code 448 ....... 408
Event Code 449 .................. 408
Event Code 450 ....... 409
Event Code 451 .............................•...... 409
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Event Code 452 409
Event Code 453 .....•.............................. 410
Event Code 454 410
Event Code 455 410
Event Code 456 .........................•.......... 411
Event Code 457 411
Event Code 458 411
Event Code 459 .........•.......................... 412
Event Code 460 412
Event Code 461 412
Event Code 462 412
Event Code 463 413
Event Code 464 413
Event Code 465 414
Event Code 466 414
Event Code 467 415
Event Code 468 415
Event Code 469 416
Event Code 470 416
Event Code 471 417
Event Code 472 417
Event Code 473 418
Event Code 474 418
Event Code 475 419
Event Code 476 419
Event Code 477 420
Event Code 478 420
Event Code 479 420
Event Code 486 420
Event Code 487 420
Event Code 488 421
Event Code 489 421
Event Code 490 422
Event Code 491 422
Event Code 492 423
Event Code 493 423
Event Code 494 423
Event Code 495 424
Event Code 496 424
Event Code 497 424
Event Code 499 424
Event Code 500 425
Event Code 501 426
Event Code 502 427
Event Code 503
Event Code 504 .............•...................... 428
Event Code 505 429
Event Code 506 430
Event Code 507 432
Event Code 508 433
Event Code 509 433
Event Code 510 .............................•...... 433
Event Code 511 ............................••...... 433
Event Code 512 .................•.................. 434
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Event Code 513 ..................•.............•..• 435
Event Code 514 , 436
Event Code 517 438
Event Code 518
Event Code 519 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
Event Code 520
Event Code 521 439
Event Code 522 439
Event Code 523 •................................... 440
Event Code 526 .................. .......... .... .... 442
Event Code 527 . .. ... . . . . . . . . . . . . 442
Event Code 528 .. . ... . . . . . . .. . . . . 443
Event Code 550 .......•.......... . . . . . . . . . . . . . . . . . . 444
Event Code 551 445
Event Code 552 . .. ... . . . . . .. . . . . . 446
Event Code 553 447
Event Code 554 . . . . . . . . . .. . . . . . .. . . . ... . . . . . .. . . . . . 448
Event Code 600 . . . ... . . . . . . . . . . . . 448
Event Code 601 449
Event Code 602 .. 449
Event Code 603 .. . .. . . . . . . . . . . . .. ... . . . . . . . . . . . . 450
Event Code 604 . .. .. . . . .. . . . . . . . . . . . ... . . . . . . . . . . . . 450
Event Code 605 . . . .. . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . 450
Event Code 606 451
Event Code 607 . . . . . . . .. . ... . . . . . . . . . . . . 451
Event Code 608 451
Event Code 609 . . . ... . . . . . . . . . . . . 452
Event Code 610 ........... ..... .. 452
Event Code 614 453
Event Code 615 . .. . . . . . . . . . . . . . . . . . . ... . . . . . . . . .. . . 454
Event Code 619 454
Event Code 620 454
Event Code 621 455
Event Code 800 456
Event Code 801 456
Event Code 802 .. ........ ...... .... 457
Event Code 803 . . . . . . . . . . . . . . .. . . . . . ... . . . . . . . . . . . . 458
Event Code 804 . . . •. . . . . . . . . .. . . . . . . ... . . . . . . . . . . . . 459
Event Code 805 ....... 460
Event Code 806 .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Event Code 807 462
Event Code 808 463
Event Code 809 464
Event Code 810 465
Event Code 811 466
Event Code 812 ...•................................ 466
Event Code 815 467
Event Code 818 468
Event Code 819 469
XIV
TABLE OF CONTENTS
mow"
Event Code 820 469
Event Code 821 469
BRAKE PAGE
Brake System 473
Stopping Distance 473
Drive Brake (BRK1) 475
Air Gap Adjustment .475
Torque Gap Adjustment 476
Brake Assembly 477
Caster Brake (BRK2) 479
Caster Wheel and Brake Removal 480
Caster Wheel and Brake Inspection 481
Drum and Bearing Assembly 481
Caster Wheel and Brake Installation 482
STEERING PAGE
Hydraulic Steering System 489
Hydrostatic Steer Control Unit 489
Forward and Reverse Steering 489
Steer Tiller 489
Steer Tiller Disassembly 490
Steer Tiller Assembly 490
Steer Tiller 491
Steer Tiller Disassembly .491'
Removing Steer Motor from Carriage 492
Assembly of Steer Motor to Carriage 492
Steering Feedback Gear and Wheel Position
Sensor (RPS1) 493
Steering Feedback Gear Alignment 493
Traction/Steer Tire Alignment and RPS1 Calibration 494
Electronic Power Steering System 495
Steer Tiller 495
Steer Tiller Disassembly 495
Removing Steer Motor from Carriage 497
Assembly of Steer Motor to Carriage 497
Steering Feedback Gear and Wheel Position
Sensor(RPS1) 498
Steering Feedback Gear Alignment 498
Traction/Steer Tire Alignment and RPS 1 Calibration 499
Hydraulic Steer Motor 501
Disassembly 501
Steer Motor Assembly 502
Motor Timing 503
xv
CJ\own
LIFTING MECHANISM PAGE
Mast ..................................•.......... 507
Torque Requirements 507
Fork Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Mast Testing (Assembled) 507
Flaking .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Mast Staging Bumper Replacement 508
Mast Dampening Screws 508
Disassembly 510
Assembly 512
Flushing 515
Bleeding 516
Lift Chains 517
Inspection 517
Wear 517
Rust and Corrosion 518
Cracked Plates 518
Tight Joints 519
Protruding or Tumed Pins 519
Chain Side Wear 519
Lift Chain Lubrication 520
Lift Chain Replacement . . . . . . . . . . . . 520
Chain Anchors and PUlleys 521
Leaf Chain Disconnect 521
Disconnect Procedures: 521
Fork Inspection . . . . . . . . . . . . . . . . . . . . 523
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Overloading 525
Fatigue 526
Bent or Twisted Forks 526
Hanger , 527
CYLINDERS PAGE
Lift Cylinders 531
Cylinder Removal 531
Right & Left Hand Lift 531
Cylinder Replacement 535
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
Seals 537
Seal Removal 537
Seal Installation - General 538
Rod U-Cup Installation 538
Cylinder U-Cup Installation 540
Cylinder Assembly 540
Cylinder - Summary 540
Cylinder Bleeding and Flushing 541
Bleeding - Free Lift Cylinder 541
Bleeding - Stage Lift Cylinders 541
XVI
TABLE OF CONTENTS
CJ\owr.
Tilt Cylinder 543
Tilt Cylinder (Optional) 543
Disassembly 544
Rod Disassembly 544
Seal Replacement 544
Cylinder Reassembly 545
Tilt Cylinder Flushing and Bleeding Procedures 545
Flushing 545
Bleeding 545
PLATFORM PAGE
Reach Assembly 549
Reach Inspection 549
Poly Stop 549
Reach Cylinder Adjustment 549
Disassembly 550
Bushing Replacement (Reach Assembly Components) .551
Center Pivot Repair and Adjustment 552
Reassembly 552
Reach Cylinders Flushing and Bleeding Procedures 553
Bleeding 553
Reach Assembly 557
Reach Inspection 557
Poly Stop 557
Reach Cylinder Adjustment 557
Disassembly 558
Bushing Replacement (Reach Assembly Components) .560
Center Pivot Repair and Adjustment 560
Reassembly 561
Flushing 562
Bleeding 563
GLOSSARY PAGE
Glossary 567
XVII
TABLE OF CONTENTS
CAOWI'
WIRING DIAGRAMS PAGE
Introduction to Diagram Usage .............•.•..•.... 575
Schematic 575
Pictorials 575
Index 577
Electrical Schematic - All Trucks 578
Electrical Schematic - AC Traction & Hydraulics ....•... 579
Electrical Schematic - DC Hydraulics 580
Distribution Panel 581
Multi-Task Control Handle ...................•....... 582
ACCESS 3 - TCM & Motors 583
ACCESS 2 - HCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
ACCESS 1 - DM & Key Switch 586
42 Inch Freezer/Corrosion Package 587
48 inch Freezer/Corrosion Package 588
ACCESS 4 - VCM 589
Mast Cable & Options . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . 590
Brakes & Floorboard 591
Power Unit Hydraulics 592
Electronic Power Steering Control 593
42 Inch Power Cables - AC Hydraulics . . . . . . . . . 594
42 Inch Power Cables - DC Hydraulics ........•....•.. . 595
42 inch Power Cables - AC Hydraulics European 596
48 inch Power Cables - AC Hydraulics . . 597
48 inch Power Cables - DC Hydraulics 598
48 Inch Power Cables - AC Hydraulics European 599
Thermo Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
InfoLink 602
Mast Camera 603
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
HYDRAULIC SCHEMATIC PAGE

Hydraulic Schematic 609
POWER UNIT PARTS PAGE

Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
Floorboard . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . 626
Undercarriage Articulation 630
Mast Guard 632
Mast Guard 638
Battery Retainers and Spacers 642
Battery Retainers and Spacers 644
Battery Retainers and Spacers - EE 648
Battery Retainers and Spacers ....•.................. 650
Overhead Guard 654
Overhead Guard ....•.............................. 656
XVIII
TABLE OF CONTENTS
CJ\owr.
HYDRAULIC PARTS PAGE
AC Hydraulic Reservoir 660
DC Hydraulic Reservoir 664
Manifold Block Hydraulics 670
Steering Control 672
Reach Hydraulics 674
Reach Hydraulics with Tilt & Sideshift 676
Mast Hydraulics - TT 680
Drive In Rack Mast Hydraulics - TT 684
DC/AC Lift Pump 688
36 V 10 cc Lift Pump 690
25 cc AC Lift Pump 692
AC Lift Pump Motor 694
DC Lift Pump Motor 698
AC Lift Pump Motor - EE 700
Manifold Block 704
Reach Assembly Manifolds 708
DRIVE UNIT PARTS PAGE

Drive Unit 712
Drive Unit Lubrication System 718
Traction Motor - M1 720
EE Traction Motor - M1 722
Traction Tire 724
ELECTRICAL PARTS PAGE

Electrical Components AC 730
Electrical Components DC 736
Contactors & Fuses 742
Contactors & Fuses EE 746
Distribution Panel 750
Contactor 752
Contactor 754
Contactor - EE 756
Multi-Task Control Handle 758
ACCESS 1 - Enhanced/COM Display 766
Height Sensor ..•................................... 770
Control Cable - TT Mast 772
Connectors 776
Strobe Light 780
Freezer Corrosion 782
Overhead Guard Accessories 784
BRAKE PARTS PAGE

Caster 790
Brake 792
XIX
l!J\OWI'
STEERING PARTS PAGE
Hydraulic Steering System 796
Steering Feedback Sensor 808
Steer Motor 810
Electronic Power Steering Motor 812
Steer Control Unit 814
LIFTING MECHANISM PARTS PAGE

Removable Outrigger Ends 818
Mast· TT 144 mm (5.69 In) Channel 822
Mast· TT 184 mm (7.25 In) Channel 838
TT • Drive In Rack Mast 856
Load Wheel 872
Load Wheel· Field Application Guide 880
Yoke 882
Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 884
Fork 886
CYLINDER PARTS PAGE

TT Lift Cylinder 892
TT Carriage Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 896
Reach Cylinder 898
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900
Sideshift Cylinder 902
REACH MECHANISM PARTS PAGE

Reach with Tilt • RR 906
Reach with Tilt & Sideshift • RR 910
Reach With Tilt· RD 916
Reach With Tilt & Sideshift • RD 922
LABELS AND DECALS PAGE

InfoLlnk Accessories 932
Work Assist Tube .............................•.... 934
Work Assist Tube Accessories 936
Camera 940
Labels & Decals 944
Labels & Decals SAA 954
Labels & Decals China ..........................•... 964
xx
mown
SAFETY
1
CAOWI'
Notes:
2
SAFETY
CAOWI' General Maintenance Instructions
General Maintenance Instructions 5. Before starting to operate truck-

- Be in operating position.
it WARNING -
-
Apply brake.
Place directional control in neutral.
TO PREVENT SERIOUS RISK OF INJURY TO
YOURSELF AND OTHERS OBSERVE THE FOL- - Before operating truck, check functions of lift
LOWING SAFETY INSTRUCTIONS systems, directional control, speed control, steer-
Power industrial trucks may become hazardous if ade- ing, warning devices, brakes and any attachments
quate maintenance is neglected. Therefore, adequate if any used.
maintenance facilities, trained personnel and proce- 6. Avoid fire hazards and have fire protection equip-
dures should be provided. ment present. Do not use an open flame to check
Maintenance and inspection shall be performed in con- level, or for leakage of electrolyte and fluids or oil.
formance with the following practices: Do not use open pans of fuel or flammable clean-
ing fluids for cleaning parts.
1. A scheduled planned maintenance, lubrication,
and inspection system should be followed. 7. Keep shop well ventilated, clean and dry.
2. Only qualified and authorized personnel shall be 8. Brakes, steering mechanisms, control mecha-
permitted to maintain, repair, adjust and inspect nisms, lift overload devices, guards, and safety de-
truck. vices shall be inspected regularly and maintained
in a safe operating condition.
3. Before leaving the truck-
- All guards must be installed to factory configu-
- Stop truck. ration and condition before operating truck. Do not
- Fully lower the load engaging means. operate truck if any guards or fasteners are dam-
aged, improperly installed or missing.
- Place directional controls in neutral.
9. Capacity, operation and maintenance instruction
- Apply the parking brake. plates or decals shall be maintained in legible con-
- Turn off power (power disconnect). dition.
- Remove key. 10. All parts of lift mechanisms shall be inspected to

maintain them in safe operating condition.
Block the wheels if truck is on an incline.
11. All hydraulic systems shall be regularly inspected
4. Before working on truck- and maintained in conformance with good practice.
- Raise drive wheel free of floor or disconnect Cylinders, valves, and other similar parts shall be
power sources. checked to assure that "drift" has not developed to
the extent that it would create a hazard.
- Use chocks or other positive positioning de-
vices. 12. Batteries, motors, controllers, limit switches, pro-
tective devices, electrical conductors, and connec-
- Block load engaging means, inter masts, or tions shall be maintained in conformance with
chassis before working under them. good practice. Special attention shall be paid to the
- Operation to check performance of truck or at- condition of electrical insulation.
tachments shall be conducted in an authorized 13. Trucks shall be kept in a clean condition to mini-
safe clearance area. mize fire hazards and facilitate detection of loose
or defective parts.
Crown 1976 PF2821-1 Rev. 10/06 MA..Q4.0-001

05 Rev. 10/08
3
SAFETY
General Maintenance Instructions CJ\OWI'
14. Modifications and additions which affect capacity
and safe truck operation shall not be performed by
the customer or user without manufacturers prior
written approval. Capacity, operation and mainte-
nance plates or decals shall be changed accord-
ingly.
- Adding electrical devices (radio, terminal,
lights, etc.) or changing existing components or
wiring can affect truck operation and could cause
an accident. Contact authorized Crown personnel
before adding to or changing the electrical system
in anyway.
- For EE rated trucks, adding electrical devices
could cause a fire or explosion, as well as void the
EE rating. Written approval must be obtained from
Crown prior to adding electrical device(s). Prior to
use, inspection of installed device(s) must be per-
formed by an appropriate nationally recognized
testing laboratory (Le. Underwriters Laboratories
Inc) orthe Authority Having Jurisdiction (see NFPA
505).
15. Care shall be taken to assure that all replacement
parts are interchangeable with the original parts
and of equal quality to that provided in the original
equipment.
16. Be sure that any equipment added to the truck (ter-
minal, fan, clipboard, etc.) is positioned so that it
does not block your vision or interfere with safe and
efficient operation of the truck.
For further information pertaining to operating and
maintenance procedures:
• All trucks except Series B and Tow Tractors, refer

to current ASME B56.1.
• Series B trucks, refer to current ASME B56.10.
• Tow Tractors, refer to current ASME B56.9.
MA-04.0-002 Crown 1976 PF 2821-2 Rev. 10/08
05 Rev. 10/08
4
SAFETY
CJ\OWI' Cleaning of Material Handling Equipment
Cleaning of Material Handling operation or immediate failure could be the resultant of

power washing. For these reasons all electronic com-
Equipment ponents including motors must be protected. Compo-
nent removal is the best method to eliminate the risk of
damage.
Cleaning Methods
Power washing will also remove or destroy lubricants in
The preferred method of cleaning built up dirt and dust or on the surface of shafts, unsealed bearings, hinges,
from electric material handling equipment is dry pres- exposed gears, bushings, chains, linkages, etc. These
sured air. For localized degreasing, use of an appropri- items must also be protected or properly lubricated af-
ate solvent is recommended. ter cleaning.
If these methods are not effective and power washing Consideration must also be given to metal surfaces.
is the only altemative, extreme care must be exercised. The cleaning process can strip away paint and protec-
Electrical components including connectors, terminal tive coatings applied to components (Le., hydraulic
boards and wiring can be permanently damaged from lines, terminal strips, linkages) for freezer/condition en-
water or cleaning solvents. Mineral and chemical resi- vironment. Paint or protective coating must be reap-
due left on or in components (Le., circuit boards, con- plied to these areas to reduce the chance of oxidation
tactors, encoders, switches, potentiometers, etc.) after and corrosion.
washing is a proponent of oxidation and corrosion.
Before installing removed components, lubricating or
Functional integrity of contaminated components may retuming the equipment to service it must be free of
be questionable. Nuisance fault logging, intermittent solvent residue and thoroughly dry.
Crown Cleaning Products Chart

,
Cleaner Type Part Number Package Quantity

Degreaser & Cleaner 363105-001 20 oz Can
363105-012 (12) 20 oz Cans
All Purpose Cleaner 363114-001 20 oz Can
363114-012 (12) 20 oz Cans
Glass Cleaner 363101-001 20 oz Can
363101-012 (12) 20 oz Cans
Waterless Hand Cleaner 363111-001 15 oz Tube
363111-012 (12) 15 oz Tubes
Pumiced & Smooth Hand Cleaner 363112-001 1 Gallon Jug
363112-004 (4) 1 Gallon Jugs
Wall Mounted Deluxe Soap Dispenser 363122 Used with 363112-001
Tough On Grease 063009-005 1 Gallon Jug
Citrus Degreaser Spray 363134-001 32 oz spray bottle
363134-012 (12) 32 oz spray bottles
Citrus Degreaser Spray 36135-001 1 Gallon refill used with 363134-001
363140-101 1 Gallon concentrated used with 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
Crown 2000 PFll969-1 Rev. 6110 MA-114Q-050

03 Rev. 6/10
5
CROWl'
Notes:
6
SAFETY
CJ\OWI' Control of Hazardous Energy
Control of Hazardous Energy Do not allow dirt, cleaning solution or other foreign
material to enter cells. Impurities in electrolyte has
a neutralizing effect reducing available charge.
LockoutlTagout If battery repair is planned, follow the battery man-
In the interest of safety and to ensure compliance with ufacturer's instructions concerning repair practices
OSHA Regulations, (Standards - 29 CFR), Control of and procedures.
Hazardous Energy (LockoutfTagout) - 1910.147,
Crown has developed guidelines for proper energy Battery Care
control when performing service and maintenance on
the truck. Before performing any service or mainte-
nance, review the appropriate sections in this service
manual for any additional procedures to be followed.
Lh CAUTION
Only qualified and experienced personnel should per-
In addition, Crown recommends that all mechanics form maintenance and repair on batteries.
wear appropriate protective items, such as safety Make certain the charger being used matches the
glasses, work gloves, and steel-toed shoes, whenever voltage and amperage of the truck battery. This
performing service or maintenance work on Crown voltage is listed on the truck serial plate.
equipment.
Before disconnecting or connecting batteries to a
charger, make sure charger is OFF. If an attempt is
Battery made to do this while charger is ON, serious injury
to you, the battery and charger could result.
Safety Rules Never use a match or lighter. Battery fumes are ex-
Wear protective clothing, such as, rubber apron, plosive.
gloves, boots and full-face shield when performing Make certain battery used meets weight, size and
any maintenance on batteries. Do not allow elec- voltage requirements of truck (refer to serial plate).
trolyte to come in contact with eyes, skin, clothing NEVER operate truck with an undersized battery.
or floor. If electrolyte comes in contact with eyes,
flush immediately and thoroughly with clean water.
Charging
Obtain medical attention immediately. Should elec-
trolyte be spilled on skin, rinse promptly with clean
water and wash with soap. A baking soda solution
(453.6 grams (1 Ib) to 3.79 Litre (1 gal) of water)
& CAUTION
will neutralize acid spilled on clothing, floor or any Never smoke or bring flame near the battery. Gas
other surface. Apply solution until bubbling stops formed during charging is highly explosive and can
and rinse with clean water. cause serious injury.
Keep vent plugs firmly in place at all times except Consult the charger manufacturer's manual covering
when adding water or taking hydrometer readings. your charger for hints on operation and maintenance.
Do not bring any type of flame, spark, etc., near the

battery. Gas formed while the battery is charging,
is highly explosive. This gas remains in the cells
long after charging has stopped.
Do not lay metallic or conductive objects on bat-
tery. Arcing will result.
Crown 2008 PF17657-1 MA-1457-100
7
SAFETY
Control of Hazardous Energy CJ\OWI'
Battery Removal
Lt CAUTION
Lt CAUTION Make certain battery used meets weight, size and volt-
age requirements of truck (refer to serial plate).
When removing the battery, move truck to area in- NEVER operate truck with an undersized battery.
tended for battery care. Floor must be level. Tum key
switch or toggle switch to OFF position and remove
Lockout - Tagout
key. Disconnect battery and lockout or tagout truck as
described in LockoutfTagout in this section. Never Always turn key switch to OFF, remove key and apply
move battery partially from truck without roller stand in tag (1) to multifunction control (2) or steering tiller (3)
place. Lower load engaging means compfetely. If bat- with cable tie warning others truck is being serviced.
tery is removed with load engaging means raised, use Refer to Figure 20916.
hoist attached to mast to provide tip overprotection. Do
not allow any metallic object to come in contact with the
top of the battery cells. This may cause a short circuit
when removing, transporting the battery. Use an insu-
lator, such as pfywood, to cover the top of the battery
before and during removal.
Figure 20916
When maintenance is to be performed and the battery

will be left in the truck, disconnect battery, remove the
main power fuses and install a commercially available
lockout device on the battery connector.
When maintenance is performed and the battery is re-
Figure 8251 moved from the truck, remove main power fuses, install
a lockout device on the trucks battery connector if pos-
sible, or if possible install a tag with a cable tie on the
Battery Installation trucks battery connector so it cannot be removed easily
warning that the truck is not available for operation.
Lt CAUTION
When installing the battery, move truck to area in-
tended for battery care. Floor must be level. Tum key
switch or toggle switch to OFF position and remove
key. Lockout or tagout truck as described in Lockout!
Tagout in this section. Ifbattery 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
installation.
MA-1457-101 Crown 2008 PF17657-2
8
SAFETY
Capacitance
Due to capacitance voltage present in the ACCESS 2
and ACCESS 3 modules, whenever performing main-
tenance which may permit contact with the bus bars
and associated power cables, discharge the capaci-
tors.
1. Move truck to a secure non-traffic maintenance
area with a level floor.
2. Chock truck wheels. Refer to Lifting and Blocking
in this section.
3. Disconnect battery. LockouVTagout truck as de-
scribed in LockouVTagout in this section.
4. Tum and hold the key switch to the start position a
minimum of 10 seconds.
5. To verify the capacitors have discharged, place a ACCESS 2 (DC Hydraulics)
volt meter across the B+ and B- terminals of
ACCESS 2. The voltage should be less than 1 V. Figure 21212
Repeat the procedure on ACCESS 3.
6. Tum key switch to OFF and remove key.
o o
ACCESS 2 (AC Hydraulics)
Figure 21150
Figure 21077
1 ACCESS 1 Display
2 ACCESS 2 Hydraulic Control Module (under cover)
3 ACCESS 3 Traction Control Module (under cover)
4 ACCESS 4 Vehicle Control Module (under cover)
5 ACCESS 5 Steering Control Module - Optional (under cover)
Crown 2008 PF17657-3 MA-1457-102
9
SAFETY
Releasing the Brakes Brake Release Service Tool Method
There are several ways to release the brakes in a During a maintenance situation in which the Tow Mode
maintenance situation. Each method has varying de- Method cannot be used to release the brakes, the
grees of operator control. The preferred method to re- brake release service tool, part number 127373, is the
lease the brakes is through the ACCESS 123 Utilities next best option. This method cannot be used in the
Menu. event of an electrical failure within the drive circuitry,
the tow circuitry or the brake. An operator may be pres-
ent on the truck.
Tow Mode Method
~
The preferred method to release the brakes in a main-
tenance situation is through the ACCESS 123 Utilities WARNING
Menu. Use this method only if the truck is electronically Use extreme care when releasing the brakes using the
functional and the operator is present on the truck. brake release service tool. The truck will be free-wheel-
ing and the brake pedal in the operator compartment
NOTE will have no effect on braking. The truck will not have
traction. There will be no power steering on a hydrauli-
When tow mode is active, the brakes can be released
cally steered truck and no steering control on an elec-
and traction will be inhibited. Steering will be active.
trically steered truck.
1. Lower load engaging means completely.
Connecting Brake Release Service Tool
2. Lockout or Tagout truck as described in LockouU
Tagout in this section. 1. Lower load engaging means completely.
3. Chock wheels or make sure truck is secured by 2. Lockout or Tagout truck as described in LockouU
some means to prevent it from rolling. Tagout in this section.
4. Use the ACCESS 1 to enter the Utilities Menu and 3. Chock wheels or make sure truck is secured by
scroll to the U2 Tow Mode to activate the tow mode some means to keep it from rolling.
function. Refer to the ACCESS 123 c apter for
4. Disconnect CA609 at the traction motor brake and
more information.
connect the brake release service tool to the brake
5. In order to maintain the brakes in the released po- connector.
sition, the operator must keep his or her feet on
5. Plug the battery connector of the brake release
both brake pedals. If the operator releases either
service tool to the battery.
pedal, the brakes will be applied.
6. Move the power switch on the brake release ser-
vice tool to ON.
7. Toggle the brake release switch to release the
brakes.
8. Remove wheel chocks and move truck to area in-
tended for maintenance. When towing the truck,
make sure all operators and pedestrians are in-
formed of the truck's lack of braking and steering
(for electric steer trucks). Refer to Towing Truck in
this section for proper towing procedures.
Applying the Brakes

To apply the brakes, move the power switch on the
brake release service tool to OFF.
MA-1457-103 Crown 2008 PF17657-4
10
SAFETY
Disconnecting Brake Release Service Tool 4. Use a spanner wrench, a punch or a screwdriver to
tum the torque adjuster plate. Doing so removes
1. Move the service tool power switch to OFF.
the spring preload.
2. Disconnect the battery connector.
5. Remove wheel chocks and move truck to area in-
3. Unplug service tool from the brake connector. tended for maintenance. When towing the truck,
make sure all operators and pedestrians are in-
4. Connect the harness connector to the brake con-
formed ofthe truck's lack of braking and steering {if
nector.
e-steer truck}. Refer to Towing Truck in this section
for proper towing procedures.
6. To reapply the brake, tum the torque adjuster plate
back to its original position to achieve the proper
spring load.
LL WARNING
Failure to return the adjuster plate to its original posi-
tion will cause the truck to have no braking.
7. Coat the top surface of the adjuster plate with a thin
layer of lubricant to reduce likelihood of bending
compression springs.
8. Refer to Torque Gap Adjustment in the Brake sec-
tion of this manual for factory settings.
Figure 8255
Mechanical Brake Release Method

In the event the truck has a failure that prevents the
brake from being electrically released by either of the
above methods, release the brake mechanically.
LL WARNING
Use extreme care when releasing the brake using the
manual brake release method. The truck will be free-
wheeling and the brake pedal in the operator compart-
ment will have no effect on braking. With the truck OFF,
the truck will not have traction or power steering on a
hydraulically steered truck. There will be no steering
control on an electrically steered truck. An operator is
not required on the truck.
1. Lower load engaging means completely.
2. Lockout or Tagout truck as described in Lockout!
Tagout in this section.
3. Chock wheels or make sure truck is secured by
some means to prevent it from rolling.
Crown 2008 PF17657-5 MA-1457-104
11
SAFETY
Towing Truck Towing Device Requirements:
• Towing device must have pulling and braking ca-
Refer to the following guidelines when towing the truck:
pacity greater than 3900 kg (8600 Ib).
Towing by Pulling in Power Unit First When attaching towing device to lift truck to be
towed, firmly attach tow device to rear, lower por-
Direction
tion of power unit skirt, within ± 51 mm (2.0 in) of
This towing method is used only when steering is avail- truck center. Fasten so as not to loosen or disen-
able. gage during towing.
Towing Guidelines:
~ WARNING Maximum travel speed while towing truck is
Towed truck must always maintain three contact 3.2 km/h (2 mph).
points with floor and towing device.
Maximum travel speed while towing truck is Towing by Pulling in the Forks First
3.2 km/h (2 mph). Direction
Do not make sharp turns when lifting or towing
truck.
Towed vehicle forks should be empty and no more ~ WARNING
than 305 mm (12.0 in) off floor. Ifpossible, tiltforks
Towing by pulling in the forks first direction is not
back and center sideshifter.
recommended.
Extreme care must be taken when using this
method to tow truck. With brakes released on un-
even surfaces, vehicle will roll. Towing by Lifting Truck and Pulling in
• Provide a safe distance for truck to coast to stop. Power Unit First Direction
Excessive acceleration by towing vehicle, or drag
This towing method is used when steering is not avail-
caused by towed vehicle (i.e., brake drag, drive
able.
unit drag, wheel drag, etc.) will greatly increase re-
quirements to pull or push a vehicle.
Preparing Truck For Towing: ~ WARNING
Refer to Releasing the Brakes in this section to re- Do not lift towed truck higher than 51 mm (2.0 in)
lease the brakes for towing. off floor.
Towed truck must always maintain three contact
points with floor and towing device.
~ WARNING Maximum travel speed while towing truck is
3.2 kmlh (2 mph).
Truck may be difficult to steer. Use extreme caution.
Do not make sharp turns when towing truck in
Driver will be required to steer truck, as there is no raised condition.
power assist from hydraulics. For applying brakes, • Towed vehicle forks should be empty and no more
refer to Applying the Brakes in this section. than 305 mm (12.0 in) offfloor. Ifpossible, tiltforks
back and center sideshifter.
Depending on brake release method truck may
need to coast to stop. Preparing Truck For Towing:
Operator actions: see WARNINGS above. Turn power OFF.
Crown 2008 PF17657~

MA-1457-105
12
SAFETY
CJ\owr. Control of Hazardous Energy
Towing Device Requirements:

Towing device must have lifting capacity of 2722 kg
(6000 Ib) at lift position at rear of skirt, when towing
vehicles 10,160 mm (400 in}and below. For trucks
above 10.160 mm (400 in), towing device must
have a minimum lifting capacity of 2950 kg
(6500Ib).
Towing device must have pulling, pushing and
braking capacity greater than 3900 kg (8600 Ib).
Ensure that a stem or ball capable of stated pulling,
pushing, braking capacity and of such a design as
to prevent disengagement during towing operation,
is used.
When attaching towing device to lift truck being
towed. engage to rear, lower portion of power unit
skirt, within ± 51 mm (2.0 in) of truck center.
Towing Guidelines:
Lh WARNING
Truck will be difficult to maneuver. Use extreme cau-
tion.
Maximum travel speed while towing truck is
3.2 km/h (2 mph).
No operator should be on lifted and towed truck.
Operator actions: see WARNINGS above.
Towing by Lifting Truck and

Pulling in the Forks First Direction
LL WARNING
Towing by lifting truck and pulling in the forks first
direction is not recommended.
Crown 2008 PF17657-7 MA-1457-106
13
SAFETY
Hydraulic
Lt 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 ofpain, and serious tissue damage
may occur. Medical attention should be sought imme-
diately by a specialist who has had experience with this
type of injury.
When maintenance is to be performed on the hydraulic
system, to make sure the hydraulic system is not under
pressure:
1. Move truck to a secure non-tr,affic maintenance Figure 21074
area with a level floor. No load on forks.
1 Lower mast completely, including fork carriage
2. Completely lower load engaging means, mast and
fork carriage or, if required for maintenance, block 2 Retract reach mechanism all the way
mast sections at appropriate height as described in 3 Tilt forks down completely
Lifting and Blocking - Mast of this section.
3. Completely retract reach mechanism or, if required
for maintenance, block extended reach mecha-
nism as described in Lifting and Blocking - Reach
Mechanism of this section.
4. Tilt forks tips all the way down. Do not continue to
tilt after fork tips are down to keep pressure from
building up at the tilt cylinder.
5. Tum key switch to OFF, remove key.
6. Disconnect battery. Lockout or tagout truck as de-
scribed in Lockoutrragout in this section.
7. Open manual lower valve to relieve hydraulic pres-
sure.
MA-1457-107 Crown 2008 PF17657-8
14
SAFETY
CROWl' Control of Hazardous Energy
Lifting and Blocking Equipment Capacities Required:

• .Hydraulic jack capacity: 3620 kg (8000 Ib)
• Crown part number: 122599
• Collapsed height minimum: 60 mm (2.25 in)
• Raised height maximum: 400 mm (16 in)
Jack stand capacity: 4500 kg (10000 Ib)
• Commercially available.
Lt WARNING
Truck stability decreases dramatically if load wheels
are raised more than 13 mm (0.5 in). Attach sling and
overhead lifting device to all cross members of the
mast to prevent truck from tipping over when raising
the side of the truck.
Figure 21075
1 Lower forks and move towards center of truck if required

2 Chock load wheels with hardwood block
Move truck to a secure non-traffic maintenance

No load on forks.
• Lockout or tagout truck as described in Lockout! 2
Figure 21076
1 Raise forks 70 to 150 mm (3.0 to 6.0 in) from floor

2 Chock both load wheels
3 Set jack stand as required - not to exceed
400 mm (16.0 in)
Crown 2008 PF17657-9 MA-1457-108
15
SAFETY
Control of Hazardous Energy CJ\OW"
Mast and Fork Carriage
Blocking Masts
Use 100 x 100 mm (4 x 4 in) or bigger hardwood blocks
of the appropriate length for supporting mast channels.
Block both mast rails of each stage to maintain stability.
Remove any carriage mounted accessory Le., carton
clamp, slip sheet, roll loader, etc. except sideshifters
before blocking masts. These accessories add signifi-
cant weight to the mast.
2. Chock wheels of truck. Refer to Lifting and Block-
ing in this section.
3. Connect battery.
4. Raise forks and position block under second stage
mast. 3 4
5. Using a clamp, secure block to mast channel. Figure 15989-02

6. Lower mast and position appropriate length block
1 Third Stage Block
under third stage mast.
2 Second Stage Block
7. Using a clamp, secure block to mast channel or
3 Clamp blocks together
second stage block.
4 Clamp block to main frame
8. Lower fork carriage until carriage rests on stops or
place block under carriage and lower until weight
rests on block.
9. Lockout or tagout truck as described in LockouU
Figure 15990
MA-1457-109 Crown 2008 PF17657-10
16
SAFETY
CJ\OWrl Control of Hazardous Energy
Reach Mechanism Tilt

1. Move truck to a secure non-traffic maintenance 1. Move truck to a secure non-traffic maintenance
area with a level floor. No load on forks. area with a level floor. No load on forks.
2. Chock wheels of truck. Refer to Lifting and Block- 2. Chock wheels of truck. Refer to Lifting and Block-
ing in this section. ing in this section.
3. Extend reach assembly. 3. Tilt forks down so weight of carriage is not on the
tilt cylinder.
4. Clamp a 50 x 100 mm (2 x 4 in) hardwood block in
either left or right channel of reach support assem- 4. Lockout or tagout truck as described in LockouV
bly below the roller. Tagout in this section.
5. Relieve hydraulic pressure from reach circuit by re-
tracting carriage until roller rests on block.
6. If mast is staged refer to Mast in this section for
blocking instructions.
7. Lockout or tagout truck as described in LockouV
Figure 21074
1 Lower mast completely, including fork carriage

2 Tilt forks down completely
Figure 15991-02 3 Retract reach mechanism all the way
1 Cut away for clarity

2 Clamp
3 Hardwood Block
Crown 2008 PF17657·11 MA-1457-110
17
CROWl'
Notes:
18
mown
INTRODUCTION
19
CROWl'
Notes:
20
INTRODUCTION
CAOWf\ Introduction
Introduction Service Training

This manual is intended for the service mechanic who Complete Service Training is available for 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 mechanic 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 operator 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 operator instructions, refer to For current part number of service manuals, operator
Crown publications, ·Operator Manual RRIRD 5700 manuals, operator training programs, truck capacities
Series·, "Operator Manual RRIRD 5700S Series". and technical specifications, contact your local Crown
dealer or at www.crown.com.
Operator Training This manual is arranged according to major sections
which cover maintenance and replacement parts. The
Crown produces a complete series of operator training
sectional descriptions are as follows:
programs available through your local Crown dealer. A
complete listing of these and other available programs
can also be found under "Training" on
www.crown.com.
Maintenance Replacement Parts
Section Description Section Description

M1 Lubrication and Adjustment 1 Basic Chassis Power Unit
M2 Hydraulic 2 Hydraulic System & Components
M3 Drive Unit 3 Drive Unit & Components
M4 Electrical 4 Electrical Components
M5 Brake 5 Brake Assemblies & Brake Systems
M6 Steering 6 Steering System & Components
M7 Mast and Main Frame 7 Main Frame and Mast Assemblies
M8 Cylinder 8 Cylinders
M9 Reach Assembly 9 Reach Assembly
M10 Glossary 10 Accessories
11 Specifications
Crown 2008 PF17422-1 ITD-1457-001
21
INTRODUCTION
Introduction CJ\own
The data plate for the RR/RD 5700 series truck is lo-
cated on the cover below the operator back rest/seat
and includes a model number and truck data number.
From these two numbers, you can identify the truck
model, series and series updates, determine relative
size or performance, capacity and specific truck data.
The following pages explain the model & truck data
numbering system.
...,......
~~~fqAomI~
..,
1lIl. . .t.....,ta
Ma
........
...,.... IIlC. YIIIIIt ...",1Ir.
........... lfl1
... FlIllIllllM %
-3
laid 1lIW 1l'IId WIdII
........... ...111l1li*
0
1IIlII ..... FlIll .......
Figure 20923
1 RRIRD 5700
2 RRIRD 57005
3 Truck Data Plate
ITD-1457-002 Crown 2008 PF17422-2
22
INTRODUCTION
CJ\owr. Introduction
MODEL NUMBER EXAMPLE

Series Update S =1220 mm (48 in) Power Unit Width
Significant change{s) to the product that
would not merit a new series number
(generation).
~-- *Capacity
=
30 1360 kg (3000 Ib)
Image Generator =
35 1585 kg (3500 Ib)
RR - Rider Reach
RD - Rider Double Reach
1RR5715 -35
=
40 1815 kg
=
45 2040 kg
(4000
(4500
Ib)
lb)
series--JT
Major technical and design changes
making the product a new and Relative Size or Performance
improved generation. 15 = 24 V, AC Drive Lift height up to 6860 mm (270 in)
25 = 36 V, AC Drive, Lift height up to 10160 mm (400 in)
95 = 36 V, AC Drive, Lift height up to 11225 mm (442 in), upper
footrest area, adjustable seat
The example of the model number shown above The example of the truck data number shown on the
(RR5715-35) is a RR 5700 series. It has a 24 volt elec- following page is an AC traction drive truck with tele-
trical system and 1585 kg (3500 Ib) capacity. scopic triple stage mast, 6095 mm (240 in) lift height, C
size battery compartment, inside straddle dimension of
*Actual rated capacity may vary, depending on special
865 mm (34 in), without freezer condition, 100 mm x
equipment or modifications. Consult capacity plate lo-
105 mm (4 in x 4.1 in) load wheels, poly drive tire, side-
cated on the power unit console.
shift, forward steering, without lights and travel alarm,
bolt on outriggers, enhanced display, and AC lift pump.
Crown 2008 PF17422-3 ITD-1457-003
23
INTRODUCTION
Introduction CROWl'
The truck data number provides you and your Crown simply provide this number to your Crown dealer, or
deafer with a wealth of information to ensure the selec- use the following breakdown if selecting your own part
tion of proper parts for your Crown truck. You may numbers or service information from this manual.
Cold Conditioning/EE Rating - - - , Drive Tires ------, r-- Steering

- = No Cold Conditioning/No EE Rating * = Special F = Forward
C = Corrosion Conditioning/No EE Rating 1 = Standard R = Reverse
F = Freezer Conditioning/No EE Rating 2 = Siped e- Outriggers
E = No Cold Conditioning/EE Rating 3 = Center Groove - = Standard
D = Corrosion Conditioning/EE Rating 4 = Non Marking B = Bolt On
T = Thermo Assist/No EE Rating 5 = Thin Sipe T = Tapered
Battery Compartment Size o = Bolt On Tapered
B = B Battery Compartment
C = C Battery Compartment . - - - Steering System
D = D Battery Compartment E = Electric
E = E Battery Compartment H = Hydraulic
* = Special
Mast Type
TT = Telescopic Triple Stage
DT = TT Drive Thru Mast
-'-- - -
- TT 240 C 34 - 2 P 2 F - B E- A - -
Standard/Custom/Special
- = Standard
--l T
Third Post
C = Custom - = No Third Post
S = Special T = Third Post
D = Drive in Rack Third Post
Lift Height - - - - - - - - - - - - '
Displays Lift Height Lift System
Dimension Le. A=AC
=
240 240 in D=DC
=
270 270 in
Display
Inside Straddle ---J E = Enhanced
Dimension C = Enhanced with CDM
Load Wheel Size ---J
Le.
1 = 4 in x 2.9 in
34 = 34 in 2 = 4 in x 4.1 in Sideshifter Travel Alarm & Light Package
42 = 42 in
3 = 5 in x 2.9 in - = No Sideshifter Options
** = Special
4 = 5 in x 4.1 in 2 = 2 inch Each Way - = No Travel Alarm & Lights
5 = 10.5 in x 4 in 4 = 4 inch Each Way 1 = Strobe Light
6 = 10.5 in x 4.5 in * = Special 2 = Travel Alarm
7 = 6 in x 2.9 in 3 = Worklights
8 = 6 in x 4.1 in 4 = Travel Alarm & Strobe Light
* = Special 5 = Worklights & Strobe Light
6 = Travel Alarm, Worklights, &
Strobe Light
7 = Travel Alarm & Worklights
ITD-1457-004 Crown 2008 PF17422-4
24
mowI'
LUBRICA TION & ADJUSTMENT
25
l!J\OWI'
Notes:
26
LUBRICATION & ADJUSTMENT
CJ\owr. 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.
CJ\Own Operators
Daily Checklist
ModeJ SeriaJNo. _ Week beginning 20_
Shift No. _
~d** ..... bt,....bf .. ndI,......cW,al. . lltMof ....... e.t.lrI--Iinood ••
""'n:NdIdon&OlMIIIlldIk.CNdl. .. itlrl-.WicltiltlOri...c.d--'.
Truck No. _
ChOCk (/)~. box ~ OK D- repalr '" adJUStmen1S (give _In comments section)
MONDAY TUESDAY YfiIN!I:Jl( TIIURSOAY FRIDAY SATURDAY SUNDAY
llNMGf
.... denIId.tn-.n ... OK OK 0~\ :.. t', :"!'f~: OK n~l
~J~\
lEAIJ
diwunlt,br&lItl,h)dra__ OK {H< nit ,'!{ ~J?; OK UK
___ uK OK
--
lIRfSlWHfll$
01<. f)i'( f;:t< UK
, .....&"
~""'INd""
l,.:t\
h pMoe, ptOflll'tf-...:l
Q!{ [i({ OK f5~ nK tlK OK
~
_...
~ .....
OWNS, CAlLES I HOm
HOOlIImlIl
OK
OK
OK
LI~
0;,
Oll.
UK
G;~
OK
[;j{
GK
01\.
:]!I.
~:K
f"1
'-'~. "
GK
n~
1AlTEJr(
n~~ ~J}t OK U~
--
~ 'RlwlewL wnleept'" ~ ctMr*-
1AlTEJr( CO.II£CTOO
a.cMd, bumt,lI;ht IllInt ~JK {~t~ uK OJ{ OK iW G~<
OWltlMd,loadbldlr... ....".,..., OK OK OK ~9~'"
'..}}t> {i~:. iJ"" Oil.,
=~~:-:--=~--= OJ( OK IO;{ J'( Ug OK 0[(
IIORI
U~; ..
pll.-
_,~ uK. n~~ GK DK OK
tTmI1I1l Oli, m: n~~ uK eX HK OK
_
IIDbhlng.lID~plI,
uK {u<
_, OK OK OK
lIlA'IElCOIl11lOlJ '~" ~t
.. "PMcI rMgM. fotwwd ,~. noWlUlUlll noiM "", til<:
IftDIIAI.U:COMl1llU . . . . . . . . lonMItltwWald
OK Gt< ~;~~ OK OK
...... ....
-_
'lh
,--
r..cttin.oul.lII6MflIt~ ..... R..l'IO~1'lDiM "iJ?"
~
~
~ ~ ~
OK OK uK [1~ Dl'~ Oll' OK

.... OK n!< OK OK ~lX O~ OK
I umR'/ CllMCf
dlldwOt IN. In tlIO'etn f1I 75'cha/OI'" ralling: btb
POWDI DIlCOIlIlfCT
CIll!aolall~poMf
AlTACHIOO1
twJi:In PfOl*Ir. no 1ftIIUIII noiM
UIIJUWlllIlfJ
hWlIlirNt"lftlbll,II'Ihh,1'tt.
OK
lW
DE
OK
OK
OK
liK
01<
OK
Oi{
O!(
OK
Oli,
OK
OK
rw
Uf~
[ji{
OK
OK
OK
O!t
OK
OK
OK
OK
OK
OK
IlOllRllflUl_e
III'IMroIl1l11111lU
SUI'DlVISOA'IOl
• . . . tudt .. loufl(l1obllnnMdNlP*orrn..,werUN.... OICXIn!l'tlu*~.,unAteCD'llllion._manw.hdblltpOl1ed~lO

.... d95IgnIded
1UIloItty• ..-dthetn.Ot.hIlInotbl~unIIl.nubMntmtndkl . . openjngClCll'dllan.
~-:~~~:--lnq..,..tlem6rshalblr~~to
.. ~lil,Ilhority,¥'d"'b\dl:. . . notbe~unliilhas
Do nat InIke ~ or 1d;l51mM1. unIIu lpeciIlcaIy alIlor\led to do so.
~InUA.A.
Figure 14990
Crown 1987 PF7886-1 Rev, 6/08 M1.0-04.0-001

17 Rev. 6/08
27
Lubrication and Adjustment CRown
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 .
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
BB(1) 063002-017 14.5 oz Cartridge

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
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 351b Pail
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 351b 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
063002-039 1 Ib
I Grease (Lift Pump Coupling)
127801S 10z
063004-002 120z
J Brake Fluid - Dot 5
063004-003 1 Gallon
(1) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
M1.0-04.0-002 Crown 1987 PF7886-2 Rev. 6/08
17 Rev. 6/08
28
CJ\OWf\ Lubrication and Adjustment
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity

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 5.30zTube
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
0 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 30cc
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. 6108 M1.0-04.0-003

17 Rev. 6/08
29
Lubrication and Adjustment CAOWI'
Alternate Lubricants & Fluids Chart
Manufacturer
Type of Lubricant Product Name
I Distributor
A Gear Lube BOW-gO (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
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 0(1) Burmah Castrol
BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
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) Nyogel774F-MS NYE Lubricants
J Brake Fluid - Dot 5 02-1141 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.
L Metal Assembly Spray Dow Coming 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
(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.
M 1.0-04.0-004 Crown 1987 PF78864 Rev. 6/08
17 Rev. 6/08
30
CJ\owr. Lubrication and Adjustment
Alternate lubricants & Fluids Chart
Manufacturer
Type of Lubricant Product Name
/ Distributor
0 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 PF788M Rev. 6/08 M1.0-04.0-005

17 Rev. 6/08
31
mow!'
Notes:
32
l!J\OWr. Planned Maintenance
Planned Maintenance it CAUTION

If the truck is found in need of repair or is, in any way,
Overview unsafe orcontributes to an unsafe condition the matter
shall be reported immediately to the designated au-
Lift trucks are designed to move products safely, effi-
thority, and the truck shall not be operated until it has
ciently and economically. In order to perform this func-
been restored to safe operating condition. If, during op-
tion day after day, lift trucks must be properly main-
eration the truck becomes unsafe in any way, the mat-
tained. The planned maintenance (PM) section of this
ter shall be reported to the designated authority, and
manual is designed to assist you in keeping your lift
the truck shall not be operated until it has been re-
truck operating as it was designed. Proper planned
stored to safe operating condition. Do no make repairs
maintenance will reduce downtime and operating cost.
or adjustments unless specifically authorized to do so.
A good PM starts with operational and visual inspection
of the truck. Refer to Daily Operator Checks in this sec- NOTE
tion. In addition to Daily Operator Checks, the techni-
cian should also perform the following visual inspec- Lubrication and inspection intervals must be changed
tions: to a frequency that will minimize corrosion and wear on
moving parts for trucks operated in extremely dusty or
• Blow off truck with low pressure air
corrosive environments.
• Inspect frame components
• Look for debris such as shrink wrap, banding or

other debris that may be lodged in or around mov-
ing or rotating components
• Look for loose or missing fasteners
• Look for damaged electrical wiring or connectors
Address any issues found during the visual inspection

following all recommended safety precautions as spe-
cific to that component and as stated in the associated
maintenance chapter or the Control of Hazardous En-
ergy section of this manual.
Next, based upon the truck's accumulated hours, per-
form planned maintenance as indicated on the proper
interval chart located in this chapter.
• 60 Day/250 Hour
• 12 Month/2000 Hour
A Planned Maintenance Inspection Report that con-

tains all of these items in check list form is available
from Crown. Contact your Crown Dealer for more infor-
mation.
Crown 2009 PF17423-1 Rev. 2110 M1.0-1457-001

01 Rev. 2/10
33
Planned Maintenance CJ\own
Component Access 7 Power Unit Door
8 Floorboard
The following is a list of covers, panels. etc. that must
9 Entry Bar
be removed to allow access when performing service
and/or maintenance to components identified in this 10 Brake Pedal
section. Refer to the figures in this section as an aid in 11 Operator Presence Pedal
locating parts that require attention. 12 Contactor Panel Cover
13 Steer Tiller
14 ACCESS 1
15 Back Pad
16 Arm Pad
it CAUTION
Disconnect the battery and chock all wheels before
proceeding. Refer to Control of Hazardous Energy
LockouVTagout.
14 Power Unit Console

--15 The power unit console is secured to the top of power
unit with clip springs. Lift and remove the console to
access:
5--~J-t- • ACCESS 1 (Display Module)
• ACCESS 2 (Hydraulic Control Module)
• ACCESS 4 (Vehicle Control Module)

6
• Multi-Task Control Handle
• Hydraulic Manifold Block

11 • Key Switch (KYS)
Figure 21776
• DC, Contactor (P2)
1 Safety Shield
2 Multi-Task Control Handle Contactor Panel Cover
3 Reservoir Cover
Remove screws securing the contactor panel cover
4 Power Unit Cover
and lift the cover to access:
5 Battery Compartment
6 Battery Retainer • ACCESS 3 (Traction Control Module)
• Contactor (ED1 )
• Fuse Panel
• Battery Connector
• Caster
M1.0-1457-002 Crown 2009 PF17423-2 Rev. 2110
01 Rev. 2110
34
CJ\owr. Planned Maintenance
Floorboard Left and Right Hand Reservoir

Remove the floorboard to access: Covers
• Operator Presence Pedal and Switch (DMS1) Remove left and right hand reservoir covers to access:
• Entry Bar
• Reservoirs
• Entry Bar Switch (ENS)

• Breather (right and left hand reservoirs)
• Brake Switch (BRS1)

• Filter Element (right hand reservoir)
Power Unit Door Lubrication

The following information provides guidelines for
Loosen bolts and swing the power unit door open to
proper lubrication intervals as called out in the lubrica-
access:
tion chart. However, some operating conditions will re-
• ACCESS 5 AC, Steer Control Module (Electronic quire more frequent checks and lubrication than listed.
Power Steering) For example, truck applications which operate in ex-
treme moisture or dust environments will require mod-
• AC, Steer Motor (M4) (Electronic Power Steering) ification for each particular application.
• Steer Control Unit (SCU) Use high grade lubricants and fluids. Sources of these
lubricants may originate from almost any oil company;
• DC, Steering Feedback Sensor (ECR7) those listed in the Lubrication Identification Chart are
typical and any lubricant with equal specifications may
• Traction Motor (M1) be used.
• Traction Encoder (ECR1) For truck applications operating continually in temper-

atures at or above 4 0 C (40 0 F), use 100% standard hy-
• Electric Brake (BRK1) draulic oil (063001-001). Refer to Figure 22831.
For truck applications operating primarily in a cooler
• AC, Lift Pump Motor (M2)
environment with intermittent freezer entry, use a 50/50
• DC, Lift Pump Motors (M2 and M3) blend of low temperature (063001-006) and standard
(063001-021) hydraulic oil. Refer to Figure 22831.
• AC, Lift Pump (P1) For trucks running continuously at temperatures of
12 0 C (10 0 F) or below, use an 80% low temperature
• DC, Lift Pumps (P1 and P2)
(063001-006) and 20% standard (063001-021) hy-
• Distribution Panel draulic oil. Refer to Figure 22831.
Trucks equipped for use in deep freezers should not be
• Hom (HN) used in high temperature applications. When mixing oil
for freezer environments, always use a premium IS032
• Travel Alarm (ALM2) (Optional)
hydraulic oil (Crown pIn 063001-021), to ensure best
• DC, Steer Motor results.
The proper mixture of freezer hydraulic oil will ensure
the best and most efficient operation of your Crown
equipment.
Coat all screws, washers, nuts, roll pins, retaining
rings, etc., with a rust preventive (078882) to protect
against corrosion. Lubrication intervals must be
changed to a frequency that will minimize corrosion
and wear on moving shafts and parts.
Crown 2009 PF17423-3 Rev. 2110 M1.0-1457-003

01 Rev. 2/10
35
Planned Maintenance CJ\OWI'
Use Planned Maintenance Inspection Report
(PF17421) to record and assure maintenance checks.
Truck Stored Temperature (-23.3°C)

o
70°F 60°F 50°F 40°F 30°F 20°F 10°F OaF ·10 F _20°F -30°F
I I I I
100% Standard Oil

Contact
Factory
o
40 F-
30oF= 32°F (OoC)
50/50% Oil Mix
OOF- (_1SoC)
o
-10 F- 80/20% Oil Mix
_20oF-
-30oF- (-34.4°C)
Contact Factory
Figure 22831
M1.0-1457-004 Crown 2009 PF17423-4 Rev. 2110
01 Rev. 2110
36
l!J\OWI' Planned Maintenance
Notes:
Crown 2009 PF17423-5 M1.0-1457-005
37
Planned Maintenance
Lubricate only where column roller makes

contact with mast channel
2 To check drive unit level, tum drive unit to
expose fill plug
L-7
L-2
Figure 21777
M1.0-1457-006 Crown 2009 PF17423-6
38
l!J\OWrl Planned Maintenance
Chart 1 - Planned Maintenance Lubrication
Lube 60 Days 12 Months

Index Component Quantity
Type 250 Hrs 2000 Hrs
L-1 Mast Channels E As Req. Check
L-2 Caster Axle & Pivot B2 As Req. Lubricate

L-3 Drive Unit Pivot B As Req. Lubricate
Drive Unit Level 0.7 Litre Check
L-4 A1 Change
(1.5 pint) 1st Change
Multi-Task Control Handle (Ramps &
L-5 M As Req. Lubricate
Plunger)
L-6 Door Hinge Pins C As Req. Check
L-7 Hydraulic Reservoir - Left3

12.3 Litre
Oil D Change
(3.25 Gallon)
Breather D 1 Change
Hydraulic Reservoir - Right3

Oil 12.3 Litre
D Change
(3.25 Gallon)
10 Micron Filter Element D 1 Change
Cap Breather Element D 1 Change
See Lubrication Identification Chart and Alternate Lubricants & Fluids Chart for lube type designation expla-
nation. Lubrication intervals must be changed to a frequency that Will minimize wear on moving shafts and
parts on vehicles used in less desirable operation conditions.
Lubrication intervals for freezer/corrosion trucks must be changed to a frequency that will minimize corrosion
and wear on moving parts.
1 In below freezing temperatures use Dextron II, Crown part number 063001-010.
2 In below freezing temperatures use low temperature, multi-purpose grease, Crown part number
063002-017.
3 Reservoirs are cross connected. Draining empties both at once.
Crown 2009 PF17423-7 M1.0-1457-007
39
Planned Maintenance CJ\own
Apply a small amount of lubricant to metal shafts
L-4
Figure 21778
M1.0-1457-008 Crown 2009 PF17423-8
40
---
I

L-1 All Lift Chains C As Req. Check
L-2 Load Wheel Axles (Left & Right Side) B As Req. Check
L-3 Fork Slides B As Req. Check
Mast Staging Bumpers (Bottom 2nd Stage
L-4 B As Req. Check
Mast)
L-5 Steering Gears B As Req. Lubricate
L-6 Lower Floorboard & Entry Bar Pivot Points B As Req. Lubricate
L-7 AC & DC Lift Pump (P1 & P2) Splines I As Req. Lubricate
See Lubrication Identification Chart and Alternate Lubricants & Fluids Chart for lube type designation expla-
nation. Lubrication intervals must be changed to a frequency that will minimize wear on moving shafts and
parts on vehicles used in less desirable operation conditions.
Lubrication intervals for freezer/corrosion trucks must be changed to a frequency that will minimize corrosion
and wear on moving parts.
Crown 2009 PF17423-9 M1.0-1457-009
41
Planned Maintenance CROWl'
L-3
L-5
Use a paint brush to lubricate bum-

pers
L-7
Figure 21779
M1.0-1457-010 Crown 2009 PF17423-10
42

L-1 Upper Inner Arms B As Req. Check
L-2 Reach Pivots B As Req. Check
L-3 Reach Cylinder Pivots L As Req. Check
L-4 Upper Outer Arms B As Req. Check
L-5 Fork Carriage Pivots L As Req. Check
L-6 Tilt Cylinder Pivot Bearings L As Req. Check
L-7 Carriage Channel E As Req. Check
L-8 Reach Carriage Staging Bumpers B As Req. Check
See Lubrication Identification Chart and Alternate Lubricants & Fluids Chart for lube type designation
explanation. Lubrication intervals must be changed to a frequency that will minimize wear on moving
shafts and parts on vehicles used in less desirable operation conditions.
Lubrication intervals for freezer/corrosion trucks must be changed to a frequency that will minimize
corrosion and wear on moving parts.
Crown 2009 PF17423-11 M1.0-1457-011
43
Planned Maintenance CAown
1-1
1-7
1-8
1-1
1-2
1-1
1-6
1-9
Figure 21780
M1.0-1457-012 Crown 2009 PF17423-12
44
CJ\OWI' Planned Maintenance
Chart 1 • Planned Maintenance Inspection

I
60 Days 12 Months
Index Component
250 Hrs 2000 Hrs
1-1 Electrical: Connections, Cables & Wiring Check
1-2 Hydraulic: Hoses & Fittings Check
1-3 Padding Check
1-4 Contactor Tips (ED1 & P2) Check
1-5 Caster Wheel Check
1-6 Floorboard Assembly (ENS, BRS1 & DMS1) Check
1-7 Horn (HN) Check
1-8 DC Lift Pump Motors (M2 & M3): Motor Brushes Check
Lift Pumps (P1 & P2) Check
1-9 Steer Motor (M4) Check
Refer to appropriate section of service manual for additional information concerning inspection or adjustment.
Crown 2009 PF17423-13 M1.0-1457-013
45
Planned Maintenance CJ\OWI'
Figure 21781
M1.0-1457-014 Crown 2009 PF17423-14
46
CROWl' Planned Maintenance
Chart 2 - Planned Maintenance Inspection
60 Days 12 Months
Index Component
250 Hrs 2000 Hrs
1-1 Electrical: Connections, Cables & Wiring Check
1-2 Hydraulic: Hoses & Fittings Check
1-3 Electric Brake (BRK1) Check
1-4 Distribution Panel (K1, K2 & ALM1) Check
1-5 ACCESS 1 Check
1-6 Travel Alarm (ALM2) (Optional) Check
1-7 Steer Control Unit (SCU) Check
Multi-Task Control Handle (POT1, POT2, POT3, FS, RS, HNS,
1-8 Check
TBSfTDS & SSS)
1-9 Undercarriage Articulation and Articulation Adjustment Check
1-10 Battery Retainer Switches (BRES1 [Right] & BRES2 [Left]) Check
1-11 Drive Unit Pump Operation Check
1-12 Overhead Guard: Secure To Truck & No Cracks Check
1-13 Mast Dampening Screws (2nd & 3rd Masts Top & Bottom) Check
Electrical: Connections, Wiring & Blow Dust Off FAN3 & ACCESS
1-14 Check
3 Heat Sink
Crown 2009 PF17423-15

M1.0-1457-015
47
Planned Maintenance l!J\OWI'
1-5 1-6
Figure 21782
M1.0-1457-016 Crown 2009 PF17423-16
48
CJ\OWI' Planned Maintenance
Chart 3 • Planned Maintenance Inspection
60 Days 12 Months
Index Component
250 Hrs 2000 Hrs
1-1 Column Rollers Check
1-2 Yoke Check
1-3 Control Cables Check

1-4 Forks Check
1-5 Load Wheels Check

1-6 Drive Tire & Lug Bolts Check
1-7 Reach Cylinders Check
1-8 Tilt Cylinder Check
1-9 Carriage Cylinder Check
1-10 Lift Cylinders Check
1-11 Rollers & Bearings Check
1-12 Lower Hangers Check
Crown 2009 PF17423-17 M1.0-1457-017
49
Planned Maintenance l!J\OWJ\
1-2
Figure 21783
M1.0-1457-018 Crown 2009 PF17423-18
50
Chart 4 - Planned Maintenance Inspection
60 Days 12 Months
Index Component
250 Hrs 2000 Hrs
1-1 Sideshift Cylinder Mounting Check
1-2 Fork Slides and Sideshift Carriage Check
1-3 Sideshift Cylinder & Hydraulic Connections Check
1-4 Lift Chain Anchors Check
1-5 Height Sensor (ECR2) Check
1-6 Free Lift Switch (FLS) Check
1-7 All Lift Chains Check
1-8 Undercarriage Pivot Points Check
1-9 Mast & Reach Carriage Staging Bumpers Check
1-10 Mast Mounting Screws (6) for Tightness Check
1-11 Tilt Position Assist (TPA) Check
Crown 2009 PF17423-19 M1.0-1457-019
51
CAOWI'
Notes:
52
CJ\OWI' Componentry
Componentry • Adjustments required, if applicable.
Components listed in this section have been alphabet- • Wiring diagram page(s) on which the component
ically categorized to assist the service technician with appears. Two additional numbers immediately fol-
the following information for each component: low the wiring diagram page number. The first
number (in parenthesis) is the grid coordinate and
• Component designator (Le., ALM1) that will be the second number (in parenthesis) is the manual
found on the wiring diagram and parts pages. page number (Le., DIA-1457-009 (C-2) (177)).
• Description of the component. • Parts page on which the component appears. Two
additional numbers immediately follow the parts
• Location of the component on the truck.
page number. The first number (in parenthesis) is
• Purpose of the component. the index number of the component and the sec-
ond number (in parenthesis) is the manual page
• Technical data of the component. number (Le., 04.0-1457-001 (1) (361 )).
Crown 2009 PF17424-1 Rev. 2110 M1.0-1457-100

01 Rev. 2110
53
Audible Indicators CJ\OWI'
Audible Indicators HN
Horn
ALM1
Location: mounted on left hand side of power unit in-
side traction motor (M1) compartment.
Status Alarm
Purpose: provides operator controlled audible warning
Location: mounted on the distribution panel.
to alert others of truck presence.
Purpose: alerts the operator of faults.
Data: controlled by K1 relay tips on the positive side
Data: controlled by ACCESS 1 (DM) as needed. View and ACCESS 4 on the negative side. Resistance
ALM1 status in ACCESS 123® Analyzer Menu A3.1.1. across HN, out of circuit, is 30 ohm. View HN output
Test ALM1 in A4.1.1. status in A3.4.16, test HN in A4.4.16.
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-1457-002 (A-1) Diagrams: DIA-1457-002 (A-3)

DIA-1457-005 (B-2) Parts Breakdown: 04.0-1457-001 (16)
Parts Breakdown: 04.3-1457-001 (3) 04.0-1457-100 (15)
ALM2 Contactors
Travel Alarm (optional)
ED1
Location: mounted on the left hand side of power unit
inside traction motor (M 1) compartment. Emergency Disconnect Contactor
Purpose: alerts pedestrians of truck movement. Location: behind the cover on the contactor panel on
Data: controlled by K1 relay tips on the positive side the right hand side of the operator compartment.
and ACCESS 3 on the negative side. Resistance Purpose: provides means for operator or
across ALM2, out of circuit, is 20 ohm. View ALM2 sta- ACCESS 123 system to remove power from control
tus in A3.3.2. Test ALM2 in A4.3.1. and/or power circuits. .
Adjustment: can be set through F20.3 to sound during Data: ACCESS 3 supplies BNEG to the coil and
forward travel, reverse travel or all travel. Alarm can ACCESS 4 provides +BV. Coil voltage 24/36 VDC, coil
also be disabled in F20.3. resistance 24 ohm. View ED1 outputs in A3.3.1.
Diagrams: DIA-1457-003 (B-3) Adjustment: N/A
DIA-1457-004 (B-3)
Diagrams: DIA-1457-002 (A-2) (A-3)
Parts Breakdown: 04.0-1457-001 (13) DIA-1457-009 (B-3)
04.0-1457-100 (12) DIA-1457-018 (C-2)
DIA-1457-019 (C-2)
DIA-1457-020 (C-2)
DIA-1457-021 (B-2)
Parts Breakdown: 04.1-1457-350
04.1-1457-400
04.4-1457-001 (0)
Crown 2009 PF17424-2

M1.0-1457-101
54
CJ\OWI' Contactors
ALM1
HN
ALM2
Figure 22105
Crown 2009 PF17424-3 M1.0-1457-102
55
Encoders CJ\OWI'
ED2 Purpose: provides M1 travel speed and direction infor-
mation to ACCESS 3, ECR1 also provides information
for truck's traction control system.
Second Emergency Disconnect (European Trucks
only) Data: 12 V and BNEG are provided by ACCESS 3.
ECR1 resolution is 48 counts per revolution. View
Location: behind the panel on the right hand side of
ECR1 outputs in A2.3.1.
the operator compartment.
Purpose: provides means for operator or Adjustment: N/A
ACCESS 123 system to remove power from control Diagrams: DIA-1457-003 (C-3)
andlor power circuits. DIA-1457-004 (C-2)
DIA-1457-007 (C-3)
Data: ACCESS 3 supplies BNEG to the coil and
ACCESS 4 provides +BV. Coil voltage = 24/36 V. Coil Parts Breakdown (trucks manufactured prior to
resistance = 24 ohm. 3/8/10): 03.1-1457-001 (12)
Parts Breakdown (trucks manufactured since
Adjustment: N/A
3/8/10): 04.0-1457-011 (80)
Diagrams: DIA-1457-002 (A-2) (A-3) 04.0-1457-110 (80)
DIA-1457-009 (B-3)
DIA-1457-020 (C-2)
DIA-1457-021 (C-2) ECR2
Parts Breakdown: 04.4-1457-001 (0) Height Sensor Encoder
Location: mounted at the top right hand side of mast.
P2
Purpose: provides measured height of forks beyond
free lift.
Pump Contactor (DC Hydraulic Trucks only)
Data: 5 V and BNEG provided by ACCESS 4. ECR2
Location: on top of the power unit under console.
resolution is 32 counts per revolution. View ECR2 out-
Purpose: switches power input to M3 via operator inputs in A2.4.23.
put at POT2.
Adjustment: refer to C2.1 in the ACCESS 123 Cali-
Data: ACCESS 2 provides BNEG and +BV to the coil. bration Menu.
Coil voltage 24 V, coil resistance 24 ohm. View P2 sta-
Diagrams: DIA-1457-002 (A-4)
tus in A3.2.2. Test P2 in A4.2.2.
DIA-1457-014 (C-3)
Adjustment: N/A
Parts Breakdown: 04.8-1457-100 (5)
Diagrams: DIA-1457-004 (B-2)
DIA-1457-019 (A-2)
DIA-1457-022 (B-1) ECR3
DIA-1457-008 (A-4)
DC Lift Pump Motor (M2) Encoder
Location: internal to the DC lift pump motor (M2).
Purpose: provides M2 speed and direction information
Encoders to ACCESS 2.
Data: 12 V and BNEG provided by ACCESS 2. ECR3
ECR1 resolution is 48 counts per revolution. View ECR3 out-
puts in A2.2.1.
Traction Motor (M1) Encoder
Adjustment: N/A
Location: internal to M1 (trucks manufactured prior to
Diagrams: DIA-1457-004 (C-1)
3/8/10) or mounted in the traction motor compartment
DIA-1457-008 (A-3)
on top of BRK1 (trucks manufactured since 3/8/10).
Crown 2009 PF174244 Rev. 2110

M1.0-1457-103
01 Rev. 2110
56
CJ\OWI' Encoders
Figure 22106
Crown 2009 PF17424-5 M1.0-1457-104
57
Fans CROW"
ECR4 Diagrams: DIA-1457-002 (A-4)
DIA-1457-Q07 (8-3)
Electronic Power Steering Motor (M4) Encoder Parts Breakdown: 06.0-1457-005 (68)
(optional)
Location: internal to the Electronic Power Steering Fans
motor (M4).
Purpose: provides M4 speed and direction information
to ACCESS 5 in trucks with Electronic Power Steering. FAN1
Data: 5 V and 8NEG provided by ACCESS 5. ECR4
Traction Motor Compartment Cooling Fan
resolution is 64/128 counts per revolution. View ECR4
outputs in A2.5.1. Location: mounted on the door of the traction motor
compartment.
Adjustment: N/A
Purpose: provides cooling for M1 and traction motor
compartment.
DIA-1457-017 (A-2)
Data: K1 provides constant +8V and ACCESS 4
Parts Breakdown: Must be replaced with M2.
switches 8NEG. Fan coil resistance = 30 ohm. View
FAN1 outputs in A3.4.15.
ECR6 Adjustment: FAN1 can be set to OFF, ALWAYS ON or
THERMAL in F7.2.
AC Lift Pump Motor (M2) Encoder
Location: on top of the AC lift pump motor (M2). DIA-1457-007 (C-4)
Purpose: provides M2 speed and direction information Parts Breakdown: 04.0-1457-003 (64)
to ACCESS 2. 04.0-1457-102 (59)
Data: 12 V and 8NEG provided by ACCESS 2. ECR6
resolution is 48 counts per revolution. View ECR6 out- FAN3
puts in A2.2.1.
Adjustment: N/A ACCESS 3 Cooling Fan
Diagrams: DIA-1457-003 (C-2) Location: mounted above ACCESS 3 behind the
cover in the right hand side of operator compartment.
02.2-1457-100 (14) Purpose: provides cooling for ACCESS 3.
Data: K1 provides constant +8V and ACCESS 3
ECR7 switches 8NEG. Fan coil resistance = 20 ohm. View
FAN3 status in A3.3.4.
Steer Tiller Command Encoder (Hydraulic Steer Adjustment: FAN3 can be set to ALWAYS ON or
trucks only) THERMAL in F7.1.
Location: on the tiller mount. Diagrams: DIA-1457-003 (8-3)
DIA-1457-004 (8-2)
Purpose: provides steer command information to
DIA-1457-007 (8-2)
ACCESS 4 via the position of the operator controlled
tiller. Parts Breakdown: 04.0-1457-003(50)
04.0-1457-100 (50)
Data: 5 V and 8NEG provided by ACCESS 4. ECR 7
resolution is 48 counts per revolution. View ECR7 out-
puts in A2.4.22.
Adjustment: N/A
M1.0-1457-105 Crown 2009 PF17424-6
58
Fans
ECR6
ECR4
Figure 22107
Crown 2009 PF17424-7

M1.0-1457-106
59
Fuses l!J\OWI'
FAN4 Parts Breakdown: 04.1-1457-352 (27)
04.1-1457-402 (27)
ACCESS 2 Cooling Fan
Location: mounted on top of the power unit next to FU2
ACCESS 2.
BRK1 Outer Coil Fuse
Purpose: provides cooling for ACCESS 2.
Location: on the fuse panel behind the panel on the
Data: K1 provides constant +BV and ACCESS 3
right hand side of the operator compartment.
switches BNEG Fan coil resistance = 20 ohm. View
FAN4 status in A3.3.4. Purpose: protects the BRK1 outer coil from over cur-
rent.
Adjustment: FAN4 can be set to ALWAYS ON or
THERMAL in F7.1. Data: 15 A, 58 V
Diagrams: DIA-1457-003 (B-3) Adjustment: N/A
DIA-1457-004 (B-2) Diagrams: DIA-1457-002 (A-3)
DIA-1457-008 (B-2) DIA-1457-009 (B-1)
04.0-1457-100 (9) 04.1-1457-402 (27)
FANS FU3
Operator Compartment Fan BRK1 Inner Coil Fuse
Location: on the overhead guard. Location: on the fuse panel behind the panel on the
Purpose: provides cooling for operator comfort. right hand side of the operator compartment.
Data: 24 V high speed, 12 V low speed, controlled via Purpose: protects the BRK1 inner coil from over cur-
operator (FNS). rent.
Adjustment: N/A Data: 15 A, 58 V
Diagrams: DIA-1457-014 (C-1) Adjustment: N/A
Parts Breakdown: 04.9-1457-050 (9) Diagrams: DIA-1457-002 (A-3)

DIA-1457-009 (B-1)
Fuses 04.1-1457-402 (27)
FU1
Key Switch Fuse
Purpose: protects control circuitry from over current.
Data: 15 A, 58 V
Adjustment: N/A
Diagrams: DIA-1457-Q02 (A-4)
DIA-1457-009 (B-1)
DIA-1457-Q11 (A-3)
DIA-1457-012 (A-3)
M1.0-1457-107 Crown 2009 PF17424-8
60
CAOWI' Fuses
Figure 22108
Crown 2009 PF17424-9

M1.0-1457-108
61
Fuses
FU4 FU7
Electronic Power Steering Fuse Freezer/Corrosion Fuse (Optional)
Location: on the fuse panel behind the panel on the Location: on the fuse panel behind the panel on the
right hand side of the operator compartment. right hand side of the operator compartment.
Purpose: protects the Electronic Power Steering or DC Purpose: protects the freezer/corrosion components
Hydraulic circuitry from over current. and associated wiring from over current.
Data: 5 A, 58 V Data: 15 A, 58 V
Diagrams: DIA-1457-003 (A-1) Diagrams: DIA-1457-002 (A-1)
DIA-1457-004 (A-1) DIA-1457-009 (B-2)
DIA-1457-009 (B-1) DIA-1457-011 (A-3)
DIA-1457-012 (A-3)
04.1-1457-402 (28) Parts Breakdown: 04.1-1457-352 (27)
04.1-1457-402 (27)
FU5
FU8
Accessory Options Fuse (Optional)
Camera Fuse (Optional)
right hand side of the operator compartment. Location: on the fuse panel behind the panel on the
Purpose: protects accessory options from over cur-
rent. Purpose: protects the camera and associated wiring
from over current.
Data: 15 A, 58 V
Data: 2 A, 58 V
Adjustment: N/A
Adjustment: N/A
DIA-1457-009 (B-1) Diagrams: DIA-1457-009 (B-2)
Parts Breakdown: 04.1-1457-352 (27) Parts Breakdown: 04.1-1457-352 (29)
04.1-1457-402 (27) 04.1-1457-402 (29)
FU6 FU9 (AC Hydraulic Trucks)

FanIWork Lights Fuse (Optional) ACCESS 2 Fuse
Location: on the fuse panel behind the panel on the Location: on the contactor panel behind the panel on
right hand side of the operator compartment. the right hand side of the operator compartment.
Purpose: protects the fans, work lights, and associ- Purpose: protects ACCESS 2 and associated wiring
ated wiring from over current. from over current.
Data: 15 A, 58 V Data: 500 A, 80 V
Diagrams: DIA-1457-Q02 (A-1) Diagrams: DIA-1457-003 (B-3)
DIA-1457-009 (B-1) DIA-1457-018 (C-2)
DIA-1457-020 (C-2)
04.1-1457-402 (27) Parts Breakdown: 04.1-1457-350 (7)
04.1-1457-400 (7)
M1.0-1457-109 Crown 2009 PF17424-10
62
CJ\OWI' Fuses
FU9
FU5
FU6
FU7
FU8
Figure 22109
Crown 2009 PF17424-11

M1.0-1457-110
63
Fuses CJ\OWI'
FU9 (DC Hydraulic Trucks) FU11
ACCESS 2 Fuse P2 Contactor and Motor (M3) Fuse (DC Hydraulic

trucks only)
Location: on the contactor panel behind the panel on
the right hand side of the operator compartment. Location: mounted on ACCESS 2.
Purpose: protects ACCESS 2 and associated wiring Purpose: protects the lift pump contactor (P2), DC lift
from over current. pump motor (M3) and associated wiring from over cur-
rent.
Data: 800 A, 80 V
Data: 300 A, 80 V
Adjustment: N/A
Adjustment: N/A
DIA-1457-019 (C-2) Diagrams: DIA-1457-004 (A-2) (B-2)
DIA-1457-021 (C-2) DIA-1457-019 (A-1)
DIA-1457-021 (A-1)
04.1-1457-400 (7) Parts Breakdown: 04.1-1457-352 (43)
04.1-1457-402 (43)
FU10
FU12
ACCESS 3 Fuse
ACCESS 5 Fuse (Electronic Power Steering trucks
Location: on the contactor panel behind the panel on
only)
the right hand side of the operator compartment.
Location: mounted below ACCESS 5.
Purpose: protects ACCESS 3 and associated wiring
from over current. Purpose: protects ACCESS 5 and associated wiring
from over current.
Data: 500 A, 80 V
Data: 50 A, 80 V
Adjustment: N/A
Adjustment: N/A
DIA-1457-004 (B-3) Diagrams: DIA-1457-003 (A-1)
DIA-1457-018 (C-2) DIA-1457-017 (B-3)
DIA-1457-019 (B-2) DIA-1457-018 (C-4)
DIA-1457-020 (C-2) DIA-1457-020 (C-4)
DIA-1457-021 (B-2)
Parts Breakdown: 04.1-1457-350 (6) 04.1-1457-402 (38)
04.1-1457-400 (6)
M1.0-1457-111 Crown 2009 PF17424-12
64
CJ\OWI' Fuses
FU11
Figure 22110
Crown 2009 PF17424-13 M1.0-1457-112
65
Lights CJ\OWI'
FU13 LGT2, LGT3
FIC Fuse (optional) Work Lights (optional)
Location: mounted on the FIC Panel near the steering Location: on the side of the mast at the overhead
tiller support. guard (optional mounting on the overhead guard).
Purpose: protects FIC components from over current. Purpose: provides work area light outside the operator
compartment, controlled via operator (LGS2 on
Data: 15 A
ACCESS 1).
Adjustment: N/A
Data: 36 V, 24 V
Adjustment: N/A
Parts Breakdown: 04.9-1457-052 (46) (47)
FU14
FIC Fuse (optional) LGT4
Location: mounted on the FIC Panel near the steering
Strobe Light (optional)
tiller support.
Location: mounted to the overhead guard.
Purpose: protects FIC components from over current.
Purpose: high intensity visual warning of truck pres-
Data: 15 A
ence.
Adjustment: N/A
Data: 36 V, 0.5 A
Adjustment: N/A
Parts Breakdown: 04.9-10.0-550
Lights 04.9-1457-050
LGT1
Dome Light (optional)
Location: on the left hand side of mast.
Purpose: provides light for the operator compartment.
Data: 12 V, controlled via operator (LGS1 on
ACCESS 1).
Adjustment: N/A
DIA-1457-010 (C-3)
M1.0-1457-113 Crown 2009 PF17424-14
66
CJ\OWI' Lights
Figure 22111
Crown 2009 PF17424-15 M1.0-1457-114
67
Miscellaneous CJ\OW"
Miscellaneous RES1
Voltage Drop Resistor for Dome Light

BRK1
Location: mounted on the display bracket.
Traction Brake Purpose: provides voltage drop for dome light.
Location: mounted on top of M1. Data: 10 ohm (24 V trucks), 20 ohm (36 V trucks)
Purpose: provides braking force to traction motor to Adjustment: N/A
stop truck and prevent movement of parked vehicle.
Data: inner and outer brake coils are electrically con-
trolled by ACCESS 4 via operator input (BRS1, BRS2)
or ACCESS 123 system, spring applied. View BRK1
outputs in A3.4.18 & A3.4.19. RES2
Adjustment: refer to ACCESS 123 Performance
Menu (P6). Voltage Drop Resistor for FANS (high speed)
Diagrams: DIA-1457-002 (A-3) Location: mounted on the display bracket.

DIA-1457-015 (C-3) Purpose: provides voltage drop for FAN5.
Parts Breakdown: 05.3-1452-100 Data: 25 ohm
Adjustment: N/A
LS
Load Sense Parts Breakdown: 04.8-1457-003 (29)
Location: on the hydraulic manifold block.
Purpose: load sensing pressure transducer that pro- RES3
vides feedback to ACCESS 4 to determine load weight
displayed on ACCESS 1. Voltage Drop Resistor for FANS (low speed)
Data: 12 V supplied by ACCESS 4, 4-20 mA signal. Location: mounted on the display bracket.
View LS current in A2.4.25. Purpose: provides voltage drop for FAN5.
Adjustment: refer to ACCESS 123 Calibration Menu Data: 12 ohm
(C2.2)
Adjustment: N/A
HYD-1457-001 (10) Parts Breakdown: 04.8-1457-003 (30)
HYD-1457-003 (12)
HYD-1457-005 (13)
Crown 2009 PF17424-16

M1.0-1457-115
68
CJ\owr. Miscellaneous
BRK1
LS
Figure 22112
Crown 2009 PF17424-17 M1.0-1457-116
69
Miscellaneous
RES 4 RESS
FIC Resistor for BRES2 (optional) FIC Resistor for EDS (optional)
Location: mounted to the LH bracket for the battery Location: mounted to the multi-function control sup-
retainer switch. port. .
Purpose: heater for BRES2 for trucks equipped with Purpose: heater for EDS for trucks equipped with
freezer conditioning. freezer conditioning.
Data: 30 ohms (24 V trucks), 70 ohms (36 V trucks) Data: 70 ohms (36 V trucks)
Diagrams: DIA-1457-011 (B-3) (C-1) Diagrams: DIA-1457-011 (B-4)
Parts Breakdown: 01.2-1457-100 (5) Parts Breakdown: 04.6-1457-001 (19)
01.2-1457-150 (5)
RESS
FIC Resistor for BRES1 (optional)
Location: mounted to the RH bracket for the battery
retainer switch.
Purpose: heater for BRES1 for trucks equipped with
freezer conditioning.
Data: 30 ohms (24 V trucks), 70 ohms (36 V trucks)
Adjustment: N/A
Diagrams: DIA-1457-011 (B-2) (C-1)
01.2-1457-150 (5)
RES6
FIC Resistor for FLS (optional)
Location: mounted to bracket on FLS.
Purpose: heater for FLS for trucks equipped with
Data: 30 ohm (24 V trucks), 70 ohm (36 V trucks)
Adjustment: N/A
Diagrams: DIA-1457-011 (B-2) (B-4)
Parts Breakdown: not shown
M1.0-1457-117 Crown 2009 PF17424-18
70
Cf\owr. LUBRICATION & ADJUSTMENT
Miscellaneous
RES5
Figure 22113
Crown 2009 PF17424-19 M1.0-1457-118
71
Miscellaneous CJ\own
RES9 RES13
Voltage Dropping Resistor for POT3 (optional) F/C Resistor for DMS1 (optional)
Location: mounted to the multi-task control handle Location: mounted to the heater plate on DMS1 in the
support. floorboard.
Purpose: provides voltage drop for POT3 (RES10) on Purpose: heater for DMS1 for trucks equipped with
trucks equipped with freezer conditioning. freezer conditioning.
Data: 82 ohm, 10 watt (24 V trucks); 140 ohm, 10 watt Data: 70 ohms (24 V trucks), 160 ohms (36 V trucks)
(36 V trucks)
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-1457-011 (8-4) (C-3)
Diagrams: DIA-1457-011 (8-4) (C-2)
RES14
RES10
F/C Resistor for BRS1 (optional)
F/C Resistor for POT3 (optional)
Location: mounted to the heater plate on 8RS1 in the
Location: mounted on POT3 in the multi-task control floorboard.
handle.
Purpose: heater for 8RS1 for trucks equipped with
Purpose: heater for POT3 for trucks equipped with freezer conditioning.
Data: 70 ohms (24 V trucks), 160 ohms (36 V trucks)
Data: 40 ohm
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-1457-011 (8-4) (C-3)
Diagrams: DIA-1457-011 (8-4) (C-2)
RES11
Location: mounted on POT1 in the multi-task control
handle.
Purpose: heater for POT1 for trucks equipped with
Data: 40 ohm
Adjustment: N/A
Diagrams: DIA-1457-011 (8-4) (C-2)
M1.0-1457-119 Crown 2009 PF17424-20
72
l!J\OWr. Miscellaneous
RES13
RES11
Figure 22114
Crown 2009 PF17424-21 M1.0-1457-120
73
Miscellaneous
RES15 RES23
F/C Resistor for ENS (optional) Voltage Dropping Resistor for POT1 (optional)
Location: mounted to the heater plate on ENS in the Location: mounted to multi-task control handle sup-
floorboard. port.
Purpose: heater for ENS for trucks equipped with Purpose: provides voltage drop for POT1 (RES11) on
freezer conditioning. trucks equipped with freezer conditioning.
Data: 70 ohms (24 V trucks), 160 ohms (36 V trucks) Data: 82 ohm, 10 watt (24 V trucks); 140 ohm, 10 watt
(36 V trucks)
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-1457-011 (8-4) (C-3)
Diagrams: DIA-1457-011 (8-4) (C-2)
RES19
RES24
F/C Resistor for ECR2 (optional)
Voltage Dropping Resistor for POT2 (optional)
Location: mounted to ECR2 on the mast.
Location: mounted to multi-task control handle sup-
Purpose: heater for ECR2 for trucks equipped with
port.
Purpose: provides voltage drop for POT2 (RES22) on
Data: 7.5 watts
trucks equipped with freezer conditioning.
Adjustment: N/A
Data: 82 ohm, 10 watt (24 V trucks); 140 ohm, 10 watt
Diagrams: DIA-1457-011 (A-1) (8-4) (36 V trucks)
Parts Breakdown: 04.8-1457-100 (12) Adjustment: N/A
Diagrams: DIA-1457-011 (8-4) (C-2)
RES22 Parts Breakdown: 04.6-1457-001 (17)

Location: mounted on POT2 in the multi-task control
handle.
Purpose: heater for POT2 for trucks equipped with
Data: 40 ohm
Adjustment: N/A
Diagrams: DIA-1457-Q11 (8-4) (C-2)
M1.0-1457-121 Crown 2009 PF17424-22
74
CJ\OWfl Miscellaneous
RES15
RES22
Figure 22115
Crown 2009 PF17424-23 M1.0-1457-122
75
Miscellaneous CJ\OWI'
RP51 TH54
Traction/Steer Wheel Position Sensor Thermostat (optional)
Location: mounted on a bracket on the top of the un- Location: on power unit at the base of the mast guard.
dercarriage in the traction motor compartment.
Purpose: monitors ambient temperature.
Purpose: feedback from RPS1 indicates the angle of
Data: Open temperature is 15.5°C (60°F), closed tem-
the traction/steer tire to ACCESS 4 (hydraulic steer
perature 4.4°C (40°F).
trucks) or ACCESS 5 (Electronic Power Steering
trucks) which communicates the information to Diagrams: DIA-1457-011 (A-4) (C-3)
ACCESS 1.
Data: for hydraulic steer trucks, the normal inputs from
RPS1 to ACCESS 4 are 0.5 V and 105° (fully clock-
wise), 4.2 V and 80° (fully counter-clockwise), nominal TH55
supply voltage is 5.3 V; for Electronic Power Steering
trucks, the normal inputs for RPS1 to ACCESS 5 are Floorboard Thermostat (optional)
800 counts and -1 or (fully clockwise), 100 counts and Location: under floorboard mounted to ENS heater
_80° (fully counter-clockwise), nominal supply voltage plate.
is 5.3 V. View in A2.5.5 and A2.4.21.
Purpose: monitors ambient temperature.
Adjustment: refer to ACCESS 123 Calibration Menus
(2.8 or 4.1) Data: Open temperature is 71°C (160°F), closed tem-
perature 60°C (140°F).
DIA-1457-003 (B-1) Diagrams: DIA-1457-011 (C-3) (A-4)
DIA-1457-013 (C-4) Parts Breakdown: 01.0-1457-052 (61)
DIA-1457-017 (A-2)
T51
RP52 Traction Motor (M1) Temperature Sensor
Location: internal to M1.
Steering Command Position Sensor (optional)
Purpose: monitors M1 temperature and communi-
Location: on the steer tiller mount of trucks with Elec- cates information to ACCESS 3.
tronic Power Steering.
Data: momentary contact thermal switch wired nor-
Purpose: feedback' from RPS2 indicates the steering mally open, over temperature condition (165°C
direction to ACCESS 5 via operator input through the [329°F]) actuates switch. View M1 temperature at
steer tiller, ACCESS 5 also supplies 5 V and BNEG to A2.3.3.
RPS2.
Adjustment: N/A
Data: RPS2 input ranges to ACCESS 5 are 0 to 32000
counts, with channel A range 150-1000 counts and Diagrams: DIA-1457-003 (C-3)
channel B range 150-1000 counts; channels are ap- DIA-1457-004 (C-3)
proximately ~ turn out of phase from one another; refer DIA-1457-007 (B-4)
to ACCESS 123 Analyzer Menus (A2.5.6). Parts Breakdown: not separately availiable.
Adjustment: N/A
DIA-1457-017 (A-1)
Crown 2009 PF17424-24

M1.0-1457-123
76
CJ\OWI' Miscellaneous
!iltt"~=1t-+-----jf--+-- THS5
Figure 22116
Crown 2009 PF17424-25 M1.0-1457-124
77
Miscellaneous CAOWI'
TS2 current, A2.3.1 for speed and A2.3.3 for temperature.
Test M1 current in A4.3.2.
AC Lift Pump Motor (M2) Temperature Sensor Adjustment: N/A
Location: internal to M2. Diagrams: DIA-1457-003 (C-4)
DIA-1457-004 (C-3)
DIA-1457-007 (C-1)
cates information to ACCESS 2.
DIA-1457-018 (A-3)
Data: momentary contact thermal switch wired nor- DIA-1457-019 (A-3)
mally open, over temperature condition (165°C DIA-1457-020 (A-3)
[329°F]) actuates switch. View M2 temperature in DIA-1457-021 (A-3)
A2.2.4.
Adjustment: N/A
Diagrams: DIA-1457-003 (C-2) M2
DIA-1457-016 (B-3)
Parts Breakdown: not separately available. Lift Pump Motor
Location: in the traction motor compartment mounted
TS4 to the power unit wall.
Purpose: provides driving force (speed and direction)
Electronic Power Steering Motor (M4) Temperature for hydraulic pump, supplying hydraulic pressure for lift,
Sensor steering (Hydraulic Steer trucks) and accessory func-
tions.
Location: internal to M4.
Data: ACCESS 2 provides speed control via operator
input (POT2). View M2 status in A3.2.1 for rms current,
cates information to ACCESS 5.
A2.2.1 for speed and A2.2.4 for temperature. View M2
Data: momentary contact thermal switch wired nor- voltage (DC trucks) in A2.2.5. Test M2 current in
mally open, over temperature condition (180°C A4.2.1.
[356°F]) actuates switch. Resistance of TS4 at 22°C
Adjustment: N/A
(72°F) = 550 ohm. View M4 temperature in A2.5.3.1.
Adjustment: N/A
DIA-1457-004 (B-2)
Diagrams: DIA-1457-003 (C-1) DIA-1457-008 (C-1)
DIA-1457-017 (A-2) DIA-1457-018 (B-1)
DIA-1457-019 (A-2)
Parts Breakdown: not separately available.
DIA-1457-020 (B-1)
DIA-1457-021 (A-2)
Motors Parts Breakdown: 02.2-1457-001
02.2-1457-050
02.2-1457-100
M1
Traction Motor
Location: in the traction motor compartment on the left
hand side of the power unit.
- Purpose: provides driving force for truck traction
(speed and direction).
Data: ACCESS 3 provides speed control via operator
input (POT1). ACCESS 3 provides 3-phase AC volt-
age. View M1 status on ACCESS 1 in A3.3.3 for rms
Crown 2009 PF17424-26

M1.0-1457-125
78
CJ\owr. Miscellaneous
M2
(DC)
Figure 22117
Crown 2009 PF17424-27 M1.0-1457-126
79
Potentiometers CJ\OWl'
M3 Data: 1.7 K ohm, ACCESS-4 supplies 5.2-V input volt-
age. Power unit first full traction = 4.4-V, handle cen-
Lift Pump Motor (DC Hydraulic trucks only)
= =
tered 2.6-V, forks first full traction 0.9-V. View POT1
inputs in A2.4.18.
Location: in the traction motor compartment mounted
Adjustment: refer to ACCESS 123 Calibration Menu
to the power unit wall.
(C1.1 )
Purpose: provides driving force (speed) for hydraulic
pump (P2).
DIA-1457-o06 (B-1)
Data: ACCESS 2 provides on/off control to P2 contac-
tor via operator input (POT2).
Adjustment: N/A
POT2
DIA-1457-019 (A-2)
Raise/Lower Potentiometer
DIA-1457-021 (A-2)
Location: at the pivot point in the multi-task control
handle.
Purpose: provides lift and lower request input to
M4 ACCESS 2.
Data: 1.7 K ohm, ACCESS 4 supplies 5.2 V input volt-
Electronic Power Steering Motor
age. Full lower = 4.0 V, handle centered = 2.4 V, full
Location: in the traction motor compartment mounted raise = 0.9 V. View POT2 inputs in A2.4.19.
to the carriage.
Purpose: reduces the steer effort provided by the op- (C1.2).
erator.
Data: ACCESS 5 provides speed control via operator DIA-1457-006 (B-2)
input (RPS2). View M4 status in A3.5.1 for rms current,
A2.5.2 for speed, A2.5.1 for current, A2.5.3 (1) for tem-
perature.
Adjustment: N/A POT3
Accessory Potentiometer
DIA-1457-017 (C-3)
Location: in the handle portion of multi-task control
Parts Breakdown: 06.2-1457-050 handle.
Purpose: provides accessory request input to
Potentiometers ACCESS 2.
Data: 1.7 K ohm, ACCESS 4 supplies 5.2 V input volt-
POT1 age. Full retract = 4.7 V, thumb-ball centered = 2.8 V,
full reach = 0.9 V. View POT3 inputs in A2.14.20.
Traction Accelerator Potentiometer Adjustment: refer to ACCESS 123 Calibration Menu
(C1.3)
Location: at the pivot point in the multi-task control
handle. Diagrams: DIA-1457-002 (B-3)
DIA-1457-o06 (B-2)
Purpose: provides traction request input to
ACCESS 2. Parts Breakdown: 04.6-1457-003 (52)
M1.0-1457-127 Crown 2009 PF17424-28
80
CJ\own Potentiometers
POT3
POT1
M3
(DC)
M4
Figure 22118
Crown 2009 PF17424-29 M1.0-1457-128
81
Relays CJ\OWI'
POT4 K3
Tilt Position Assist Potentiometer Accessory Options and Fie Relay (optional)
Location: on the reach carriage. Location: on the ACCESS 1 display mounting
bracket.
Purpose: provides tilt position input to ACCESS 3.
Purpose: provides voltage to accessory options and F/
Data: 5 Kohm, ACCESS 3 supplies 12 V input voltage.
C panel.
View POT4 inputs in A2.3.6.
Data: 24/36 V coil energized upon keyswitch closure.
(C2.6). Diagrams: DIA-1457-002 (A-1) (B-4)
DIA-1457-Q09 (B-2)
DIA-1457-004 (C-2) Parts Breakdown: 04.8-1457-003 (36)
DIA-1457-014 (C-3)
09.0-1452-100 (72)
Relays
K1
Power Up Relay
Location: on the distribution panel.
Purpose: provides power up, power down sequence
interlock
Data: 24/36 V coil energized upon keyswitch closure
Diagrams: DIA-1457-002 (A-4) (B-4)
DIA-1457-Q05 (B-2) (A-2)
K2
Options Relay (optional)
Location: on the distribution panel.
Purpose: provides voltage path to work lights (LGT2,
LGT3), strobe (LGT4) and FAN5.
Data: 24/36 V coil energized upon keyswitch closure.
Diagrams: DIA-1457-Q02 (B-4) (A-1)
DIA-1457-Q05 (A-2) (B-2)
M1.0-1457-129 Crown 2009 PF1742<h30
82
CJ\owr. Relays
K3
K1 K2
POT4
Figure 22119
Crown 2009 PF17424-31 M1.0-1457-130
83
Solenoids CAOWI'
K11 Solenoids
F/C Thermostat Relay
PYA
Location: mounted on the FIC panel near the steering
tiller support. Proportional Valve Accessory
Purpose: provides a voltage path to the thermostat
(THS4).
Purpose: provides proportional flow control of acces-
Data: 24 V
sory functions.
Diagrams: DIA-1457-Q12 (A-4) (B-2)
Data: ACCESS 4 provides constant positive to PYA
Parts Breakdown: 04.9-1457-001 (4) coil and switches BNEG in proportion to command
when accessory function is requested via POT3 or
= =
SSS. Off 0 V, Accessory request 2-10 V. Coil resis-
K12 tance = 30 ohm. View PYA outputs in A3.4.5. Test PYA
in A4.4.5.
F/C Heater Relay
Location: mounted on the FIC panel near the steering (C2.4).
tiller support.
Purpose: provides a voltage path to the FIC resistors DIA-1457-016 (B-2) (C-3)
(heaters). HYD-1457-001
HYD-1457-003
Data: 24 V/36 V
HYD-1457-005
Diagrams: DIA-1457-012 (A-3) (B-2)
M1.0-1457-131 Crown 2009 PF17424-32
84
CJ\OWrl Solenoids
PYA
K12
Figure 22715
Crown 2009 PF17424-33 M1.0-1457-132
85
Solenoids CJ\own
PVL Diagrams: DIA-1457-002 (A-2)
DIA-1457-Q16 (B-1) (B-3)
Proportional Valve Lower Parts Breakdown: 02.4-1457-Q01 (21)
Purpose: provides proportional flow control of raise SVBY
and lower functions.
Solenoid Bypass Valve
Data: ACCESS 4 provides constant positive to PVL
coil and switches BNEG in proportion to command Location: on the hydraulic manifold block.
when raise/lower function is selected via POT2. Off =
Purpose: provides hydraulic flow path for raise func-
o V, Full speed lower = 20 V, Coil resistance = 30 ohm.
tion.
View PVL outputs in A3.4.1. Test PVL in A4.4.1.
Data: ACCESS 4 provides constant positive to SVBY
(C2.3).
and switches negative in proportion to command. Off =
o V, Raise = 20 V, Coil resistance = 30 ohm. View
Diagrams: DIA-1457-002 (A-2) SVBY outputs in A3.4.8. Test SVBY in A4.4.8.
DIA-1457-016 (B-2) (C-3)
Adjustment: N/A
DIA-1457-Q16 (B-2) (C-3)
SCV HYD-1457-Q01
HYD-1457-003
HYD-1457-Q05
Solenoid Valve Holst
Purpose: provides hydraulic flow path to lift pump for
hoist function. SVL
Data: ACCESS 4 provides constant positive to SCV
Solenoid Valve Lower
and switches negative when hoist function is selected
via POT2. Off = 0 V, Lower = 20 V, Coil resistance = 30 Location: on the hydraulic manifold block.
ohm. View SCV outputs in A3.4.9. Test SCV in A4.4.9.
Purpose: provides hydraulic flow path for lower func-
Adjustment: N/A tion.
Diagrams: DIA-1457-Q02 (A-2) Data: ACCESS 4 provides constant positive to SVL

DIA-1457-016 (B-2) (C-3) and switches negative in proportion to command. Off =

o = =
V, Lower 2-10 V, Coil resistance 30 ohm. View
SVL outputs in A3.4.1 O. Test SVL in A4.4.1 O.
Adjustment: N/A
SVA
DIA-1457-Q16 (B-2) (C-3)
Solenoid Valve Accessory
Parts Breakdown: 02.4-1457-Q01 (17)
Purpose: selects direction of hydraulic flow for acces-
sory function. .
Data: ACCESS 4 provides constant positive to SVA
and switches negative when hoist function is selected
via POT3 or SSS. Off = 0 V, Retract/tilt down/sideshift
right = 20 V, Coil resistance = 30 ohm. View SVA out-
puts in A3.4.11. Test SVA in A4.4.11.
Adjustment: N/A
M1.0-1457-133 Crown 2009 PF17424-34
86
CJ\OWf\ Solenoids
PVL
SVL
Figure 22120
Crown 2009 PF17424-35 M1.0-1457-134
87
Switches CAOW"
SVR Switches
Solenoid Valve Reach
BRES1
Location: on the reach carriage manifold block.
Purpose: provides hydraulic flow path for reach func- Battery Retainer Switch
tion.
Location: on the right hand side of the battery com-
Data: ACCESS 4 provides constant positive to SVR partment.
and switches negative. Coil resistance = 30 ohm. View
Purpose: indicates whether battery restraint is in place
SVR outputs in A3.4.12. Test SVR in A4.4.12.
to ACCESS 4.
Adjustment: N/A
Data: switch wired normally open, held closed by bat-
Diagrams: DIA-1457-002 (A-2) tery retainer in place. View status of BRES1 & BRES2
DIA-1457-014 (C-2) in A2.4.4.
Parts Breakdown: 02.4-1457-200 (1) Adjustment: slight adjustment available through elon-
gated holes in the mounting bracket.
SVS Diagrams: DIA-1457-002 (B-2)

DIA-1457-014 (B-4)
Solenoid Valve Sideshift Parts Breakdown: 01.2-1457-100 (13)
Purpose: provides hydraulic flow path for sideshift left BRES2
function.
Battery Retainer Switch
Data: ACCESS 4 provides constant positive to SVS
and switches negative. Coil resistance = 30 ohm. View Location: on the left hand side of the battery compart-
SVS outputs in A3.4.13. Test SVS in A4.4.13. ment.
Adjustment: N/A Purpose: indicates whether battery restraint is in place
to ACCESS 4.
DIA-1457-014 (C-2) Data: switch wired normally open, held closed by bat-
tery retainer in place. View status of BRES1 & BRES2
parts Breakdown: 02.4-1457-200 (19)
in A2.4.4.
Adjustment: slight adjustment available through elon-
SVT gated holes in the mounting bracket.
Solenoid Valve Tilt
DIA-1457-014 (C-4)
Purpose: provides hydraulic flow path for tilt back
function.
Data: ACCESS 4 provides constant positive to SVT
and switches negative. Coil resistance = 30 ohm. View
SVT outputs in A3.4.14. Test SVT in A4.4.14.
Adjustment: N/A
DIA-1457-014 (C-2)
Parts Breakdown: 02.4-1457-200 (10) (14)
M1.0-1457-135 Crown 2009 PF17424-36
88
LUBRICATION & ADJUSTMENT I
CJ\owr. Switches
SVR
SVT
BRES1
BRES2
Figure 22121
Crown 2009 PF17424-37 M1.0-1457-136
89
Switches
BRS1 ENS
Left Brake Pedal Switch Entry Bar Switch

Location: under the floorboard, left foot pedal. Location: under the floorboard.
Purpose: allows operator to actuate the brakes Purpose: disables the traction circuit through
through ACCESS-4. ACCESS 4 whenever the operator's foot is resting on
the power unit skirt along the operator compartment.
Data: momentary contact wired normally closed, held
open. Switch activated when operator is not on the Data: wired normally closed, presence of operator's
pedal. View BRS1 status in A2.4.5. foot on entry bar actuates the switch. View ENS status
in A2.4.11.
Adjustments: N/A
Adjustments: N/A
DIA-1457-015 (B-1)
DMS1
FLS
Operator Presence Switch
Free Lift Switch
Location: under the floorboard, right foot pedal.
Location: on the reach carriage.
Purpose: limits truck operation when the operator's
foot is not in the proper position for stand up operation. Purpose: informs ACCESS 4 when the mast is within
the free lift range
Data: wired normally closed, held open. Switch is actu-
ated when operator's foot is on the pedal. View DMS1 Data: wired normally open, held closed when mast is in
status in A2.4.1 O. free lift range; opens when mast is not in free lift range.
View FLS status in A2.4.12.
Adjustments: N/A
Adjustments: slight adjustment possible with the jam
nut on the shaft.
DIA-1457-015 (B-1)
DIA-1457-014 (C-2)
EDS 07.2-1452-116 (102)
Emergency Disconnect Switch

Location: on the multi-task control handle.
Purpose: resets the emergency disconnect contactor
(ED1), removing battery power from control and power
circuits.
Data: wired normally closed. Pressing switch button
actuates the switch.
Adjustments: N/A
DIA-1457-006 (B-3)
Crown 2009 PF17424-38

M1.0-1457-137
90
CJ\owr. Switches
FLS
ENS
Figure 22122
Crown 2009 PF17424-39 M1.0-1457-138
91
Switches l!J\OWI'
FNS HNS
Operator Compartment Fan (FANS) Switch Horn Switch
Location: on ACCESS 1. Location: part of the handle harness in the multi-task
control handle.
Purpose: allows the operator to control FAN5 with
OFF, LOW and HIGH selections. Purpose: allows the operator to sound horn.
Data: three position selector switch Data: momentary contact switch wired normally open;
when the horn button is depressed, the switch closes
Adjustments: N/A
and actuates the ACCESS 4 driver which supplies
Diagrams: DIA-1457-014 (A-1) BNEG to the hom. View status of HNS in A2.4.3.
Parts Breakdown: 04.8-1457-001 (3) Adjustments: N/A
FS DIA-1457-006 (B-2)
Forward Switch
Location: in the multi-task control handle. KYS
Purpose: informs ACCESS 4 of forward travel direc-
tion selection from the operator. Keyswltch or Keyless Keyswltch
Data: optic switch with 0 V output when forward travel Location: in the operator compartment near
direction is selected, 5 V output when neutral or re- ACCESS 1.
verse travel direction is selected. View status of FS in
Purpose: allows the operator to key truck ON and
A2.4.17.
OFF.
Adjustments: N/A
Data: key (or keyless) operated selector switch which
Diagrams: DIA-1457-002 (B-3) energizes K1 in the start position and maintains K1 in
DIA-1457-006 (C-2) the ignition position.
HGTRS2 DIA-1457-006 (B-3)
Parts Breakdown: 04.0-1457-001 (19) (24)
Height Reset Switch 04.0-1457-100 (18) (23)
Location: on the inside of the mast top cross brace.
Purpose: reports mast status to ACCESS 4 to indicate
when the mast is fully collapsed (or staged).
Data: wired normally open, held closed when mast is
below staging; output to ACCESS 4 is 3 V below stag-
ing and 5 V above staging. View HGTRS2 status in
A2.4.2.
Adjustments: N/A
Diagrams: DIA-1457-Q02 (B-2)
DIA-1457-010 (B-2)
DIA-1457-029 (B-2)
07.2-1452-100 (27)
07.2-1457-200 (11)
Crown 2009 PF17424-40

M1.0-1457-139
92
lUBRICATION & ADJUSTMENT
Cl\OWI' Switches
(\
KYS
\
HGTRS2
FNS
Figure 22123
Crown 2009 PF1742441 M1.0-1457-140
93
~--------------------------------
LUBRICATION & ADJUSTME~T

Switches CJ\own
LGS1 RS
Dome Light Switch (optional) Reverse Switch

Location: on ACCESS 1 Location: in the multi-task control handle.
Purpose: allows the operator to control the dome light. Purpose: informs ACCESS 4 of reverse travel direc-
tion selection from the operator.
Data: toggle switch, wired normally open.
Data: optic switch with 0 V output when reverse travel
Adjustments: N/A
direction is selected, 5 V output when neutral or for-
Diagrams: DIA-1457-002 (B-2) ward travel direction is selected. View RS status in
DIA-1457-010 (B-2) A2.4.16.
LGS2 DIA-1457-006 (C-3)
Work Light Switch (optional)
Location: on ACCESS 1
Purpose: allows the operator to control the work lights.
Data: toggle switch, wired normally open.
Adjustments: N/A
ORS
Lift Cutout Override Switch (optional)

Location: on ACCESS 1
Purpose: allows the operator to override a lift cutout.
Data: momentary contact toggle switch, wired normally
open. View ORS status in A2.4.13.
Adjustments: none required
Diagrams: DIA-1457-Q02 (B-2)
M1.0-1457-141 Crown 2009 PF17424-42
94
CJ\owr. Switches
RS
LGS2
o Lbs\ ®J
_ 185 in
ORS
Figure 22124
Crown 2009 PF1742443

M1.0-1457-142
95
Switches l!J\OW"
SSS TBS
Sideshift Select Switch Tilt Back Select Switch

Location: part of the handle harness in the multi-task Location: part of handle harness in the multi-task con-
control handle. trol handle
Purpose: allows the operator to indicate sideshift se- Purpose: allows operator to indicate tilt back selection
lection to ACCESS 4. to ACCESS 4
Data: momentary contact switch wired normally open, Data: momentary contact switch wired normally open,
held closed; actuated when sideshift is selected and held closed; actuated when tilt back is selected via the
switch opens. View SSS status in A2.4.15. thumbwheel and switch opens. View TBS status in
A2.4.7.
Adjustments: N/A
Adjustments: N/A
DIA-1457-006 (B-2)
TOS
Tilt Down Select Switch

Location: part of the handle harness in the multi-task
control handle.
Purpose: allows the operator to indicate tilt back selec-
tion to ACCESS 4.
Data: momentary contact switch wired normally open,
held closed; actuated when tilt back is selected via the
thumbwheel and switch opens. View TBS status in
A2.4.6.
Adjustments: N/A
DIA-1457-Q06 (B-2)
Crown 2009 PF1742444

M1.0-1457-143
96
CJ\owr. Switches
~-TBS
TDS
SSS
Figure 22125
Crown 2009 PF1742445

M1.0-1457-144
97
CJ\OW"
Notes:
98
CROWl) Metric Torque Values
Metric Torque Values

All Crown trucks are manufactured with class 8.8 or
better screws and bolts. The information contained in
this section will aid you when replacing any screws and
bolts that are necessary when performing maintenance
on your lift truck.
Grade
Grade Marking Bolt and Screw

Specification Material
(on Head) Size (mm)
@ Class 5.8 Low Carbon Steel M5 through M36
Medium Carbon Steel

@ Class 8.8
Quenched and Tempered
M5 through M36
Medium Carbon Alloy Steel

@ Class 10.9
M5 through M36
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all of 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.
Figure 15048
Crown 1989 PF8514-1 Rev. 11108 M1.9-06.6-001

02 Rev. 11/08
99
Metric Torque Values CJ\OWI'
Torque Chart - Metric Hex Head Cap Screws and Nuts
Thread Diameter Tightening Torque Nm (ft Ib)

& 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)
M10x1.50 39 - 43 (29 - 32) 56 - 61 (41 - 45) 68 - 75 (50 - 54)
M12x1.75 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 340357 (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: Torque values called out in the maintenance section of this manual will take precedence over torque
values found on this page.
Torque Chart - Metric Hex Socket Countersink Head Screws

M5x 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)
M10x1.50 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
M1.9-06.6-002 Crown 1989 PF8514-2 Rev. 11/08
02 Rev. 11/08
100
CJ\OWI' Metric Torque Values
Torque Chart· Metric Socket Head Cap Screws

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)
Torque Chart· Metric Flanged Hex Head Cap Screws and Nuts
I

M5 x 0.80 8-11 (6-8) 9-12(7-9}
M6 x 1.00 14-16(10-12} 16-19(12-14}
M8 x 1.25 31 - 34 (23 - 25) 38 - 41 (28 - 30)
M10 x 1.50 62 - 68 (46 - 50) 75 - 81 (55 - 60)
M12 x 1.75 108 -117 (80 - 86) 130 - 141 (96 - 104)
M14 x 2.00 174 - 187 (128 -138) 209 - 225 (154 -166)
M16 x 2.00 273 - 294 (201 - 217) 327 - 354 (241 - 2610
M20 x 2.50
Crown 1989 PF8514-3 Rev. 11108 M1.9-06.6-003

02 Rev. 11/08
101
CJ\OWI'
Notes:
102
CJ\owr. Torque Values
Torque Values
All Crown Trucks are manufactured with Grade 5 or
better screws and bolts. The information contained in
this section will aid you when replacing any screws and
bolts that are necessary when performing maintenance
on your lift truck.
Grade
Grade Marking Bolt and Screw

Specification Material
(on Head) Size (Inches)
0 SAE - Grade 2 Low Carbon Steel 1/4 thru 1-1/2
Medium Carbon Steel,

(0 SAE - Grade 5
1/4 thru 1-1/2
Medium Carbon Alloy Steel,

@© SAE - Grade 8
1/4 thru 1-1/2
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted
assemblies. 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.
Figure 14916
Crown 1979 PF5067-1 Rev. 9106 M1.9-14.D-001

04 Rev. 9/06
103
Torque Values CJ\OWI'
Torque Chart
Bolt Grade 5 Grade 8

Diameter Dry Torque Requirement Dry Torque Requirement
in ftlb kgm Nm ftlb kgm Nm
1/4 9±3 1.2 ±.4 12 ±4 13 ±4 1.8± .5 17.5 ± 5.5
5/16 18 ± 5 2.5± .7 24.5 ± 7 25 ±5 3.5± .7 34±7
3/8 32 ± 5 4.4± .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
Mounting bolt torque requirements
involving hydraulic valves.
5/16 13 ± 2 1.8 ±.3 17.5±2.5

3/8 24±2 3.3 ±.3 32.5 ± 2.5
7/16 39 ±2 5.4± .3 53 ± 2.5
NOTE:Torque values called out in the maintenance section of this manual will take prece-
dence over torque values found on this page.
M1.9-14.0-002 Crown 1979 PF5067-2 Rev. 9/06
04 Rev. 9/06
104
mow"
HYDRAULIC
105
CAOW"
Notes:
106
HYDRAULIC
CJ\owr. Hydraulic System
Hydraulic System 1 10 Micron Filter

2 100 Mesh Filter
3 Pneumatic Pump
Adding Hydraulic Oil
4 Heavy-Duty Polyethylene Funnel 250 x 175 mm
The hydraulic system is very susceptible to dirt and (10.0 x 7.0 in)
contamination that could, over time, create hydraulic 5 To air source
malfunctions. Therefore, before adding oil to the truck,
filter the oil with a 10 micron filter or with a 100 mesh
strainer. This is especially important when the oil it WARNING
source is a 55 gallon drum. An example of a pneumatic A VOID HIGH PRESSURE FLUIDS-Escaping fluid un-
pump with a 10 micron in-line filter and a funnel with a der pressure can penetrate the skin causing serious in-
100 mesh strainer is shown below. jury. Relieve pressure before disconnecting hydraulic
To select the appropriate hydraulic oil, refer to the Lu- lines. Tighten all connections before applying pres-
brication and Adjustment section. sure. Keep hands and body away from pin holes which
hand.
type of injury.
Hydraulic Lines and Fittings

1. Blow air through all the hoses and lines to remove
loose particles before installing. Any rubber hoses
with a wire braid inner construction, thermoplastic
hose and any steel tube lines which have been col-
lapsed or kinked are permanently damaged and
must be replaced even if the damage is not exter-
nally visible.
2. Flexible hoses shall be replaced if they collapse in
their normal operating position.
3. All hoses and lines are to be clear of any surface or
edge which will cause damaging wear and cuts, or
anything upon which they can become caught.
4. All connections are to be leak free.
5. Beaded elbows in the suction ports of all pumps
must be positioned such that the suction hose re-
tains its full volume flow and does not collapse.
Figure 16837-01
Crown 2009 PF17425-1 M2.0-1457-001
107
HYDRAUliC
Hydraulic System CROWl'
Filter Reservoir
The internal filter is contained within the reservoir filter! Check the reservoir fluid level when the oil is warm. If it
fill assembly. is not, operate the lift for fifteen minutes first before
checking the fluid level.
91 With all the cylinders in the retracted position, and after

1 all the air has been bled from the hydraulic system, fill
the reservoir so that the oil level is at the "add" marks.
Excess oil above the "add" mark should be removed.
The total capacity of the hydraulic system at this level
should be approximately:
• Trucks with dual reservoirs: 24.6 liters (6.5 gal)
• Trucks with a single reservoir: 27.4 liters (7.25 gal)
Lt CAUTION
Never stand or work under a suspended load.
Figure 16838-01
Torque to 22 - 27 Nm (16 - 20 ft Ib) Secondary Lift Pump {P2} Cutout

To access the filter, rotate the filter cap counterclock- If the truck is equipped with two lift pumps, verify that
wise and remove. Grasp the inner support tube and re- the secondary lift pump cuts out when the forks are ap-
move the filter element. The filter element can be re- proximately 304.8 mm (12.0 in) from full elevation.
moved from the support tube and replaced. Insert the
filter element and support tube and replace the filter
cap. Torque the cap to 22 - 27 Nm (16 - 20 ft Ib). Dis-
pose of the filter and used oil in accordance to the laws
and regulations conceming the disposal of hazardous
waste.
M2.0-1457-002 Crown 2009 PF17425-2
108
HYDRAULIC
CJ\OWrl Hydraulic System
Lift Speed Hoist Drift

1. Elevate the capacity load (Le., 1587.6 kg [3500 Ib]
NOTE on the RR 5725-35) to a height above the mast
staging height. Return the control handle to the
The test load for testing must be evenly stacked within
neutral position.
limits of a 1.22 x 1.22 m (4 x 4 ft) pallet and must be
secured to the fork carriage with the forks spread to the 2. The load drift may not exceed 50.8 mm (2.0 in) in
maximum width. five minutes. If the drift exceeds this amount, cor-
rective action may be required.
NOTE
If high speed lift is requested but the lift slows down, Tilt Drift
check FU11 for a blown fuse.
1. Using a rated capacity load (Le., 1587.6 kg
1. Determine the lift speed while raising the capacity [3500 Ib] on the RR 5725-35) at the 609.6 mm
load (Le., 1587.6 kg [3500 Ib] on the RR 5725-35) (24.0 in) load center, put the forks in the tilted up
with full handle command and while load is moving position and elevate the carriage to a convenient
at a maximum constant speed in the extended height below free lift. Return the accessory control
(staged) portion of mast travel. Refer to Chart 2 - to the neutral position.
Minimum Lift Speeds.
2. The tilt drift may not exceed 1.25° or 12.7 mm
(0.5 in) in five minutes (measured at the 609.6 mm
Chart 2 • Minimum Lift Speeds [24 in] load center). If the drift exceeds this amount,
corrective action may be required.
Minimum Lift Speed in
Truck Model Number Feet Per Minute (fpm) Hydraulic System Contamination
with a Capacity Load
Contamination in the hydraulic system can cause se-
RR 5715-35 25
vere damage to the system. Any maintenance done to
RR 5715-40 23 the hydraulic system should be done in a clean work
area and the component parts should be kept as clean
RR 5725-35 59
as possible during assembly. Any hydraulic oil put into
RR 5725-35 AC Lift 75 the system should be clean and strained as described
in Adding Hydraulic Oil in this section.
RR 5725-45 47
RR 5725-45 AC Lift 60
Main Lift Cylinder and Carriage Cyl-
RD 5725-30 57
inder Contamination
RD 5725-30 AC Lift 72
1. Move the truck to a secure non-traffic maintenance
RR 5795-45 47 area with a level floor, preferably under a hoist, and
RR 5795-45 AC Lift 60 chock the wheels.
RD 5795-30 57 2. Raise the mast and block the 2nd stage mast
915 mm (36.0 in) from the floor. Key the truck OFF
RD 5795-30 AC Lift 72 and disconnect the battery. LockoutfTagout the
truck as described in the Control of Hazardous En-
2. If the truck is equipped with freezer oil, it is recom-
ergy section.
mended that the oil is less than 38° C (100° F)
when recording lift speed or slow lift speeds will re- 3. Open the manual lowering valve (MVL) and slowly
sult. lower the carriage.
3. If the lift speed is outside the specified range, cor-
rective action may be required. Check the relief
=
pressure; RV1 22063 kPa (3200 psi).
Crown 2009 PF17425-3 M2.0-1457-003
109
HYDRAULIC
Hydraulic System CJ\own
2 3
Manual Lowering Valve
Figure 22075
4. Refer to Figure 16840-01. Loosen the fitting on the

cross over hydraulic tube leading from the main
supply line on the left lift cylinder as viewed facing
the front of the truck. Loosen the fitting and remove
the hydraulic tube from the bottom of the right hand
lift cylinder.
Figure 16840-01
1 Loosen fitting; do not remove

2 Left hand Lift Cylinder
3 Right hand Lift Cylinder
4 Loosen and remove fitting from bottom of cylinder
5. Remove the hydraulic lines from both lift cylinders,

from the bottom of the carriage cylinder and from
the hydraulic hose to the truck's power unit. Blow
air through the hoses and lines to remove loose
particles. Catch any hydraulic oil that may be
spilled and do not reuse.
6. Remove the rams from both main lift cylinders.
Flush both cylinders with a water based degreaser,
Crown part number 063009-005, and blow all de-
greaser and moisture from the cylinder tubes mak-
ing sure they are clean and dry. Check the rams
and cylinder tubes for damage.
M2.0-1457-004 Crown 2009 PF17425-4
110
HYDRAULIC
CJ\OWI' Hydraulic System
7. Remove the ram from the carriage cylinder. Flush 1. Lower the carriage to the floor and open MVL to
the carriage cylinder tube with a water based de- relieve the pressure. Disconnect the battery, re-
greaser, Crown part number 063009-005, and move all hydraulic hoses and lines from the mani-
blow all degreaser and moisture from the cylinder fold block, and cap lines and hoses with plastic
tube making sure it is clean and dry. Check the ram plugs to avoid oil leakage and contamination.
and cylinder tube for damage. Catch any oil that may be spilled.
8. Remove the hydraulic line from port "c" on the 2. Remove the manifold block from the truck and
manifold block going to the lift cylinder and blow air place it on a clean piece of cardboard in a clean
through the line to remove loose particles. Connect area to avoid contamination while disassembling.
the hydraulic lines to the cylinders but do not con-
nect the hydraulic line to the manifold block. Cap NOTE
the line with plastic plug to prevent dirt or contami-
nation from getting into it. ORF3 is accessed by removing the SAE plug and then
unscrewing ORF3 from the cavity. Also, ensure ORF4
is removed from the PCL cavity. ORF4 is an orifice disc
Hydraulic Tank Contamination positioned at the base of PCL.
1. Check the condition of the hydraulic filter element 3. Remove all valves from the manifold block and
and breather element, and change as required per place them on a clean piece of cardboard. During
the Planned Maintenance section. Crown recom- the entire disassembly, flushing, putting valves
mends replacement of the following every 2000 back into the manifold block and proper torque of
hours of operation: valves, it is extremely important to keep work sur-
faces and parts as clean as possible to avoid con-
• Hydraulic Oil tamination.
• Filter Element 4. Make a visual inspection of the valves, valve seals
and valve cavities for any signs of defects or con-
• Breather Element tamination. Check operation of the valve mecha-
nisms for sticking or rough operation. If any valves
2. If contamination has reached the hydraulic reser-
are contaminated or do not function properly, dis-
voirs, Crown recommends draining them com-
card the valve and replace with a new valve.
pletely. Remove the hydraulic lines or tubes and
flush the tanks with a water based degreaser,
Crown part number 063009-005, and blow all de- NOTE
greaser and moisture from the hydraulic reser- When using a siphon sprayer to clean the valves and
voirs. Reconnect all lines and tubes to the hydrau- ports, or the compressed air nozzle to remove moisture
lic reservoirs. from the manifold block, do not exceed 275 kPa
3. Clean the outside of the manifold block with the (40 psi) of air pressure to the sprayer to avoid doing
same water based degreaser to remove surface any damage.
dirt. A decision needs to be made at this point 5. Thoroughly clean the valves using a siphon
whether to clean and flush the manifold block or sprayer, Crown part number 065174-001, and a
replace it with a new assembly. If contamination in- water based degreaser, Crown part number
side the manifold block is extensive, replacement 063009-005.
should be seriously considered.
6. After cleaning, blow all liquid from the valves with
an air nozzle, check the valve operation again and
Hydraulic Manifold Block Removal place the valves in a clean, lint free location.
and Flushing
~ CAUTION
Do not put the manifold block or components into a de-
greaser tank to clean. Do not use spilled oil.
Crown 2009 PF17425-5

M2.0-1457-005
111
HYDRAULIC
Hydraulic System l!J\OW"
NOTE 14. Refer to Figure 22017 for valve and plug place-
ment. Refer to Chart 3 - Torque Values for the
Be careful not to damage the hex hole or the plug by torque values of the valves and plugs.
using excessive force.
7. Remove the SAE plugs from the manifold block. It
sometimes helps to tap the top of the plugs using a
small hammer and a large diameter (6.5 mm
[0.25 in)) flat punch prior to loosening them with a
wrench.
8. Check all the ports for contamination and then
place the manifold block in a clean container for
flushing. With the same sprayer and water based
degreaser used in step 5, thoroughly flush each
port on the manifold block.
9. Remove the manifold block from the container and
place it into a clean container on top of a clean
block. Use the compressed air nozzle to blow air
over and through the manifold block to completely
remove any moisture. It is very important that the
inside and outside of the manifold block be totally
dry and clean.
10. Check each port on the manifold block with a flash-
light for contamination that may not have been
completely flushed out. If contamination is found,
flush the manifold block a second time as previ-
ously described.
11. Remove the top (cap) O-ring seal from each valve,
cover the threads on each valve with sleeve or tape
to prevent damage to the new seal and carefully
replace the top O-ring seal supplied in the kit. The
top O-ring (cap) seal will be the one closest to the
outside surface of the manifold block after the
valve is installed in the manifold block. Visually in-
spect all other O-ring seals and back-up rings and
replace as required. These O-rings are not sup-
plied in the kit, but are listed in the Manifold sec-
tion, and are available through Crown.
12. Apply a light film of hydraulic oil to the O-ring
threads of all the valves before installing into the
manifold block. When installing ORF4 and PVL
into the cavity, spread a clean, light grease on the
flat side of ORF4, stick it on the nose of PVL and
carefully insert it into the cavity. Ensure that ORF4
is positioned with the flat surface contacting PCL.
The surface with the chamfer edge is inserted into
the cavity. This will properly orient ORF4 and pre-
vent it from changing position during installation.
13. Install each valve into the manifold block by hand
until snug.
M2.0-1457-006 Crown 2009 PF1742!Hl
112
HYDRAULIC
CJ\OWI' Hydraulic System
,/#6
$---ORF3
~ RV2
@"
I
#6
Figure 22017
Crown 2009 PF17425-7 M2.0-1457-007
113
HYDRAULIC
Hydraulic System CJ\OWI'
Chart 3 - Torque Values
Cartridge Torque Coil Nut Torque Top a-Ring

Reference Valve/Plug Part Seal Kit
Replacement
Designation Number Nm (ft Ib) Nm (ft Ib) Part Number
Part Number
#4 Plug . 064091-006 14 - 15 (10-11) 064019-031
#6 Plug 064091-002 23 - 24 (17-18) 064019-029
#8 Plug 064091-001 41 -43 (30 - 32) 064019-030
#10 Plug 064091-007 41 -43 (30 - 32) 064019-045
CV1 123255-003 95 -108 (70 - 80) 064019-075 111790-023
CV2 117380-002 47 - 54 (35 - 40) 064019-045 111790-020
CV3 114816-004 20 - 23 (15 - 17) 064019-030 111790-016
MVl 145114 47 -54 (35 - 40) 064019-030 111790-016
ORF3 145119 8-9 (6 - 7)
ORF4 106845-008
PCA 147195 68 -75 (50 - 55) 064019-075 111790-026
PCl 144605 68 -75 (50 - 55) 064019-075 111790-024
PVA 135724-001 47 - 54 (35 - 40) 7-9 (5 - 7) 064019-045 111790-020
PVl 135800-001 54 - 61 (40 - 45) 7-9 (5 - 7) 064019-075 111790-023
RV1 145115 47 -54 (35 - 40) 064019-045 111790-020
RV2 138361-002 47 -54 (35 - 40) 064019-030 111790-005
SCV 117304-005 47 - 54 (35 - 40) 7-9 (5 - 7) 064019-045 111790-020
SVA 117385-004 47 - 54 (35 - 40) 7-9 (5 - 7) 064019-045 111790-029
SVBY 117377-003 34 -41 (25 - 30) 4-7 3-5 064019-030 111790-016
SVl 135723-001 68 -75 (50 - 55) 7-9 (5 - 7) 064019-075 111790-023
15. Install the manifold block into the power unit, removing the mast block, key the truck OFF, discon-
move all plastic plugs and connect all hydraulic nect the battery and leave the mast in an elevated
lines and hoses previously removed from the man- position.
ifold block, cylinders and power unit.
18. Slowly open the bleed screw on the carriage cylin-
16. Fill the hydraulic reservoirs with hydraulic oil using der and bleed air from the cylinder until a solid
a 100 micro strainer; use the hydraulic oil specified stream of hydraulic oil flows out around the bleed
in the Planned Maintenance section. screw.
17. Connect the battery and key the truck ON, allowing 19. Tighten the bleed screw and wipe off any excess
the truck to run for a minute or two. Open MVl and oil.
slowly actuate raise to purge the air out of the
20. Slowly open the bleed screw on the right hand or
manifold. After a short period of time, stop raise
left hand lift cylinder and bleed air from the cylinder
and close MVL. Slowly elevate the carriage through
until a solid stream of hydraulic oil flows out around
free lift to re-stage the mast. Continue to slowly lift
the bleed screw.
the mast until the mast block can be removed from
under the second stage mast. After carefully re-
M2.0-1457-008 Crown 2009 PF17425-8
114
HYDRAULIC
CJ\OW" Hydraulic System
21. Tighten the bleed screw and wipe off any excess
oil.
22. Bleed the second lift cylinder as described above.
23. After bleeding the cylinders, connect the battery,
key the truck ON and use the multi-task control
handle to raise the carriage through free lift and
into stage; stop and hold the position.
24. With the carriage raised, examine the cylinders for
any leaks.
25. Lower the carriage through free lift to examine op-
eration and staging.
26. Raise and lower the carriage rapidly through the
complete lift and lower cycle a minimum of ten cy-
cles to flush the system. Recheck the lift cylinders
and bleed them if required.
27. Key the truck OFF and check the hydraulic oil level.
Add the hydraulic oil specified in the Lubrication
and Adjustment section as required.
28. Remove the wheel chocks and verify all truck func-
tions are operational.
Crown 2009 PF17425-9 M2.0-1457-009
115
l!J\OWI'
Notes:
116
HYDRAULIC
CJ\OWI' Hydraulic Circuits
Hydraulic Circuits
Oil Flow for Hydraulic Steering

This schematic represents a 5725 truck equipped with
+
DC Hydraulics. The only difference between this sche-
matic and a schematic for a 5795S truck equipped with
DC Hydraulics is the number of reservoir symbols. The I
I
5795S truck only has one reservoir. Additionally, the I 1::----++---'------,
only difference between this schematic and a sche- I
matic for a 5715 truck is the number of hydraulic I
1
pumps. The 5715 truck does not have pump P2. Refer EF
to Figure 22618. 2
With the reservoirs (only a single reservoir on the
5795S truck) properly filled and any air bled out of the
system, oil will be present at the pump inlets.
Figure 22619
,
M
,
,
,
: P, '9 ,
P2: : 't, P1:
.--- --Ls!:~:L~P-fDJ
Figure 22618
Refer to Figure 22619. Trucks equipped with DC Hy-

draulics are also equipped with hydraulic steering. Op-
erating either (or both) steering or traction will cause
the motor that drives pump P1 to energize. When pump
P1 begins to rotate it causes oil flow through the body
of LSPFD, across the spool inside that assembly, and
out port P to the SCU (1). Pilot passages inside the
body of LSPFD route some of that oil flow through a
small internal filter and a couple of control orifices to
both sides of the spool (2). This pilot flow, combined
with tension from the bias spring on one side, sets up
a. pressure differential across the spool. Some of the
pilot oil flowing to the spring side of the spool is able to
flow through another control orifice and out port LS to-
wards the SCU (3).
Crown 2009 PF17426-1 M2.0-1457-025
117
HYDRAULIC
Hydraulic Circuits l!J\OW"
Oil flow from port P of the LSPFD flows into port P of With the oil flow in the LS line being vented back to the
the SCU (1). If the steering tiller is not being turned, oil reservoir, the pilot oil pressure on the spring side of the
will be present inside the SCU but will not flow through LSPFD spool (1) will be less than it is on the other side
it (2). The pilot oil flow from port LS of the LSPFD will (2). When the pilot oil pressure to the non-spring side
flow into port LS of the SCU (3). If the steering tiller is of the spool builds up enough pressure to overcome
not being turned, this port is connected (through a con- the spring tension, the spool will shift to a position
trol orifice inside the SCU) to port T (4) allowing this where the oil flow from pump P1 is simultaneously sup-
pilot oil flow and pressure to vent back through the plied out of ports P and EF (3). Refer to Figure 22621.
main manifold to the reservoir (5). Refer to Figure
22620.
r----------. +
I
I
I
I
LI ,
4
lI
I
----'L.=!IIt-+-+--'------ 2
-.......~-+--++-
Figure 22621
+5
Figure 22620
M2.0-1457-026 Crown 2009 PF17426-2
118
HYDRAULIC
Hydraulic Circuits
Rotating the steering tiller shifts the spool inside the

SCU, allowing the oil that is present at port P to flow
through the SCU, through the steer motor, back 4
through the SCU and to the reservoir (1). During this
operation, the control orifice (inside SCU) that previ-
ously connected port LS to port T is blocked and a path 2
that connects port LS to port P is opened. This will di-
vert a small amount of pressurized oil to port LS where
it will flow back to pump P1 (2). Refer to Figure 22622.
NOTE
I I I
Figure 22622 demonstrates the oil flow through the I ~ I
SCU while rotating the tiller in one direction. Rotating LSI
the tiller in the opposite direction would change the di- I
I
rection of the oil flow inside the SCU, causing the sup- I
ply oil (3) to flow through the SCU from port P to port L
and return oil (4) from the steer motor would flow
through from port R to port T.
Figure 22622
5 To the Tank
6 To Pump P
7 To Pump LS
Crown 2009 PF17426-3 M2.0-1457-027
119
HYDRAUL.IC
Hydraulic Circuits CAOW"
The configuration of the two hydraulic lines connected end of the truck will turn clockwise (right). If the truck is
to the steering motor (1) is what really determines set up for reverse steering (3) it means that, during for-
which way the truck will tum when the steering tiller is ward or fork first travel, when the steering tiller is ro-
rotated. If the truck is set up for forward steering (2) it tated clockwise, the fork or forward end of the truck will
means that, during forward or fork first travel, when the turn counterclockwise (left). Refer to Figure 22623.
steering tiller is rotated clockwise, the fork or forward
1 2 3
Figure 22623
To change the truck's steering direction, key the truck

OFF, disconnect the battery, and then swap the two hy-
draulic lines on the steering motor.
During steering operation, the pressurized oil flow from
port LS of the SCU into port LS of the LSPFD will be
applied to the spring side of the LSPFD spool (1).
When the combined pressure of this oil flow and the
bias spring overcomes the pressure of the pilot pres- I
sure on the other side of the spool, the spool will shift I
to a position where a larger portion of oil supplied by I
I
~
pump P1 flows out of port P to the SCU (2). Refer to I 1
Figure 22624. I 1
EF
2
~II 19
.. ~
:
I
t ~-~~-~--~:-l1
LSIL LSPFD_ I
Figure 22624
M2.0-1457-028 Crown 2009 PF17426-4
120
HYDRAULIC
CJ\owra Hydraulic Circuits
This is why the valve body attached to pump P1 is Refer to the Hydraulic Troubleshooting section of the
called a load sensing priority flow divider. Any demand Service and Parts Manual for a list of possible causes
for steering in this system is sensed through changing of these issues and recommended remedies.
pressure differentials causing the LSPFD spool to shift,
increasing oil supply to the SCU. If steering demand
decreases, LSPFD would again be shifted to a position
similar or identical to that shown in Figure 22621.
Refer to Figure 22625. The spool in the SCU is spring
biased. This means that when the steering tiller is no
longer being turned, spring tension will return the spool
to the neutral position. This prevents oil, supplied by
pump P1, from flowing across the SCU to the steer mo-
tor. This will also trap oil in the steer motor lines (1).
This trapped oil will hold the steer motor in the position
it was steered to and the truck will track along that path.
r----------.
I I
I I
I I
I I
LI IT
- I
...!IP
I I I
1- ~ I
LSI
Figure 22625
Possible hydraulic steering circuit issues include:
• Slow or sluggish steering
• Abrupt or jerky operation
• The truck is unable to maintain steered position.
Crown 2009 PF17426-5

M2.0-1457-029
121
HYDRAULIC
Hydraulic Circuits CJ\OWI'
Hoist Raise, Dual Pumps
Refer to Figure 22626. 6
p---------------------------------------------
o --------~
1. The oil flow from pump P1 will enter port P1 of the ,o

'P2 c:v2
main manifold. This pressurized oil will be present ......
.
Cl,
at the gauge port (Gp), SCV, RV1, PVA and PCA. : _"""",-1 o
o
o
o
o
o
o
NOTE 5 o
o
,,
o
The movement of PCA is (variably) proportional to the SVL ,,

hoist raise command. During the hoist raise command ,o,
o
(and no accessory command), PCA shifts to divert oil o
o
o
to the hoist circuit. Pump P1 speed detennines the ac- ,, SVA
,,:
tuallift speed. Less movement of the multi-task control ,,, ,,
,, 'B
handle will result in slower RPM ofthe motor that drives ,
pump P1. Pump P1 will provide a lower rate of flow into 'Gp
A:,
port P1, resulting in less flow into the PCA pilot pas-
,,,
o
.---.CV3
sage. PCA will not shift as far against its bias spring, RVl ,
resulting in a lesser rate of oil flow going across CV1
and out port C1. This action makes hoist raise speed
'\.
, .
~ :::~ ~~-~----------- !1
,
~:
directly proportional to the multi-task control handle po- 1
sition.
Figure 22626
2. The oil flow into the pilot passage on the non·
spring side of PCA will build up enough pressure to
push PCA against its bias spring. Hoist Raise, Single Pump
3. Oil will flow across PCA and on to SVBy and CV1. Refer to Figure 22627. 5715 model trucks will only be
The coil of SVBy is energized during hoist raise, equipped with a DC hydraulic system with only one hy-
causing the valve to shift and block the oil flow draulic pump. 5725 and 5795S model trucks can be
across SVBy. equipped with an AC hydraulic system, but such a sys-
tem uses only one hydraulic pump. Hoist raise on a sin-
4. With PCA fully shifted, the majority of oil from pump gle pump system functions the same as a dual pump
P1 will flow into the hoist raise circuit. However, system except for:
some small amount of oil will flow across PCA to
RV2, ORF3 and SVA, but not enough to affect 1. On trucks equipped with only one hydraulic pump,
hoist operation. port P2 will be plugged.
5. The oil flow will unseat CV1 and flow out manifold 2. When high speed hoist raise is requested, the mo-
port C1 to the carriage and mast cylinders. tor driving pump P1 will run at full speed and SCV
will energize and shift. This allows the oil flow en-
6. 5725 and 5795S trucks equipped with DC hydrau- tering port P1 to flow across SCV, through CV2
lics will have pump P2. When the voltage signal and out port C1.
from POT2 indicates high speed raise is required,
ACCESS 2 will use the P2 contactor to energize
the motor that drives pump P2. The oil flow from
pump P2 will enter port P2, unseat CV2 and in-
crease the rate of the oil flow out port C1. SCV
does not energize on dual pump equipped trucks.
Crown 2009 PF174~

M2.0-1457-030
122
HYDRAULIC
CJ\OWI' Hydraulic Circuits
1
~[~-------~---------------------------------- GC------j
MVL C1
.- -. C1 ,
PVl 0
o
o
0
0
0
,,,
SVl
SVl
SVA
o
o
o SVA
o
'B
G
A:, B
--.
.--.---.CV3 ,,
,,,
A:,
:
I~ : n
RV1
..... S T2 T1 :
,
4I
:
,'P1
. . sn T2
.- - --.
.---,CV3
T1:
:
,
,
,,,
. -------------------------- ---f------------- --------,

Figure 22627
1
Hoist Raise Stopped Figure 22628
Refer to Figure 22628.

1. When hoist raise is stopped, pump P1 will wind
down to a stop and the oil flow into port P1 will
quickly cease.
2. SVBy will de-energize and shift, venting residual
pressure in the hoist circuit out port T2 to the res-
ervoir.
3. As oil pressure in the pilot passage on the non-
spring side of PCA decreases, the bias spring on
PCA will gradually close PCA.
4. Once the spring has shifted PCA fully, ORF3 will
continue to vent oil pressure after PCA to port T2.
5. The weight of the mast will cause the carriage and
mast cylinder rams to exert oil pressure on CV1
and CV2, causing them to seat. This same pres-
sure will be exerted through ORF4 to the non-
spring side of PCL.
6. Oil in the manifold between PVl and SVl will
(through a pilot passage) oppose the bias spring
on PCl but the trapped oil assists the pilot spring,
balancing the pressures. Thus, the bias spring
holds PCl in position.
Crown 2009 PF17426-7 M2.0-1457-031
123
HYDRAULIC
Hydraulic Circuits CJ\OWI)
Hoist Lower Refer to Figure 22630.
When hoist lower is operated, PVl, PCl and SVl all 1. With the loss of oil pressure in the pilot passage on
work very quickly in order for lower to occur without de- the spring side of PCl, oil pressure in the pilot pas-
lay or fork bounce. Figures 22629, 22630, 22631 and sage after ORF4 will cause PCl to shift against its
22632 will help explain pressure compensated lower- spring, closing the passage between PVl and
ing by cycling one valve at a time. SVL. This will prevent the forks (and mast) from
beginning to lower too quickly as PVl opens.
1. As soon as hoist lower is operated, the SVl coil will
energize and that valve will shift fully. ~---------------------------------------------
,, -----
~
'2 CV2
2. This allows oil trapped below PVl, including oil in MVL Cl:
the pilot passage on the spring side of pel, to vent -,, '
to the reservoir through port T1.
PVL
.,
'
:,'
.
~---------------------------------------------
,
--------
·
'2 CV2
C1 : ,,,
,, SVA
,, ,, ,
, ,,, ,,,
,
,, B'
'Gp
A:,
,,, t - --. ,,
,, ,,,
···,,, 'Pl
----·CV3
,,
·,,,
,
SVA
, ____~~ ~~ 1
, ,:
·,,,, ,,,
B' Figure 22630
,
'Gp
A',
,, ,,
,, .- - --. ,,
, ----·CV3
, ,
'P1
, , ''
: I __ ~ S T2 T1:
._-------------------------- --- ------------- --------,
Figure 22629
M2.0-1457-032 Crown 2009 PF17426-a
124
HYDRAULIC
CJ\owr. Hydraulic Circuits
PVl will open in proportion to multi-task control handle Opening MVl will allow oil in the hoist cylinders to by-
movement. Refer to Figure 22631. pass PVl, PCl and SVL. MVl would be used only for
maintenance or if an event affecting hoist lower was to
1. As the oil flows across the PVl spool, some of that
occur. Refer to Figure 22632.
oil flow will be piloted into the PCl spring cavity.
2. When the combined pressure of that pilot oil flow
and the PCl spring overcomes the pressure ex- f--------------------------------------------- ~------'
erted by the pilot oil applied through ORF4, PCl ,

'P2 Cl/2
will shift, allowing oil from the hoist cylinders to flow MVl C1
through the manifold. ,,.- -.,,
CV1 , ,
3. The oil flowing towards port T1 will unseat CV3.
This allows some of the oil returning to the reser-
voirs to flow out port T2 and through the return fil-
ter.
•--------------------------------------------- GC------·
B
Gp
,,
,,,
'P1
Figure 22632
,,,
SVA
,,:
,,
B'
Gp
A:,
,,
,,,
P1
, ,
. ~ ~z~_~ ~~ ~
Figure 22631
PCl's purpose in this circuit is to act as a pressure

compensator to control actual flow out of the circuit re-
gardless of the load on the forks. Thus, the same com-
mand applied to the multi-task control handle to lower
will result in the same lower speed regardless of the
load.
Crown 2009 PF17426-9 M2.0-1457-033
125
HYDRAULIC
Hydraulic Circuits CJ\owr.
Accessory Hydraulics Refer to Figure 22634.
1. As PYA opens further, more oil will flow across its
When the thumb ball on the multi-task control handle is
rolled left or right, PYA will open in proportion to that spool to PCA, increasing flow to the accessory cir-
cuit.
movement. (When operating either the tilt back switch
(TBS) or tilt down switch (TDS), PYA will open to a set 2. Excess flow is bypassed by PCA and vented to the
point.) Refer to Figure 22633. tank through SVBy.
1. With PYA closed, pilot pressure acts on the PCA
spool opposite of the spring, shifting the spool such
that flow to the accessory circuit is restricted, and
:--------------------------------------------- ~------~
,
flow to the hoist circuit is opened. 'P2 CV2
MVL C1
PVL :- -:
2. When PYA is energized (by the operator control- rr- "
, Y I •
, ,
ling the multi-task control handle), the PYA spool is
shifted open proportional to the command. As PYA
is opened, fluid flow is established to PCA, with pi-
SVL
lot pressure applied to the spring side of the PCA
spool (additive to the spring bias), and shifts PCA
open to supply oil flow to the accessory circuit. The
SVA
pilot pressure balance determines the PYA spool
position, and provides pressure compensation to ,,
,
the accessory flow. 'Gp
A:,
,,
CV3
,,
,,
.--------------------------------------------- Gc------· , . ,
~ ~:~. ~ l2 I1. ~
P2 CV2
MVL C1'
PVL :- -:
" Y I • rr- ", ,
Figure 22634
SVL
SVA
B
Gp
A:,
,,
CV3 ,,,
P1 ,,
,,
Figure 22633
M2.0-1457-034 Crown 2009 PF17426-10
126
HYDRAULIC
CJ\owr. Hydraulic Circuits
PCA will also be positioned by pressure differential in Refer to Figure 22636.

order to provide simultaneous oil flow for hoist raise
1. The oil flow in the accessory circuit after PCA will
and one accessory. Refer to Figure 22635.
flow on to SVA, which has two envelopes, lower
1. If hoist raise is operated, SVBy will energize and and upper.
shift, blocking the oil flow to port T2.
2. During the operation of reach, sideshift left and tilt
2. With SVBy no longer venting oil flow to the reser- back, SVA stays de-energized, allowing the oil af-
voir, the oil will flow to CV1 and the hoist circuit. ter PCA to flow across the lower envelope and out
port B and oil returning from an accessory function
3. During hoist raise, the speed of the motor that
to flow into port A, across the lower envelope and
drives pump P1 is directly proportional to the multi-
out port T2.
task control handle position. An increase in the oil
flow supplied by pump P1 will accompany a com- 3. During operation of retract, sideshift right and tilt
mand for hoist raise, further increasing the amount down, SVA will energize and shift, allowing the oil
of oil flow into the hoist circuit. after PCA to flow across the upper envelope and
out port A and oil returning from an accessory func-
4. PCA will now have oil and spring pressure on one
tion to flow into port B, across the upper envelope
side and an increase in oil pressure opposing that
and out port T2.
on the other side, proportionally positioning PCA
so that enough oil flow is provided to each hydrau-
lic function.
:--------------------------------------------- GC------~ SVL

,
o P2 CV2
SVL
A',,
,
o
CV3 o
o
SVA ,, o
I
I
A:,
,,
o
CV3 o
o
o
, . 0
, . 0
~-----------------~~~"------~ --- -~----------- !!_-----~

SVL
Figure 22635 3
~
As a pressure compensator, PCA will quickly react in
response to a change in the volume of oil flow created
when the commanded speed of a hydraulic function is SVA
Bo
changed. This compensates the flow to the accessory
circuit to provide the same flow as commanded regard- o
o
less of system pressure or load changes. A:o

CV3 ,,
o
,,
I
Figure 22636
Crown 2009 PF17426-11 M2.0-1457-035
127
HYDRAULIC
Hydraulic Circuits l!J\own
Refer to Figure 22637. Refer to Figure 22638.
1. When reach is operated, SVA (in the main mani- 1. When retract is operated, SVA (in the main mani-
fold) stays de-energized and the supply oil after fold) will energize and shift. The supply oil after
PCA flows from port B of the main manifold into PCA flows from port A of the main manifold into
port B of the reach manifold. port A of the reach manifold.
2. This supply oil flows through the check valve por- 2. This supply oil flows through the check valve por-
tion of the lower CBV with some of that oil piloted tion of the upper CBV with some of that oil piloted
to the relief portion of the upper CBV. to the relief portion of the lower CBV.
3. SVR energizes and shifts, allowing oil to flow out of 3. SVR energizes and shifts, allowing oil to flow out of
the R1 ports of the manifold and into the rear of the R2 ports of the manifold and into the rod end of
both reach cylinders, where it pushes against the both reach cylinders, where it pushes against the
piston in each reach cylinder to extend the cylin- piston in each reach cylinder.
ders.
4. As the piston in each cylinder moves, the rods will
4. As the piston in each cylinder moves, the rod will be retracted and the oil in the cylinder housings on
extend and the oil in the cylinder housings on the the other side of the pistons will be pushed out of
rod side of the pistons will be pushed out of the the housings and into the R1 ports of the reach
housings and into the R2 ports on the reach mani- manifold.
fold.
5. This oil will flow across SVR to the relief portion of
5. This oil will flow across SVR to the relief portion of the lower CBV. Pilot flow to this CBV will assist the
the upper CBV. Pilot flow to this CBV will assist the pilot flow from the supply side in opening this valve
pilot flow from the supply side in opening this valve to allow the return oil to flow across. The spring on
to allow the return oil to flow across. The spring on the other side of the valve opposes the two pilot oil
the other side of the valve opposes the two pilot oil pressures controlling the amount of oil that can es-
pressures controlling the amount of oil that can escape the reach manifold out port B. This control
cape the reach manifold out port A. This control prevents overrun, a situation where the forks move
prevents overrun, a situation where the forks move too quickly for the command given.
too quickly for the command given.
6. The oil flow from port B of the reach manifold will
6. The oil flow from port A of the reach manifold will flow into port B of the main manifold, across SVA
flow into port A of the main manifold, across SVA and out port T2.
and out port T2.
~4
--e
:T3 • ,
I I
: I
I I
I I
I I
I I
IT2 A'
R1 R2
4
I 3
3
--
Reach Extend
Reach Retract
Figure 22638
Figure 22637
M2.0-1457-036 Crown 2009 PF17426-12
128
HYDRAULIC
CAOWI' Hydraulic Circuits

1. When sideshift left is operated, SVA (in the main
manifold) stays de-energized and the supply oil af-
ter PCA flows from port B of the main manifold into
R1 R2
port B of the reach manifold. 6 ~ -.__-_-_-_-_-_-_-_-_-_-_-, --I>
, I SVR :T3. •
2. This supply oil flows through the check valve por- :I :I CBV 5 : I
tion of the lower CBV with some of that oil piloted \ I I I

I
I
I
A" I I
to the relief portion of the upper CBV. I I
I I
IT2 A'
3. SVR stays de-energized and the supply oil flows
t1 '--f---------R1
out port T1 of the reach manifold and into port B of
I
the tiltlsideshift manifold. I CBV
4. SVS energizes and shifts, directing the supply oil

out of port SS2 of the tiltlsideshift manifold. This oil 2
enters the rod side of the sideshift cylinder and
pushes against the piston, causing the rod to re-
tract and the carriage to shift to the left. As the pis- Sideshift Left
ton in the cylinder moves, the oil in the cylinder on
the other side of the piston will be pushed out of the Figure 22639
cylinder housing and into port SS1 of the tiltlside-
shift manifold.
5. This oil will flow across SVS, out port A of the tiltl
sideshift manifold, into port T2 of the reach mani-
fold and to the relief portion of the upper CBV. Pilot
flow to this CBV will assist the pilot flow from the
supply side in opening this valve to allow the return
oil to flow across. The spring on the other side of
the valve opposes the two pilot oil pressures con-
trolling the amount of oil that can escape the reach
manifold out port A. This control prevents overrun,
a situation where the carriage moves too quickly
for the command given.
6. The oil flow from port A of the reach manifold will
flow into port A of the main manifold, across SVA
and out port T2.
Crown 2009 PF17426-13 M2.0-1457-037
129
HYDRAULIC
Hydraulic Circuits CJ\OWI'
1. When sideshift right is operated, SVA (in the main
manifold) will energize and shift. The supply oil af-
ter PCA flows from port A of the main manifold into
port A of the reach manifold.
2. This supply oil flows through the check valve por-
tion of the upper CBV with some of that oil piloted
to the relief portion of the lower CBV.
out of port T2 of the reach manifold and into port A
of the tiltlsideshift manifold.
4. SVS energizes and shifts, directing the supply oil
out of port SS1 of the tiltlsideshift manifold. This oil 5
enters the left side of the sideshift cylinder and
pushes against the piston, causing the rod to ex-
tend and the carriage to shift to the right. As the Sideshift Right
piston in the cylinder moves, the oil in the cylinder
on the other side of the piston will be pushed out of Figure 22640
the cylinder housing and into port SS2 of the tiltl
sideshift manifold.
1. When tilt back is operated, SVA (in the main man-
5. This oil will flow across SVS, out port B of the tiltl
ifold) stays de-energized and the supply oil after
PCA flows from port B of the main manifold into
fold and to the relief portion of the lower CBV. Pilot
port B of the reach manifold.
supply side in opening this valve to allow the return 2. This supply oil flows through the check valve por-
oil to flow across. The spring on the other side of tion of the lower CBV with some of that oil piloted
the valve opposes the two pilot oil pressures con- to the relief portion of the upper CBV.
trolling the amount of oil that can escape the reach 3. SVR stays de-energized and the supply oil flows
manifold out port B. This control prevents overrun, out of port T1 of the reach manifold and into port B
a situation where the carriage moves too qUickly
of the tiltlsideshift manifold.
4. SVT energizes and shifts, directing the supply oil
6. The oil flow from port B of the reach manifold will out of port T1 of the tiltlsideshift manifold. This oil
flow into port B of the main manifold, across SVA enters the back of the tilt cylinder behind the piston
and out port T2. and pushes against the piston, causing the rod to
extend and the fork carriage to tilt up. As the piston
in the cylinder moves, the oil in the cylinder on the
other side of the piston will be pushed out of the
cylinder housing and into port T2 of the tiltlsideshift
manifold.
5. This oil will flow across SVT, out port A of the tiltl
fold and to the relief portion of the upper CBV. Pilot
manifold out port A. This control prevents overrun,
a situation where the carriage moves too quickly
Crown 2009 PF17426-14

M2.0-1457-038
130
HYDRAULIC
CAOWI' Hydraulic Circuits
6. The oil flow from port A of the reach manifold will 5. This oil will flow across SVT, out port B of the tilU
flow into port A of the main manifold, across SVA sideshift manifold, into port T1 of the reach mani-
and out port T2. fold and to the relief portion of the lower CBV. Pilot
--e manifold out port B. This control prevents overrun,
:T3 .
I I
, a situation where the carriage moves too quickly
: I for the command given.
I I
I I
I
I
I
I 6. The oil flow from port B of the reach manifold will
IT2 A'
flow into port B of the main manifold, across SVA
I
I
I
1
t CBV
R1
and out port T2.
Tilt Back (Up) ----

Figure 22641

1. When tilt down is operated, SVA (in the main man- IT1 B,
I
I
ifold) will energize and shift. The supply oil after I
R1 R2 I
PCA flows from port A of the main manifold into 6 I
I
port A of the reach manifold.
2. This supply oil flows through the check valve por-
tion of the upper CBV with some of that oil piloted
to the relief portion of the lower CBV. Tilt Down
Figure 22642
out of port T2 of the reach manifold and into port A
of the tilUsideshift manifold.
4. SVT energizes and shifts, directing the supply oil
out of port T2 of the tilUsideshift manifold. This oil
enters the rod side of the tilt cylinder and pushes
against the piston, causing the rod to retract and
the carriage to tilt down. As the piston in the cylin-
der moves, the oil in the cylinder on the other side
of the piston will be pushed out of the cylinder
housing and into port T1 of the tilUsideshift mani-
fold.
Crown 2009 PF17426-15 M2.0-1457-039
131
l!J\OW"
Notes:
132
HYDRAULIC
CJ\OWI' Hydraulic Schematic Symbols
Hydraulic Schematic Symbols
VENTED RESERVOIR
with lines above fluid level ELECTRIC MOTOR
unidirectional single speed
VENTED RESERVOIR
with lines below fluid level
ELECTRIC MOTOR
unidirectional variable speed
FILTER or STRAINER
HYDRAULIC LINE HYDRAULIC PUMP

with full flow (plumbing - may be fixed displacement unidirectional
tubing, hose, or flow passage in
manifold
PILOT or DRAIN LINE

HYDRAULIC MOTOR
limited flow
bi-directional
+ LINES CROSSING
++ LINES CONNECTED
GAUGE
pressure
QUICK DISCONNECT
(disconnected) GAUGE
temperature
PLUGGED PORT
)(
(test port)
o FLOWMETER
ACCUMULATOR
gas charged diaphragm type
Figure 3559-03
Crown 1979 PF5066-1 Rev. 2110 M2.1-00.0-001

05 Rev. 2110
133
HYDRAULIC
Hydraulic Schematic Symbols CJ\OWI'
PRESSURE SWITCH
ACTUATOR MANUAL
CYLINDER
Y
SPRING
double acting unequal area (bias to normal ..
de-energized posItion)
CYLINDER
-R- double acting equal area

(steer) (double end)
SOLENOID
single coil or winding
CYLINDER
~ single acting spring returned

(rod erid vented)
~
HYDRAULIC PILOT
OPERATED
CYLINDER
single acting ram type
~
SOLENOID
pilot operated
CYLINDER
single acting with cushion
SOLENOID DUAL
---------1
! : COMPONENT ENCLOSURE
i J manifold block SOLENOID PROPORTIONAL
ACTUATOR MANUAL LEVER

VALVE PILOT CHECK
(pilot to open)
Figure 3560-04
M2.1-00.0-002 Crown 1979 PF5066-2 Rev. 2/10
05 Rev. 2110
134
HYDRAULIC
CJ\OWrl Hydraulic Schematic Symbols
ORIFICE THROTILE
VALVE SHUTILE
fixed
ORIFICE THROTILE
adjustable
VALVE
SINGLE COUNTERBALANCE
FLOW CONTROL in manifold
-t:::=::: PRESSURE COMPENSATED
fixed
FLOW CONTROL
PRESSURE COMPENSATED
fixed with reverse flow bypass
)(---
- -,, FLOW DIVIDER/COMBINER
--.
)(_r
FUSE VELOCITY
BYPASS FLOW CONTROL
regulated flow
pressure compensated
y
,------,
VALVE RELIEF
fixed setting -1 ~. r- VALVE MANUAL SHUTOFF
y-- ~I
,..-----,
TORQUE GENERATOR
VALVE RELIEF
adjustable
~~L
STEER UNIT
hydrostatic
VALVE CHECK
P R
Figure 3561-04
Crown 1979 PF5066-3 Rev. 2110

M2.1-00.0-003
05 Rev. 2110
135
HYDRAULIC
Hydraulic Schematic Symbols CJ\OWI'
B VALVE
2 way 2 position
VALVE
3 way 2 position
spring bias, solenoid control
B VALVE
3 way 2 position
VALVE
4 way 3 position
dual spring centered,
B VALVE manual lever control

4 way 2 position
VALVE
4 way 3 position
NOTE: The type of valve

depends on the number of
spools found in the
8 VALVE component enclosure

2 way infinite positions (Triple spool valve
shown)
B VALVE
4 way infinite positions
Figure 3562-{)3
Crown 1979 PF5066-4 Rev. 2110

M2.1-00.0-004
05 Rev. 2/10
136
HYDRAULIC
CJ\OWI' Lift Pump
Lift Pump
Figure 21373
a Position of gears shown with counterclockwise rotation

Routine maintenance consists of periodic checks for
tightness of the mounting screws and port fittings plus
b Torque 45 - 50 Nm (34 - 38 ft Ib)
visual examination for oil leaks. The unit should be kept
Lift pumps are comprised of an end cover, body hous- externally clean, especially in the area of the drive shaft
ing a dual element gear set, bushings and a mounting seal as dirt can accelerate seal wear and cause leak-
flange bolted together with through screws. The gear age.
set is comprised of a dual element arrangement with The direction of rotation is indicated by the word rota-
phased teeth to give low pressure ripple and hence tion and an arrow etched on the body adjacent to the
overall low system noise. The gear journals are sup- drive shaft. Rotation is always specified as viewed on
ported in plain bearings within pressure balanced the drive shaft.
bushes to give high volumetric and mechanical effi-
ciencies.
Crown 2009 PF17427-1 M2.1-1457-001
137
HYDRAUL.IC
Lift Pump CJ\OWI'
DC Lift Pump Disassembly Parts Inspection
Disassemble the lift pump in a clean, dust free location, Each component should be thoroughly cleaned, in-
using clean tools and equipment. Dirt or grit will dam- spected in the order disassembled for wear and dam-
age the highly polished machined surfaces and will re- age and assessed for suitability of reuse.
sult in leakage or premature lift pump failure.
Inspect the body bore cutin where gears wipe into the
Before beginning disassembly, scribe matched marks body.
on the body assembly, end cover and mounting flange
The body can only be reused if the cutin is bright and
to ensure that the lift pump will be reassembled prop-
polished in appearance and the depth does not exceed
erly. This lift pump can be assembled for either clock-
0.08 mm (0.003 in).
wise or counterclockwise rotation as viewed from the
drive shaft end. Note which direction the arrow is point- The body is unserviceable if the surface is scored, has
ing next to the word rotation prior to disassembly. a matte appearance or shows signs that the tip of the
gears have dug in and torn away the surface metal.
NOTE The body should be inspected to ensure there is no
For steps 1 through 8, refer to Figure 21373. superficial damage which may adversely affect perfor-
mance or sealing. Pay particular attention to the port
1. Remove the screws (2) and lockwashers (3). threads and body O-ring seal recesses.
2. Remove the end cover (4), body O-ring (5), back-
up seal (6) and seal (7). Mounting Flange and End Cover
3. Turn the unit over and slide the mounting flange
The inner surfaces should be inspected to ensure there
(13) off the drive shaft (12).
is no unusual wear or scoring in the regions where the
4. Remove the retaining ring (15) and push the drive body O-rings and seals contact, which could result in
shaft seal (14) out of the mounting flange taking external leakage.
care not to damage any sealing surfaces.
Inspect the drive shaft seal recesses for scoring or
5. Remove the remaining body O-ring (5), back-up damage that could result in oil leakage around the
seal (6) and seal (7). outer diameter of the drive shaft seal. Replacement
drive shaft seal can be refitted with hydraulic sealant
NOTE (061004-023) to overcome slight damage in this area.
Before removing internal components, mark the bush-

ings to denote location in the body. Bushings
6. With the unit lying on its side, hold the drive shaft The side faces which abut the gears should be per-
and pull it squarely out of the body (10) along with fectly flat showing no sign of scoring. Characteristically
the gear (12). there are bright polished areas on this surface caused
7. Remove the bushings (8 and 9) and driven gear by loading against the gear faces, which is often more
pronounced on the low pressure side. These should
(11) from the drive shaft.
not be used if there is any general scoring or fine scor-
8. Remove the remaining bushings (8 and 9) from the ing with a matte appearance or tearing of the surface
body bores. material. There must be no noticeable wear step as it
is critical that the bushing side face is completely flat to
the gear side face.
Bushing bearing liners are acceptable providing that
they are not scored or show other damage. The gen-
eral outside area of the bushing should not show any
prominent signs of wear.
Crown 2009 PF17427-2

M2.1-1457-002
138
HYDRAULIC
CJ\OWI' Lift Pump
Gears
Gear side faces should be inspected for bruising or
scoring. Often operation on contaminated fluid shows
scoring between the root of the gear and the journal,
which leaves a wear step. If a wear step can be felt,
coincidental with the root diameter, by drawing a sharp
pointed tool across the surface from the journal out-
wards towards the tip of the gear, then the gear is un-
serviceable.
Gear teeth should be carefully inspected to ensure
there are no signs of bruising or pitting.
Journal bearing surfaces should be completely free
from scoring or bruising. The surface should appear
highly polished and smooth to touch.
Inspect the area where the drive shaft seal lips run on
the drive shaft; this shows up as a polished ring or
rings. If a noticeable groove can be felt or there is scor-
ing, the drive shaft is unserviceable.
Inspect the drive keyway in the drive shaft journal ex-
tension to ensure it is not damaged or chipped.
If the drive shaft and gears are not damaged then they
can be reused. If the gears are damaged they are un-
serviceable.
Crown 2009 PF17427-3 M2.1-1457-003
139
HYDRAULIC
Lift Pump CJ\OWI'
DC Lift Pump Assembly be to the side of the body with the cusp removal
flat.
All parts should be perfectly clean. Lubricate the bush-
ings and gears with clean hydraulic oil. Ensure the 0- 2. Place the end cover against the end of the body
ring recess and end faces of body remain dry. This will and stand the assembly on the end cover.
assist assembly of components into the body bores. 3. Hold the drive shaft and gear (12) and driven gear
(11) together and carefully install into the body
NOTE bores with the drive shaft positioned to suit the re-
qUired direction of rotation. For clockwise rotation,
For steps 1 through 11, refer to Figure 21373. the drive shaft should be in the top bore, and for
1. Install the end cover (4) and bushings (8 and 9) into counterclockwise rotation, the drive shaft should
the end of the body (10) from where they were re- be in the bottom bore. Refer to Figure 21909.
moved. The C shape cutout in the bushings must
Inlet Outlet
Counterclockwise Rotation Clockwise Rotation
Figure 21909
7. Install the drive shaft seal assembly sleeve over

1 Cusp Removal
the drive shaft and carefully install the mounting
2 Drive Shaft Position
flange ensuring the holes line up correctly with the
4. Install the mounting flange (13) and bushings (8 body. Remove the assembly sleeve.
and 9) into their original bores remembering the C 8. Holding the whole unit together, carefully tum it
cutout must be to the side of the body with the cusp over and support it on the mounting flange, not the
removal flat and that they match the end cover drive shaft.
bushings.
9. Remove the end cover and install the replacement
5. Install the replacement body O-ring (5), seal (6) body O-ring (5), seal (6) and back-up seal (7).
and back-up seal (7) ensuring the seals locate cor-
rectly on the seal grooves. 10. Install the end cover, screws (2) and lockwashers
(3). Torque the screws to 45 - 50 Nm (34 - 38 ft Ib).
6. Install the drive shaft seal (14) into the recess in the
mounting flange with the garter spring facing the lift 11. Pour a small amount of clean hydraulic oil into a
pump. Remember that if the seal recess was port and check that the shaft can be rotated without
scored then hydraulic sealant (061004-023) must undue force.
be applied to the outer diameter of the seal. Apply
a coat of high melting point grease to the shaft seal
lips. Install the retaining ring (15) in its groove.
M2.1-1457-004 Crown 2009 PF17427-4
140
HYDRAULIC
CJ\OWI' Lift Pump
Load Sensing Flow Control Valve (a) Torque 27 Nm (20 ft Ib)

(b) Torque 50 - 60 Nm (37 - 44 ft Ib)
The load sensing flow control valve mounts directly
onto the end of the lift pump and its function is to split 1. Remove the spool plug (8) and spring seat (4) al-
the output flow into two independently usable flows. lowing the spring (6) and spool (7) to be removed.
The output from a fixed displacement gear lift pump will Examine spool and bore for signs of damage.
vary if the drive speed is altered.
2. Remove the O-rings (5) and install replacement 0-
The load sensing flow control valve will supply suffi- rings.
cient flow to power steering rather than a constant flow.
This means that more flow is available to the second- 3. The spring seat has an orifice in its base. It is im-
ary circuit. portant that this orifice is clear and free of contam-
inants.
Load Sensing Flow Control Valve Disas-
sembly Load Sensing Flow Control Valve Assem-
bly
Clean all accumulations from the outside of the valve.
Remove valve from the lift pump and place in a clean,
NOTE
dirt free location.
For steps 1 through 3, refer to Figure 21910.
NOTE
1. Replace the spool (7), spring (6), spool plug (8)
For steps 1 through 3, refer to Figure 21910. and spring seat (4). Torque the spool plug and
spring seat to 50 - 60 Nm (37 - 44 ft Ib).
2. Install the load sensing flow control valve (3) to the
lift pump (1) ensuring inlet to the valve in the rear
face is over high pressure side of the lift pump
(semicircular cutout in bushings).
3. Torque the screws (2) to 27 Nm (20 ft Ib).
Initial ~tart Up Procedure

This procedure will cover the steps to be taken when
first starting a lift pump on a vehicle that has had any of
the follOWing operations performed:
"3 • The lift pump has been replaced or an existing lift

pump has been removed and reinstalled.
• The lift pump suction line has been replaced or the

lift pump suction line has been removed and rein-
CF EF stalled.
• The reservoir has been drained and refilled.
LS
• Any other operation that may cause the lift pump to
lose its prime.
Figure 21910
Crown 2009 PF17427-5 M2.1-1457-005
141
HYDRAULIC
Lift Pump CJ\OWI'
Lh WARNING AC Lift Pump Disassembly
Before proceeding, review the Control of Hazardous NOTE
Energy LockoutlTagout section and Hydraulic chapter
of this manual. For steps 1 through 3, refer to Figure 22003.
1. Key truck OFF and disconnect the battery. 1. Remove the bolts (4) and flatwashers (3) which
hold the pump to the lift motor.
Lh CAUTION 2. Remove the lift pump (1) from the lift pump motor.
The lift pump itself is not a serviceable part.
Before priming the lift pump, verify that clean hydraulic
3. Carefully remove the a-ring seal (2).
fluid has been added to the reservoir(s) to the appropri-
ate fill level.
2. Inspect equipment prior to use and inspect all suc- Parts Inspection
tion plumbing to prevent any air from entering the Each component should be thoroughly cleaned, in-
suction plumbing. spected in the order disassembled for wear and dam-
age and assessed for suitability of reuse.
Lh CAUTION The body should be inspected to ensure there is no
superficial damage which may adversely affect perfor-
Lift pump priming may be done at the initial start up, but
mance or sealing. Pay particular attention to the port
no hydraulic operation may occur until the lift pump(s)
threads and body a-ring seal recesses.
priming is completed.
3. Fill the lift pump(s) with clean hydraulic fluid prior to
initial start up.
AC Lift Pump Assembly
4. Connect the battery and key truck ON.
NOTE
5. Run the lift pump(s) at slow speed and minimum
For steps 1 through 3, refer to Figure 22003.
pressure to purge the suction plumbing of any air.
1. Make sure that all pump components are perfectly
clean and lubricated with hydraulic oil to be used in
the pump, prior to assembly.
2. Lubricate the a-ring seal (2) and seat it at the front
of the lift pump (1). Apply grease (063002-038) to
the splined shaft and attach the lift pump to the lift
motor.
3. Insert the bolts (4) and f1atwashers (3) into the lift
pump body and hand tighten into tapped holes in
2 the mounting flange of the lift motor. Torque to 25
\ - 30 Nm (18 - 22 ft Ib).
CJ
Figure 22003
(a) Torque 25 - 30 Nm (18 - 22 ft Ib)
Crown 2009 PF17427~

M2.1-1457-007
142
HYDRAULIC
CROWl' Lift Pump
Initial Start Up Procedure

This procedure will cover the steps to be taken when
first starting a lift pump on a vehicle that has had any of
the following operations performed:
• The lift pump has been replaced or an existing lift

pump has been removed and reinstalled.
• The lift pump suction line has been replaced or the

lift pump suction line has been removed and rein-
stalled.
• The reservoir has been drained and refilled.
• Any other operation that may cause the lift pump to

lose its prime.
Lh WARNING
Before proceeding, review the Control of Hazardous
Energy LockoutlTagout section and Hydraulic chapter
of this manual.
1. Key truck OFF and disconnect the battery.
Lh CAUTION
Before priming the lift pump, verify that clean hydraulic
fluid has been added to the reservoir(s) to the appropri-
ate fill level.
2. Inspect equipment prior to use and inspect all suc-
tion plumbing to prevent any air from entering the
suction plumbing.
it CAUTION
Uft pump priming may be done at the initial start up, but
no hydraulic operation may occur until the lift pump(s)
priming is completed.
3. Fill the lift pump(s) with clean hydraulic fluid prior to
initial start up.
4. Connect the battery and key truck ON.
5. Run the lift pump(s) at slow speed and minimum
pressure to purge the suction plumbing of any air.
Crown 2009 PF17427-7 M2.1-1457-007
143
CJ\OWI'
Notes:
144
HYDRAULIC
CJ\owr. Manifold Block
Manifold Block Adjustment

A fully charged battery should be installed in the truck
Relief Valves (RV1 & RV2) Operation and all truck calibration and feature configurations
should be completed before attempting any measure-
The lift circuit is protected from excessive oil pressure ments or adjustments.
by the main relief valve (RV1) and the accessory
(reach, tilt, etc.) circuit is protected by the accessory
function relief valve (RV2). If pressure within the circuit RV1
exceeds the relief valve preset level, the valve will open To adjust RV1 on 24 or 36 Vdc trucks:
and relieve the pressure by directing the oil to the res-
ervoir thus maintaining a maximum pressure limit for 1. Connect a 0 - 35 mPa (0 - 5000 psi) pressure
the circuit. gauge to the test port of the manifold block. Install
oil temperature measuring instrumentation.
2. Place the forks under the frame of the weight pole
RV1
or a large stack of weights. Hold the multi-task con-
trol handle in the full raise position while reading
the gauge indication. The pressure reading must
be taken while passing full flow over relief. Refer to
Chart 1 - RV1 Pressure Range (24 or 36 Vdc).
Figure 22014
Quick Disconnect Test Port
Chart 1 - RV1 Pressure Range (24 or 36 Vdc)
Oil Temperature Pressure (24 Vdc) Pressure (36 Vdc)

Hydraulic Fluid
Co p mPa psi mPa psi
Standard 27 - 60 80 -140 17.24 - 18.27 2500 - 2650 21.72 - 22.75 3150 - 3300
Freezer/Corrosion 21 - 38 70 -100 17.24 - 18.27 2500 - 2650 21.37 - 22.75 3100 - 3300
3. If the RV1 setting does not fall within the required 4. Tighten the jam nut and recheck the pressure set-
range, loosen the jam nut on RV1, located in the ting. Readjust if the pressure falls outside the tar-
main manifold block assembly, and adjust RV1 to get range.
reach the target pressure setting.
Crown 2009 PF17428-1 Rev. 12109 M2.4-1457-001

01 Rev. 12/09
145
HYDRAULIC
Manifold Block CROWl'
To adjust RV1 on AC trucks: be taken while passing full flow over relief. Refer to
Chart 2 - RV1 Pressure Range (AC).
1. Connect a 0 - 35 mPa (0 - 5000 psi) pressure
gauge to the test port of the manifold block. Install 3. If the RV1 setting does not fall within the required
oil temperature measuring instrumentation. range, loosen the jam nut on RV1, located in the
main manifold block assembly, and adjust RV1 to
2. Place the forks under the frame of the weight pole reach the target pressure setting.
or a large stack of weights. Hold the multi-task con-
trol handle in the full raise position while reading 4. Tighten the jam nut and recheck the pressure set-
the gauge indication. The pressure reading must ting. Readjust if the pressure falls outside the tar-
get range.
Chart 2 - RV1 Pressure Range (AC)
Oil Temperature Pressure

Hydraulic Fluid
Co F O
mPa psi
Standard 27 - 60 80 - 140 21.72 minimum 3150 minimum
Freezer/Corrosion 21 - 38 70 - 100 21.37 minimum 3100 minimum
RV2 2. Record the RV2 pressure when passing full flow

over relief by operating the reach function into the
RV2 is not adjustable. To check for proper operation: reach extend limit.
1. Connect a 0 - 35 mPa (0 - 5000 psi) pressure 3. The indicated pressure should fall in the range
gauge to the test port of the manifold block. Install given in Chart 3 - RV2 Pressure Range. If the pres-
oil temperature measuring instrumentation. sure falls outside this range, the need for some cor-
rective action may be indicated.
Chart 3 - RV2 Pressure Range
Oil Temperature Pressure

Hydraulic Fluid
Co F O
mPa psi
Standard 27 - 60 80 -140 11.72 -12.41 1700 -1800
Freezer/Corrosion 21 - 38 70 -100 11.72 -12.41 1700 -1800
M2.4-1457-002 Crown 2009 PF17428-2 Rev. 12109
01 Rev. 12109
146
HYDRAULIC
CJ\owr. Manifold Block
Proportional Valves (PVA & PVL)

If PVA and PVL are replaced, the valves must be cali-
brated. To calibrate, refer to the ACCESS 123® Menus
section.
PVL
MVL
Figure 22016
it WARNING
A VOID HIGH PRESSURE FLUIDS - Escaping fluid un-
der high pressure can penetrate the skin causing seri-
ous injury. Relieve pressure before disconnecting hy-
draulic lines. Tighten all connections before applying
PVA pressure. Keep hands and body away from pin holes
which eject fluids under high pressure. Use a piece of
Figure 22015
cardboard orpaper to search for leaks. Do not use your
hand. .
Manifold Block Q-Ring Replacement Any fluid injected into the skin under high pressure
1. Move the truck to the service area on a level floor,
chock the wheels and disconnect the battery. Re-
is a delayed onset of pain and serious damage may
fer to the Control of Hazardous Energy section.
occur. Medical attention should be sought immediately
2. Remove the console covering the manifold block. by a specialist who has had experience with this type
of injury.
3. Open the Manual Lowering Valve (MVL) on the
manifold block to relieve system pressure. Refer to 4. Remove all hydraulic hoses and lines from the
Figure 22016. manifold block, and cap lines and hoses with plas-
tic plugs to avoid oil leakage and contamination.
Catch any oil that may be spilled.
5. Remove the manifold block from the truck and
place it on a clean piece of cardboard in a clean
area to avoid contamination while disassembling.
Crown 2009 PF17428-3

M2.4-1457-003
147
HYDRAULIC
Manifold Block CROWl'
NOTE NOTE
ORF3 is accessed by removing the SAE plug and then Refer to Chart 4 - O-Rings whenever installing a top
unscrewing ORF3 from the cavity. Also, ensure ORF4 replacement O-ring. Seal kits are available to replace
is removed from the PCL cavity; this is the only orifice all O-rings on each cartridge type valve. Refer to the
that is not screwed into the manifold block. Manifold Block and Reach Assembly Manifolds sec-
tions for seal kit part numbers.
6. Remove all valves from the manifold block and
place them on a clean piece of cardboard. During 8. To remove the top (cap) O-ring from each valve,
the entire disassembly, replacement of O-rings, in- cover threads on the valve with a sleeve or tape to
stalling valves back into the manifold block and prevent damage to the replacement o-ring and
proper torque of valves, it is extremely important to carefully replace the top O-ring. The top O-ring
keep work surfaces and parts as clean as possible (cap) will be the one closest to the outside surface
to avoid contamination. of the manifold block after the valve is installed in
the manifold block. Visually inspect all other O-ring
7. Make a visual inspection of the valves and valve
and back-up rings and replace as required. Refer
cavities for any signs of contamination. Check op-
to Chart 4 - O-Rings for O-ring usage.
eration of the valve mechanisms for sticking or
rough operation. If any valves are contaminated or
do not function properly, discard the valve and re-
place with a new valve.
Chart 4 - O-Rings
a-Ring Dimension O-Ring Dimension

Reference Valve/Plug a-Ring Part (mm) (in)
Location
Designation Part Number Number
Width 1.0. 0.0. Width 1.0. 0.0.
Lift!Accessory
#4 Plug 064091-006 064019-031 1.85 8.90 0.072 0.351
Manifold
Lift!Accessory
#6 Plug 064091-002 064019-029 1.98 11.89 15.85 0.078 0.468 0.624
Manifold
Lift!Accessory
#8 Plug 064091-001 064019-030 2.20 16.35 0.087 0.644
Manifold
Lift!Accessory
#10 Plug 064091-007 064019-045 2.45 19.20 0.097 0.755
Manifold
Carriage
CBV 121819 064019-045 2.45 19.20 0.097 0.755
Manifold
Lift!Accessory
CV1 123255-003 064019-075 0.62 59.50 55.65 0.103 1.987 2.19
Manifold
Lift!Accessory
CV2 117380-002 064019-045 2.45 19.20 0.097 0.755
Manifold
Lift!Accessory
CV3 114816-004 064019-030 2.20 16.35 0.087 0.644
Manifold
Lift!Accessory
MVL 145114 064019-030 2.20 16.35 0.087 0.644
Manifold
Lift!Accessory
PCA 145084 064019-075 0.62 59.50 55.65 0.103 1.987 2.19
Manifold
M2.4-1457-004 Crown 2009 PF174284
148
HYDRAULIC
Manifold Block
Chart 4 - O-Rings
Lift!Accessory
PCl 144605 064019-075 0.62 59.50 55.65 0.103 1.987 2.19
Manifold
Lift!Accessory
PYA 135724-001 064019-045 2.45 19.20 0.097 0.755
Manifold
Lift!Accessory
PVl 135800-001 064019-075 0.62 59.50 55.65 0.103 1.987 2.19
Manifold
Lift!Accessory
RV1 145115 064019-045 2.45 19.20 0.097 0.755
Manifold
Lift!Accessory
RV2 138361-002 064019-030 2.20 16.35 0.087 0.644
Manifold
Lift!Accessory
SCV 117304-005 064019-045 2.45 19.20 0.097 0.755
Manifold
Lift!Accessory
SVA 117385-004 064019-045 2.45 19.20 0.097 0.755
Manifold
Lift!Accessory
SVBY 117377-003 064019-030 2.20 16.35 0.087 0.644
Manifold
Lift!Accessory
SVl 135723-001 064019-075 0.62 59.50 55.65 0.103 1.987 2.19
Manifold
SVRlSVS/ Carriage
122167-001 064019-030 2.20 16.35 0.087 0.644
SVT Manifold
11. Refer to Figure 22017 for valve and plug place-

9. Apply a light film of hydraulic oil to the O-ring
ment and Chart 5 - Torque Values for torque val-
threads of all the valves before installing into the
ues of valves and plugs. Torque each valve to the
manifold block. When installing ORF4 and PVl
value given. If using a crowfoot or other extension,
into the cavity, spread a clean, light grease on the
position it at 90° to the torque wrench handle to
flat side of ORF4, stick it on the nose of PVl and
keep the torque value the same as the torque
carefully insert it into the cavity. This will properly
wrench setting.
orient ORF4 and prevent it from changing position
during installation.
10. Install each valve into the manifold block by hand
until snug.
Crown 2009 PF17428-5

M2.4-1457-005
149
HYDRAULIC
Manifold Block CROW"
scv
1 Quick Disconnect Test Port

2 Part of Power Unit
Figure 22017
Crown 2009 PF1742~

M2.4-1457-006
150
HYDRAULIC
CJ\own Manifold Block
Chart 5 - Torque Values
Reference Valve/Plug Part Cartridge Torque Coil Nut Torque

location
Designation Number Nm ftlb Nm ftlb
#4 Plug 064091-006 Lift/Accessory Manifold 14 -15 10 - 11
#6 Plug 064091-002 Lift/Accessory Manifold 23 -24 17 -18
CBV 121819 Carriage Manifold 34 25
CV1 123255-003 Lift/Accessory Manifold 95 -108 70 - 80
CV2 117380-002 Lift/Accessory Manifold 47 - 54 35 -40
CV3 114816-004 Lift/Accessory Manifold 20 - 23 15 -17
MVl 145114 Lift/Accessory Manifold 47 - 54 35 -40
ORF3 145119 Lift/Accessory Manifold 8-9 6-7
PCA 145084 Lift/Accessory Manifold 68 -75 50 - 55
PCl 144605 Lift/Accessory Manifold 68 -75 50 - 55
PVA 135724-001 Lift/Accessory Manifold 47 - 54 35 -40 7-9 5-7
PVl 135800-001 Lift/Accessory Manifold 54 - 61 40 -45 7-9 5-7
RV1 145115 Lift/Accessory Manifold 47 - 54 35 -40
RV2 138361-002 Lift/Accessory Manifold 47 - 54 35 -40
SCV 117304-005 Lift/Accessory Manifold 47 - 54 35 -40 7-9 5-7
SVA 117385-004 Lift/Accessory Manifold 47 - 54 35 -40 7-9 5-7
SVBY 117377-003 Lift/Accessory Manifold 34 -41 25 - 30 4-7 3-5
SVl 135723-001 Lift/Accessory Manifold 68 -75 50 - 55 7-9 5-7
SVRlSVS/SVT 104164-015 Carriage Manifold 27 20 9 7
Crown 2009 PF17428-7 M2.4-1457-007
151
CJ\OWI'
Notes:
152
HYDRAULIC
CJ\owr. Hydraulic Troubleshooting
Hydraulic Troubleshooting more complete troubleshooting. Use the chart carefully

and completely. Do not make the system more compli-
The following Troubleshooting Chart contains general cated than necessary. Do not overlook the simplest
information necessary to effectively solve the more reasons for a hydraulic issue.
common hydraulic issues. Know the system to the best
of your ability. Understand the components and their NOTE
function within the system. Develop a systematic pat-
tern to locate and solve the various hydraulic issues Many hydraulic components are monitored by the
that occur. The ability to identify issues and proceed in truck's electrical system. If issues occur in the moni-
solving the issue grows with experience. The following tored components, an event code will be displayed on
chart contains issues, probable cause and remedy. ACCESS 1. Truck event codes can be referenced in
The information is general in nature and a remedy may .the Event Codes section of this manual.
simply refer you to a maintenance section that has
Chart 1 - Troubleshooting
Issue Probable Cause Remedy

Hydraulic oil is foaming. Introduction of air into the lift pump. Inspect the reservoir oil level.
Inspect for proper oil viscosity.
Inspect the hydraulic plumbing.
Water is in the oil. Inspect the reservoir.
Hydraulic oil is overheating. 1 Oil is too thin. 1 Change to the proper viscosity oil.
Oil is contaminated. Change the filters and fill with clean
oil.
Introduction of air into the lift pump. Inspect the hydraulic plumbing.
Oil level is low. Inspect the reservoir oil level.
Loss of the lift function. Mast assembly is binding. Inspect the mast for damage, mis-
alignment, shimming, etc.
Lift pump motor or lift pump is not Refer to the Lift Pump section.
operating.
PCA is stuck. Inspect PCA.
CV1 is stuck in the closed position. Inspect CV1.
Binding or jammed spool in SVBy. Inspect SVBy.
Oil level is low. Inspect the reservoir oil level.
Reduced lift function. PCA spool is sticking. Inspect PCA.
MVL is not closed. Inspect MVL.
RV1 is opening prematurely. Inspect RV1.
Loss of the lowering function. Velocity fuse is actuated. Inspect for a severe oil leak.
Mast assembly is binding. Inspect the mast for damage, mis-
Binding or jammed spool in PVL. Inspect PVL.
Binding or jammed spool in SVL. Inspect SVL.
Binding or jammed spool in PCL. Inspect PCL.
Crown 2009 PF1T7~1 M2.9-1457-001
153
HYDRAULIC
Hydraulic Troubleshooting CJ\OWI'
Reduced lowering function. Debris in the cylinder, velocity fuse Cycle through lift and lower to free
or flow control valves. possible debris.
Line restriction. Inspect the hydraulic plumbing.
Mast assembly is binding. Inspect the mast for damage, mis-
Binding or jammed spool in PVL. Inspect PVL.
Spring failure in PCL (partially Inspect PCL.
closed).
ORF4 is contaminated (partially Inspect ORF4.
closed).
PVL calibration is incorrect. Inspect PVL and recalibrate.
Excessive lowering function (Iow- MVL is open. Inspect MVL.
ers too fast). External oil leak. Inspect the hydraulic plumbing.
Contamination of PCL (stuck open). Inspect PCL.
Blockage of ORF4. Inspect and clean ORF4.
PVL calibration is incorrect. Inspect PVL and recalibrate.
Sudden movement or jerking. PVL calibration is incorrect. Inspect PVL and recalibrate.
PVL spool is sticking. Inspect PVL and retorque.
Lift pump motor and lift pump are Relief valve is malfunctioning. Reset or replace the relief valve.
overheating. 1 Load capacity has been exceeded. Inspect the load weight.
Fluid level is low. Inspect the fluid level and fill.
Worn or damaged lift pump motor Inspect the lift pump motor and lift
or lift pump. pump and repair or replace as
needed.
Oil is too thin. 1 Change to the proper viscosity oil.
Abnormal hydraulic oil usage. External oil leak. Inspect the hydraulic plumbing.
Carriage drifts down (in excess of Worn tilt cylinder packings. Refer to the Lift Cylinder section for
the drift test). replacement.
Broken spring or dirty CV1 (stuck Inspect CV1.
open).
Broken spring or dirty CV2 (stuck Inspect CV2.
open).
Broken spring or dirt in PVL. Inspect PVL.
Broken spring or dirty SVL (stuck Inspect SVL.
open).
MVL is open or damaged. Inspect MVL.
Carriage drifts up slightly. PCA is stuck in the closed position. Inspect PCA.
SVBy is not open. Inspect SVBy.
Forks drift down (in excess of the Worn tilt cylinder packings. Refer to the Lift Cylinder section for
drift test). replacement.
Broken spring or dirty CBV. Inspect CBV.
Loss of accessory functions (no Binding or jammed spool in PYA. Inspect PYA.
functions occur when requested). Binding or jammed spool in SVA. Inspect SVA.
Binding or jammed spool in SVR. Inspect SVR.
Binding or jammed spool in SVS. Inspect SVS.
Binding or jammed spool in SVT. Inspect SVT.
M2.9-1457-002 Crown 2009 PF1n09-2
154
HYDRAULIC
CJ\OWI' Hydraulic Troubleshooting
Reduced accessory functions (low Contaminated or dirty PCA or PVA. Inspect PCA or PVA.
flow rate). RV1 is set incorrectly. Reset RV1.
RV2 is set incorrectly. Reset RV2.
Broken spring or dirty SCV6 (stuck Inspect SCV6.
open).
Oil is too thick. 1 Change to the proper viscosity oil.
SVA calibration is incorrect. Inspect SVA and recalibrate.
Accessories function with no com- PVA is stuck open. Inspect PVA.

mand or input. Broken spring or dirty SVR (stuck Inspect SVR.
open).
Broken spring or dirty SVS (stuck Inspect SVS.
open).
Broken spring or dirty SVT (stuck Inspect SVT.
open).
Accessories function in reverse (tilt Broken wire, spring or coil at SVA. Inspect SVA.
up goes down instead, etc.). Incorrect calibration of POT3. Inspect POT3.
Excessive accessory operation Contaminated or dirty PVA. Inspect PVA.
(accessories operate too fast). RV2 is set incorrectly. Reset RV2.
Broken spring in PCBY (partially Inspect PCBY.
closed).
PVA calibration is incorrect. Inspect PVA and recalibrate.
Slow or sluggish steering. Dirty or worn priority flow divider. Inspect the lift pump priority flow
divider.
Dirty or worn steer control unit or Refer to the Hydraulic Steering Sys-
steer motor. tem section.
Binding of steer gears or steer con- Inspect for binding, damaged gears
trol unit. or steer control unit alignment.
Load sense line is blocked. Inspect for kinked or broken line.
Steer control unit relief (RV3) is set Replace RV3.
incorrectly.
Steering jerks abruptly. Dirty or worn priority flow divider. Inspect the lift pump priority flow
divider.
Dirty or worn steer motor. Refer to the Hydraulic Steering Sys-
tem section.
Air is in the system. Inspect fittings for leaks.
Steer control unit bolts are over- Inspect steer control unit bolt
tightened. torque.
Unable to maintain steered position Dirty or worn steer control unit or Refer to the Hydraulic Steering Sys-
(steering will not track straight). steer motor. tem section.
1 Ensure the truck has been performing its normal

duty cycle at this time. Freezer/corrosion trucks
require a thinner weight oil.
Crown 2009 PF17709-3 M2.9-1457-003
155
CJ\OWI'
Notes:
156
--------------
mow"
DRIVE UNIT
157
l!J\OWI'
Notes:
158
DRIVE UNIT
CROWr. Disassembly and Assembly
6. Discard existing tire.

Disassembly and Assembly
7. Check the OD leading edge chamfer of the hub to
it CAUTION 8.
verify it is free of burrs or gouges.
Check the circumference of the hub for heavy gall-
Disconnect battery and chock load wheels before per- ing, replace if necessary.
forming any maintenance procedure.
9. Verify the base band of the tire has not been. previ-
ously pressed.
Drive Tire Replacement 10. Place new tire on press, centered below ram.
it CAUTION 11. Lightly lubricate inside top 75 mm (3 in) of tire band

with light oil.
Replacement of original equipment tires with other 12. Place hub directly over tire with leading edge
than those recommended by Crown may result in de- chamfer inserted into tire band. Refer to Figure
creased operating performance, traction and stability. 16864-01.
Consult appropriate truck Service & Parts manual.
When replacing the drive tire, make sure the composi-
tion and size are such that maneuverability and braking
requirements are maintained. Refer to truck data plate 1
for tire information.
Drive tire is press-on type; press old tire off of the hub 2
and press new tire on.
1. Disconnect battery and chock wheels. LockoutfTa- 3
gout the truck as described in LockoutlTagout in
the Control of Hazardous Energy section of the 4
manual.
it CAUTION
Make sure the lifting device and blocking material are
sufficiently rated and strong enough to withstand the
weight ofthe truck. Never work under or around a truck
that is not properly blocked and secure.
2. Raise and block the power unit so drive tire is off of
the floor. Refer to the Control of Hazardous En-
ergy, Lifting and Blocking for correct procedures.
3. Remove eight lug bolts and remove drive tire from
truck. Be careful not to damage the threaded studs
when removing tire.
it CAUTION Figure 16864-01

Extreme pressure is used to press tires, always exer-
cise caution and assure that only trained personnel are 1 Minimum 240 mm (9.5 in) Diameter
allowed to operate a hydraulic press. 2 Tire Press Tool
4. Place eXisting tire assembly on hydraulic press di- 3 Hub
rectly below ram. 4 Tire
5. Use suitable press tooling for press to contact hub

circumference and remove existing tire from hub.
Crown 2009 PF1758~1 M3.0-1457-001
159
DRIVE UNIT
Disassembly and Assembly CJ\OWI'
13. Place tire press tool, 134169, over top of hub (3) 18. Finger tighten lug bolts. Then, according to the se-
with alignment pins in lug bolt countered bored quence shown in Figure 21258, torque bolts to
holes. 135 -150 Nm (100 -110 ft Ib).
14. Center tire press tool (2), hub (3), and tire (4) below
ram plate (1), which should be a minimum 240 mm
(9.5 in) diameter.
15. Several checks should be made during the press
operation:
- Monitor hub tire alignment closely during first
75 mm (3 in) of insertion, misalignment can
damage tire band.
- Monitor press force during process, low force
may indicate a worn out hub.
- Always press the hub into the tire for proper in-
stallation.
- DO NOT press directly on center of the convex Figure 21258
hub.
- Press until hub face is flush with tire band.
19. Remove blocks, lower power unit, connect battery
16. Press hub (3) into tire band until flush, monitor and remove wheel chocks.
alignment during press operation.
20. Adjust the articulation as described later in this
17. Inspect hub (2) and remove any paint that may be section.
present on tapered lug seats (3) or on inner hub
face (1) that contacts truck axle. Refer to Figure
21078.
Figure 21078
M3.0-1457-002 Crown 2009 PF17589-2
160
DRIVE UNIT
CJ\OWI' Disassembly and Assembly
Drive Unit Lubrication Oil Pump Disassembly

The drive unit has a capacity of approximately 710 ml 1. Disconnect battery and chock wheels. LockoutlTa-
(1.5 pints) of 80/90W gear oil. Refer to Lubrication & gout truck as described in Control of Hazardous
Adjustment chapter for correct lubricant part number. Energy section.
Remove drain plug (1) to completely drain unit. Apply
hydraulic sealer (part number 061004-023) to drain
plug and replace. To fill, remove fill plug (2). Add gear
oil until present at fill plug. Refer to Figure 16866-01.
Figure 16867-01
1 Oil Pump Housing 8 Spring

2 a-Ring 9 Piston
3 a-Ring 10 Bearing Cup
4 Ball 11 Bearing Cone
5 Spring 12 Axle
6 Special Plug 13 Cam
Figure 16866-01
7 Ball 14 Drive Unit Housing
Drive unit gear oil should be changed at the first 500
hours and then every 2000 hours thereafter. Refer to
Lubrication & Adjustment chapter for appropriate lubri-
cant information.
• Normal application 0 0 C (32 0 F) and above
- Use 80/90 weight gear lube
• Freezer application 0 0 C (32 0 F) and below
- Use Automatic Transmission Fluid
Crown 2009 PF17589-3 M3.0-1457-003
161
DRIVE UNIT
Remove drain plug (13); drain oil from drive unit. Refer Oil Pump Assembly
to Figure16868.
Inspect all component parts and drive unit casting for
dirt and burrs before assembly. Refer to Figure 16868.
" 19
1. Place ball (4) and spring (5) into oil pump housing
16 / 18 (1 ).
2. Place ball (7), spring (8) and special pipe plug into
piston (9). Lubricate piston with oil to aid in smooth
action and install piston into oil pump housing (1)
installed in drive unit housing.
3. Install a-rings (2) and (3) onto oil pump body.
4. Oil the oil pump body (1) and port thoroughly and
14 screw oil pump assembly into casting until seated.
13 ." ! 5. Apply hydraulic sealer (061004-023) to drain plug

and replace drain plug. Fill drive unit with 710 ml
11 (1.5 pints) of gear oil. Refer to Lubrication & Ad-
justment chapter for lubricant information.
6. To check oil pump output remove pipe plug (13)
and observe oil flow from port.
'~f 8
10
2 ~ :4--9:
I I 7
1 I') I
l...--- 6
Figure 16868
(1) Tubing is installed through cored hole in casting
2. Remove oil pump housing (1) from drive unit and

move to a clean work area for further disassembly.
3. Check a-rings (2) and (3) for damage and replace
if necessary.
4. Remove piston (9), spring (8) and ball (7) from oil
pump housing.
5. Remove special pipe plug (6), spring (5) and ball
(4) from oil pump housing.
6. Thoroughly clean housing and all parts.
M3.0-1457-004 Crown 2009 PF175894
162
DRIVE UNIT
CJ\owr. Disassembly and Assembly
Under Carriage Inspections and NOTE

Adjustments Under normal maintenance operations it is recom-
mended the undercarriage not be completely removed
Refer to Figure 21096. from the power unit.
1. Disconnect battery and remove from compartment. 6. Inspect springs and mounting hardware.
Refer to Control of Hazardous Energy. Lift up and
remove power unit door. 7. Inspect caster and wheel assembly (6).
2. Disconnect all wiring to traction motor (1) and elec- 8. Inspect caster assembly bearings. For RRIRD
trical brake (2). 57005 trucks, torque the locknut securing the
caster assembly to the undercarriage to 95 -
3. Disconnect hydraulic hoses to steer motor (3) and 108 Nm (70 - 80 ft Ib). For RRIRD 5700 truck,
cap hose ends. torque the locknut securing the caster assembly to
4. When removing undercarriage note the number the undercarriage to 68 - 75 Nm (50 - 55 ft Ib). Ro-
and position offlatwashers (4) and replace in same tate caster assembly while tightening to insure
position during assembly. centering of bearings.
5. The four 0.75 inch diameter bolts (5) that clamp

pivot shaft to the power unit must be tightened to
305 - 340 Nm (225 - 250 ft Ib) during assembly.
10
9
14 /
15
12
r---
I~~--'_'_--'
3
16
Figure 21096
Crown 2009 PF17589-5 M3.0-1457-005
163
DRIVE UNIT
Articulation Adjustment 2. Refer to Figure 21097. Inspect wear plug (1),
springs (11), caster (5) and wheel (6). Replace as
necessary.
RRIRD 5700 Series
3. On the drive tire side of the undercarriage, adjust
Correct articulation adjustment will help maintain articulation distance (2) from the top of the wear
proper traction and truck stability. It will also increase plug (1) to the bottom of the adjustment screw (4)
drive tire life. to 1.5 mm + 0.0 - 0.5 mm (0.06 in + 0.0 - 0.02 in).
1. Refer to Figure 16869-01. When making articula- Torque jam nut (3) to 375 - 405 Nm
tion adjustments, it is very important to have the (275 - 300 ft Ib).
truck on a level floor surface. 4. On the caster side of the undercarriage, adjust ar-
ticulation distance (7) of both stops (9) from the top
• Place a 4 ft level across the outriggers (1) and be-
of the undercarriage (8) to the bottom of the stops
hind the power unit (3) as shown in Figure
(9) to 89 mm + 0.0 - 1.0 mm (3.5 in +0.0 - 0.04 in).
16869-01. Move the truck until it is level in both lo-
Torque jam nuts (10) to 375 - 405 Nm
cations.
(275 - 300 ft Ib). After adjustment, springs (9)
• After finding a floor area that is level in both loca- should be able to rotate, but should not be able to
move up and down. Using incorrect spacers, stops
tions, mark the area with tape or paint (4) so that it
or springs can affect truck stability. The proper gap
can be used for future articulation adjustments.
and spring rate is directly related to lift height and
The trailing edge of the caster wheel must be pointing sideshift specifications. Refer to chart 1 and Figure
towards the drive tire as shown (2). 16871-01. Identify the spacer by the number of
grooves machined into it, and the spring, by its
color.
Figure 16869-{)1
M3.0-1457-006 Crown 2009 PF17589-8
164
DRIVE UNIT
l!J\OWr. Disassembly and Assembly
CHART 1
Articulation SPACER Selection Spacer

Quantity
Lift Height mm (in) Part Number
All Trucks Without Sideshift 126780-001 2
Trucks With Sideshift
5030 mm (198 in) thru 5335 mm (210 in) 126780-002 2
5360 mm (211 in) thru 10160 mm (400 in) 126780-004 2
Articulation SPRING Selection Spring
Quantity
5030 mm (198 in) thru 6860 mm (270 in) 122457 RED 2
6885 mm (271 in)thru 10160 mm (400 in) 122456 BLUE 2
1~
I
2-~
i
o
Figure 16871-01
1 Spring
2 Spacer
Crown 2009 PF1758~7 M3.0-1457-007
165
DRIVE UNIT
Disassembly and Assembly CROWl'
Figure 21097
RRiRD 5700S Series 3. On the caster side of the undercarriage, adjust ar-
ticulation distance (9) from the top of the wear plug
Correct articulation adjustment will help maintain (8) to the bottom of the adjustment screw (10) to
proper traction and truck stability. It will also increase 6.4 mm + 0.0 - 1.0 mm (0.25 in +0.0 - 0.04 in).
drive tire life. Torque jam nut (11) to 375 - 405 Nm
1. Refer to Figure 16869-01. When making articula- (275 - 300 ft Ib).
tion adjustments, it is very important to have the 4. On the drive tire side of the undercarriage, adjust
truck on a level floor surface. articulation distance (12) from the top of the wear
plug (13) to the bottom of the adjustment screw
• Place a 4 ft level across the outriggers (1) and be-
(14) as described below.
hind the power unit (3) as shown in Figure
16869-01. Move the truck until it is level in both lo- • Trucks with mast heights up to and including
cations. 8155 mm (321 in); articulation adjustment is
6.4 mm + 0.0 - 1.0 mm (0.25 in + 0.0 - 0.04 in).
• After finding a floor area that is level in both loca-
tions, mark the area with tape or paint (4) so that it • Trucks with mast heights 8180 mm (322 in) and
can be used for future articulation adjustments. above; articulation adjustment is 3.0 mm +
The trailing edge of the caster wheel must be pointing 0.0 -1.0 mm (0.12 in + 0.00 - 0.04 in).
towards the drive tire as shown (2). 5. Torque jam nut (15) to 375 - 405 Nm (275-
2. Refer to Figure 21096. Inspect wear plugs (8) on 300 ft Ib)
both ends of undercarriage. Replace as neces-
sary.
M3.0-1457-008 Crown 2009 PF17589-8
166
DRIVE UNIT
CJ\OW" Disassembly and Assembly
10
11
) 8
14 I
(
\.
15
\ :11
\?Jjlo.~~
Figure 21096
Crown 2009 PF17589-9 M3.0-1457-009
167
DRIVE UNIT
Disassembly and Assembly CAOW"
Drive Unit Removal
1. Chock load wheels, disconnect battery.
2. Using a floor jack, raise and block rear of truck high
enough to allow for drive unit removal, but not
higher than 400 mm (16 in). Refer to Control of
Hazardous Energy, Lifting and Blocking for correct
procedures.
3. Remove the eight lug bolts and drive tire assembly
(34).
4. Support and stabilize the drive unit (18) with a floor
jack or transmission jack.
5. Remove the five 0.625 inch screws (3) and two
dowel pins (1) that secure the drive unit stud as-
sembly to the undercarriage.
it CAUTION
Make sure truck is properly blocked and jack stands
securely under the power unit before removing drive
unit.
6. Carefully lower drive unit using jack, refer to step 4.
When drive unit is clear of power unit, remove it to
a clean work area for further disassembly and re-
pair.
--21
Figure 21079
M3.0-1457-010 Crown 2009 PF17589-10
168
DRIVE UNIT
CJ\OWf\ Disassembly and Assembly
LL CAUTION
Drive unit may tip over when lowering it. Keep hands
and feet away from pinch points
LL CAUTION
After reinstallation of drive unit, recalibrate steer feed-
back sensor. Refer to the Calibration section of Ana-
lyzer 123 Menus chapter.
Drive Unit Replacement

1. Make sure load wheels are chocked and rear of
truck is securely blocked high enough to allow
drive unit replacement, but not higher than 400 mm
(16 in). Refer to Control of Hazardous Energy, Lift- Figure 16875-01
ing and Blocking.
2. Refer to Figure 21079. Clean all mounting surfaces
on undercarriage (17) and drive unit (18) and
check for damage.
3. Install seal (16), bearing cup (15), bearing cone
(14) and seal (13) into undercarriage (17).
4. Install ring gear (12) on drive unit (18). Apply blue
thread locking adhesive, 061004-026, to screws
(11) and torque to 34 - 41 Nm (25 - 30 ft Ib).
5. Install dowel pin (10) and bearing stud (9) into drive
unit (18). Use red thread locking adhesive,
061004-019, on screw (5) and torque to 47 Nm
(35 ft Ib).
6. Install metallic seal (8), bearing cone (7) and bear-
ing cup (6).
7. Raise drive unit into position using floor jack. Figure 16876-01
8. If re-installing original drive unit, use same shims Trucks with Factory Stamp
(19) that were removed during disassembly. If in-
Locate the undercarriage factory stamp, letters A - K.
stalling replacement drive unit, use the following in-
Two possible locations have been used to stamp your
structions to determine the correct shim quantity.
drive carriage. The first (1) is located on the machined
The replacement drive unit is shipped with one
surface near the steering unit towards the left side of
thick shim that brings it to a factory - established
the undercarriage, see Figure 16875-01. The second
standard measurement. Five 0.05 mm (0.002 in)
(2) is located on the lower left side near the bearing cup
shims are included in the kit. To determine the
proper quantity shims required: mounting surface, see Figure 16876-01. For all trucks
with undercarriage stamps refer to Chart 1 for correct
quantity of shims.
Crown 2009 PF1758~11 M3.0-1457-011
169
DRIVE UNIT
Disassembly and Assembly CROWl'
CHART 1
Articulation SPACER Selection Spacer

Quantity
All Trucks Without Sideshift 126780-001 2
Trucks With Sideshift
5030 mm (198 in) thru 5335 mm (210 in) 126780-002 2
5360 mm (211 in)thru 10160 mm (400 in) 126780-004 2
Articulation SPRING Selection Spring
Quantity
5030 mm (198 in) thru 6860 mm (270 in) 122457 RED 2
6885 mm (271 in) thru 10160 mm (400 in) 122456 BLUE 2
M3.0-1457-012 Crown 2009 PF17589-12
170
DRIVE UNIT
CJ\owra Disassembly and Assembly
Trucks without Factory Stamp

Some trucks do not have an undercarriage stamp.
These trucks will require use of a special tool, Crown CHART 2
part number 126383, to determine the correct number
of shims required, in addition to the thick shim provided Steel Thin
Gap Measurement
with the drive unit kit. Note: If old drive unit is being Stamps Shims
returned for core value or warranty, include the old
mm in Quantity
Bearing Cup Holder, 125362, and shims when return-
ing. 0.00 - 0.25 0.000 - 0.010 K 0
9. Thoroughly clean the mounting surface on the un- 0.25 - 0.28 0.010 - 0.011 J 0
dercarriage. Remove steer bearing cup from un-
0.28 - 0.30 0.011 - 0.012 I 1
dercarriage (1), punch access holes are provided
on motor mount surface to aid in removal. Mount 0.30 - 0.33 0.012 - 0.013 H 1
Crown tool 126383 (2) to the undercarriage using
0.33 - 0.36 0.013 - 0.014 G 2
motor mounting screws and washers (3). Deter-
mine the gap measurement (4) with a feeler gauge. 0.36 - 0.38 0.014 - 0.015 F 2
Use Chart 2 to determine both letter stamp and
0.38 - 0.41 0.015 - 0.016 E 3
correct number of shims to be used. Stamp appro-
priate letter on undercarriage in either location, 0.41-0.43 0.016 - 0.017 D 3
noted in Figure 16875-01 or 16876-01, for future
0.43-0.46 0.017 - 0.018 C 4
reference. Refer to Figure16877-01.
0.46 - 0.48 0.018 - 0.019 B 4
0.48 - 0.51 0.019 - 0.020 A 5
10. Install two dowel pins (1) and align bearing cup
holder (20). Apply red thread locking adhesive,
061004-019, to screws (3) and secure bearing cup
holder (20) and drive unit (18) to undercarriage
(17). Torque five screws (3) 285 - 312 Nm (210-
230 ft Ib).Refer to Figure 21079.
11. Install drive tire (21) as described in Drive Tire Re-
placement in this section.
12. Apply hydraulic seal, 061004-023, to drain plug
and install. Fill drive unit with gear oil. Refer to
Drive Unit Lubrication in this section. Apply hydrau-
lic seal to fill plug and install.
13. Lower truck, remove chocks and test for proper op-
eration.
Figure 16877-{)1
Crown 2009 PF17589-13 M3.0-1457-013
171
DRIVE UNIT
Disassembly and Assembly mown
Drive Unit Dowel Pins
Refer to the following repair procedure for dowel pins
that are missing or protruding out of their respective
holes.
1. Raise and securely block truck so drive tire is off
floor.
2. Loosen the four hex socket head screws (1) secur-
ing bearing cup holder (2) (contains lower drive
unit bearing).
3. Insert the two dowel pins (3) and tighten the four
socket head screws. (This ensures alignment of
the dowel pin holes since they may have previ-
ously shifted.)
4. Remove dowel pins (3).
5. Tap dowel pin holes (4) with special 1/2 inch 13 NC Figure 21098
BH7 roll tap, Crown part number 126105.
6. Insert dowel pins (3).
7. Torque hex socket head screws (1) 285 - 312 Nm
(210 - 230 ft Ib).
M3.0-1457-014 Crown 2009 PF17589-14
172
mown
ELECTRICAL
173
l!J\OWr\
Notes:
174
ELECTRICAL
CJ\OWI' Electrical System
circuit in which it is used. Each wire is assigned a three

Electrical System
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 StripelWhite Positive that has gone thru a switch
59** Green StripelWhite 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. 10106 M4.1-272D-001

03 Rev. 10/06
175
ELECTRICAL
Electrical System CJ\OWI)
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
TO Time Delay
DR Driver Module
TOR 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
0 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 PFll845-2 Rev. 10/06
03 Rev. 10106
176
ELECTRICAL
CJ\OWrl 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. 10106 M4.1-2720-003

03 Rev. 10106
177
ELECTRI€AL
Electrical System CJ\OW"
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 FIC 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
03 Rev. 10/06
178
ELECTRICAL
CJ\OWI' Electrical System
Momentary or Maintained Contact

Switches
Switch symbols convey: • Momentary contact is a shaded triangle.
1. Type of switch.
2. Number of terminals.
Figure 8119-01
3. Momentary or maintained contact.
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
-0 0-
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
-0 0-
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
Crown 2000 PF11845-5 Rev. 10106 M4.1-2720-005

03 Rev. 10106
179
ELECTRICAL
Electrical System CROWl'
Examples (All Momentary)
With Common (Transfer) Without Common (Double Break)

Wired normally --
---o-----~
open, held open -..0. ~
Wired normally
~ ~
open, held closed Figure 8122
Figure 8123
Wired normally --
closed, held open ---0-----0- -0 0-
Wired normally
--0--0- ----o--u-
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 =
DrivefTow 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 PFll84!Hl Rev. 10/06
03 Rev. 10/06
180
ELECTRICAL
CJ\OW" 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
NO SPST 2 ---O----L-
--
----A L-
I~
- 1-
SPDT 3 ~L- ~
-Q.....----O- -Q......-O-
SPOT 4
----A L- -0 0-
4
----o---r-L-
~
L-
----A
DPDT - I-
~L- ----A L-
~ ~
I
OPOT 6 L-
I
---a--l-O-L-
~0-
-Q......-O-
~L-
----A -0 I 0-
DPDT 8 I I
~ ~
----A L- -0 0-
NOHC SPST 2 --{)--"1- ~
SPOT 3
~
4 -0 0-
SPOT ~
~ ~
DPDT 4 I I
I I
--{)--"1- ~
OPOT 6 ~
10-
~
-0 0-
~
OPDT 8
---0 I 0-
I
~
Figure 8100-01
Crown 2000 PF11845-7 Rev. 10106 M4.1-2720-007

03 Rev. 10/06
181
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
NC SPST 2 ~ ~-o-
- -- r--
SPOT 3
--<>--0- ~
SPOT 4
---. r-- -0 0-
~ ~
---o-r-t>- ---{)I\}----
OPST 4 I I
----o-J-o- ~
r--
OPOT 6 ~ ~
I r-- 10-
~ ~
---. r-- ~ 0-
~ ----a-r-o--
OPOT 8 I
---. I r-- ~ I 0-
~ ~
NCHO SPST 2 --0---0- ~

--0-
SPOT 3
~ ~
SPOT 4
-0 0-
----o---r-
0-
----,--
I -0 I 0-
OPST 4
- I-
~o- -0 0-
OPOT 6
~ I
I
~
~
-0 10-
OPOT 8 I
~
-0 0-
Figure 8101-02
M4.1-2720-008 Crown 2000 PF11845-8 Rev. 10/06
03 Rev. 10/06
.182
ELECTRICAL
CJ\OW" 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
Ace
Ign
Off
Figure 8131-01
Crown 2000 PF11845-9 Rev. 10106 M4.1-2720-009

03 Rev. 10/06
183
ELECTRICAL
Electrical System CROW"
Other Electrical Symbols
Signal Flow Terminal

> One Way Strip
Heater
Signal Flow ./
>< Simultaneous T-Connection Thermistor
Signal Flow
<> Alternate
Double Mov/
Junction Transzorb
Chassis
Ground -0-0- Mast Cable
Capacitor
~
*A-Analog Common Power Nonpolarized
*
B-Battery
L·Logic Return -0- Termination
Capacitor
Female/ Polarized
9 Test Point -{ Socket

Current
Male Shunt
Cable Pin
Shielded Inductor
~ ..
Cable Socket & Pin
Twisted Pair
\7 LVDT
Cable Multi-
JC -D Connector
Fixed/Jack
Ferrite Bead
Twisted Pairs
PC -0 Connector
Moveable/
Plug
Diode
~ Cable Multi-
~ Conductor CA~ Connector
Assembly
LED
Cable Multi-
Conductor
-JVV'v- Resistor
Zener Diode
Cable SI P Resistor
) Unconnected SCR
Cable
Unconnected Pot
Transistor
Insulated
NPN
• Junction
Point Rheostat
Figure 8132-02
M4.1-272Q-010 Crown 2000 PF11845-10 Rev. 10/06
03 Rev. 10106
184
ELECTRICAL
CJ\owra Electrical System
Other Electrical Symbols
Transistor DC/DC 1 234 5

-( PNP ---F=7I-
~
Converter
Power Supply
W°4!J 115487
Dual
Suppressor
Darlington Battery + +
Dual
NPN
Contactor I~A~I Suppressor
Normally 082495,086322,093757
Darlington Open
PNP
Contactor Filter Block
*
Normally
N-FETWith
Closed
Diode Clamp
- 0- Coil OR Gate
P-FETWith
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
Hom
Permanent AND Gate

Magnet
Encoder
Motor
NAND Gate
Separately
-8bB-
on732
Suppressor
Excited Motor, DC X-OR Gate

+~- Suppressor
Motor, AC 077728,085670,091181 X-NOR Gate
Suppressor
Transformer Integrated
085484,086755 Circuit
Figure 8133-02
Crown 2000 PF11845-11 Rev. 10106 M4.1-2720-011

03 Rev. 10106
185
CJ\OW"
Notes:
186
ELECTRICAL
CJ\owra Height Sensor
Height Sensor 9. Refer to Figure 21846. Remove the arm (3) from
bracket (1) by sliding it to the side away from the
The friction height sensor is mounted near the top of spring (4).
the main frame in one of the two positions shown, de-
pending on mast collapsed height.
Figure 21845
Figure 21846
Removal and Disassembly 10. Remove spring (4) from arm (3) shaft.
11. Remove the sensor retainer (11).
LL CAUTION 12. If freezer condition truck, remove the heater re-
tainer (9). If ECR2 is to be replaced then remove
The encoder is ESD sensitive. Personnel must be
the heater assembly (8).
grounded to mast member, with a wrist strap, when
handling the height sensor to protect from static charge 13. Remove screw (6) and washer (7) from the wheel
damage. The wrist strap must remain on until the (2).
height sensor is fully assembled to the mast.
14. To remove wheel (2) from ECR2 (5), place the arm
1. Move truck to a secure maintenance area. (3), ECR2 and wheel assembly in a vise with the
jaws spread far enough apart to allow the wheel to
2. Lower mast completely, turn key switch OFF.
face down between the jaws, but be free to move.
3. Chock wheels and disconnect the battery. Refer to Use a flat nose punch and hammer to tap the
Control of Hazardous Energy. wheel out of ECR2. Then remove ECR2 from the
arm.
4. LockoutfTagout truck as described in Control of
Hazardous Energy.
5. Remove the console.
6. Disconnect the height sensor harness. Note the
number and position of cable ties that hold it in po-
sition and remove the cable ties.
7. If freezer condition truck, disconnect the two heater
assembly connectors close to the height sensor.
8. Refer to Figure 21845. Remove height sensor as-
sembly (1) from the top of the main frame by re-
moving the two screws (2) that hold it in place.
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187
ELECTRICAL
Height Sensor cnoWl'
Assembly and Installation 15. If freezer condition truck, connect heater wires into
the heater assembly.
it CAUTION 16. Route the height sensor harness down the mast in
the same manner as previously removed and se-
The encoder is ESD sensitive. Personnel must be cure with cable ties as noted during removal.
grounded to mast member, with a wrist strap, when 17. Connect the height sensor harness into the har-
handling the height sensor to protect from static charge ness below console.
damage. The wrist strap must remain on until the
height sensor is fully assembled to the mast. 18. Re-ealibrate the height sensor as described in
ACCESS 123® - Calibration section of this manual.
1. Place ECR2 (5), into the arm (3) counterbore as
shown in Figure 21846. 19. Install console back on the truck and remove wheel
chocks.
2. Place the wheel (2) on the opposite side ofthe arm
(3) and tap it into position in the encoder (5) using 20. Connect battery and check truck operation.
a cylindrical bar, approximately 19 mm (0.75 in) di-
ameter, and a small hammer.
3. Install washer (7) and screw (6), into back of wheel
(2) and torque the screw to 2.8 ± 0.6 Nm (25 ±
5 in Ib).
4. If freezer condition truck, install the heater assem-
bly (8), on the outer race on the bottom side of the
encoder (5) with the leads exiting at the same loca-
tion as the encoder leads. Install the heater re-
tainer (9), over the heater to keep it in position.
5. If replacing the gasket (10), place the adhesive
side against the sensor retainer (11).
6. Clip the sensor retainer (11), over arm (3) and
ECR2 (5) and secure in position using screw (6).
7. Use clip (12) to secure the wire to the arm (3).
8. Apply a light film of grease, 063002-017, to both
ends of the arm (3) shaft.
9. Position the spring (4) as shown in Figure 21846.
Slide the spring over the end of the arm (3) shaft
and insert the spring end into the arm.
10. Slide the arm (3) shaft into the slotted hole (13) in
the bracket (1).
11. Insert the long end of the arm (3) shaft into the hole
at the other end of the bracket (1).
12. Rotate the arm (3) down into the groove in the
bracket and secure with cotter pin, 060038-003.
13. Using the existing mounting screws, install the
height sensor to the top section of the main frame.
Ensure the assembly is in the same position and
orientation as removed.
14. Apply blue thread locking adhesive to mounting
screws and torque screws to 4.1 ± 0.6 Nm (36 ±
5 in Ib). Remove cotter pin, 060038-003.
M4.3-1452-301 Crown 2001 PF13139-2 Rev. 5109
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ELECTRICAL
CJ\OWI' Access 1 2 3® Menus
Access 1 2 3® Menus Quick Reference Guide

The ACCESS 1 module, commonly referred to as the A troubleshooting guide for field service technicians is
display, is the interface between the operator or service available and is a supplement to this manual section.
technician and the truck electronic system. This sec- The 115 x 215 mm (4.5 x 8.5 in) Quick Reference
tion covers the control components of ACCESS 1 for Guide (PF17420) includes display messages, menus,
monitoring and testing truck operation. a list of components, and status codes.
o DDDDD 2
o DDDDD 2
Enhanced Display Enhanced Display with CDM
Figure 21207
1 Message Display
ACCESS 1 provides a four line information display to
communicate data from the truck's ACCESS 123 sys-
2 Navigation Keys
tem to the user. After entering the Service Menu, the
3 Capacity Data Monitor (COM) top line of the display indicates which Service Menu is
active. Pressing the right arrow causes the next line of
LL CAUTION the display to show the current submenu, while naviga-
tion through the remainder of the menu structure re-
When replacing an ACCESS 123® module or updating mains the same as the previous one line display and as
module software, verify the settings and recalibrate as shown in the following menu pages. If menu informa-
needed. Refer to the Calibration section of tion exceeds the display space, it will scroll from right
ACCESS 123 Menus for detailed instruction. to left.
NOTE
To ensure your truck's ACCESS 123 software is up-to-
date, refer to the ACCESS 1 Utilities Menu (U1) where
you will be able to view the module and software part
numbers applicable to your truck.
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ELECTRICAL
Access 1 2 3® Menus l!J\own
Operator Menus NOTE
The following pages describe operator controlled dis- The Info Screen is controlled by the Features Menu
play options. Messages longer than the display field (FB). FB allows one message field or all messages to
will scroll across the display from right to left. Press the be displayed. If only one message is selected in FB,
up and down arrows to scroll through the Operator that message will be the only one displayed and the
Menu choices. Press the right arrow to enter any of the operator will not be able to scroll through other mes-
submenus. The operator may choose from the follow- sages. If all is selected in FB, the display will continu-
ing message display options, provided the Features ously scroll through all messages.
Menu (F8) settings do not restrict otherwise and a
higher authority message is not active:
Info Screen
• Info Screen
Info Screen Menus allow the user to select what is dis-
played on the Info Screen if no higher priority items are
• Hour Meters
active. It also allows the user to control the trip meter
• Event Codes and timer. Only the appropriate menus will be made
visible based on the setting in the Features Menu.
• Service
To enter the Info Screen, key the truck ON. With a mes-
sage on the display, (Le., H1 = 2345) press the right
• Performance =
arrow to enter the Info Screen. Press the up and down
• User Rack (Visible if enabled in Features Menu) arrows to scroll through the following menu choices:
• Rack Select (Visible if enabled in Features Menu) • Weight & Height
The following messages will be displayed in order of • Model

priority (if enabled), regardless of user selection.
• Timer
1. User Code
2. PM Due
• Trip
• Height
User Code • Hours
User Code is available only if User Codes (F11) is en-
abled. This feature allows the user to create a four-digit • Odometer
code that will need to be entered to operate the truck
when it's initially keyed ON.
• Speed
1. Press the right arrow to enter the user code. ####

will be displayed. Timer
2. Press the up and down arrows to scroll to the first This selection allows the operator to display a stop-
digit. Press the right arrow to advance to the next watch. Press the right arrow to enter the Timer Menu.
digit. Press the up and down arrows to scroll through the fol-
lowing choices:
3. Continue step 2 until the last digit has been en-
tered. Press enter to accept the user code. • Stop
• Start
• Reset
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ELECTRICAL
CJ\OWrl Access 1 2 3® Menus
Timer· Start Speed

Press enter. ACCESS 1 will display an incrementing This selection allows the operator to view the current
stopwatch starting at 00:00:00. truck speed. The speed is displayed on ACCESS 1 in
=
kilometers per hour if F2 Enabled or in miles per hour
if F2 = Disabled.
Timer· Stop
In the Timer Menu, press the up and down arrows to Weight & Height
scroll to Stop. Press enter. The stopwatch, displayed
on ACCESS 1, will stop at the elapsed time. This selection allows the operator to view the truck
weight and height. The measurements are displayed
on ACCESS 1 as _ kilograms @ _ centimeters if
Timer· Reset =
F2 Enabled or _ pounds @ _ inches if F2 Dis- =
In the Timer Menu, press the up and down arrows to abled.
scroll to Reset. Press enter. The stopwatch, displayed
on ACCESS 1, will reset to 00:00:00. Model
This selection allows the operator to view the truck
Trip model on ACCESS 1 (Le., RR5700).
This selection allows the operator to view the distance
traveled in either direction since the last reset. When Hour Meters
this message is selected, the trip distance is displayed
on ACCESS 1 in meters if F2 = Enabled or miles if F2 This menu allows the operator to view one of seven
= Disabled. Press the right arrow to enter the Trip hour meters. For a full description of each meter, refer
Menu. Press the right arrow again to view the Reset to Hours in the Service Menu section of this chapter.
Menu. Press enter to confirm reset. Trip distance will
To enter the Hour Meters Menu, key the truck ON.
be reset to O.
Press the down arrow to display Hour Meters. Press
the right arrow; H1 will be displayed. Press the up and
Height down arrows to scroll through the available meters.
Press the right arrow at the desired meter to view the
This selection allows the operator to view the current accumulated operation time of that meter.
fork height. The fork height is displayed on ACCESS 1
in centimeters if F2 = Enabled or inches if F2 = Dis- • H1 - Total truck hours (key switch ON, operator in
abled. the seat)
• H2 - Total truck hours (key switch ON, operator in

Hours the seat plus programmable time out)
This selection allows the operator to view the truck run- • H3 - Odometer
time. The runtime, displayed as H1 = _ on
ACCESS 1, will correspond to the Features Menu set- • H4 - Traction Motor (M1)
ting (H1 or H2) selected in F9.
• H5 - Lift Pump Motor (M2)
Odometer • H6 - Lift Pump Motor 2 (M3) - DC Trucks only

This selection allows the operator to view the total ac- • H7 - Steer Motor (M4) - Electronic Power Steering
cumulated distance the truck has traveled. The odom- Trucks only
eter is displayed on ACCESS 1 in kilometers if F2 =
Enabled or in miles if F2 = Disabled.
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ELECTRICAL
Access 1 2 3® Menus CROWl'
Event Codes
This menu allows the operator to view up to 16 stored
it CAUTION
The User Rack and Rack Select features are primarily
event codes.
intended to relieve operator strain by assisting in posi-
To enter the Event Codes Menu, key the truck ON and tioning the forks near a selected rack position. It is al-
press the down arrow to scroll to Event Codes. Press ways the responsibility of the operator, whether or not
the right arrow; Last = _ will be displayed. Press the Rack Select is used, to assure the forks are at the re-
up and down arrows to select the desired event from quired height before inserting them into a load or be-
Last-1 = _ to Last-1S, with the most recent event before depositing a load into a rack. Variations in pallet or
ing Last = _ . Refer to Events in the Service Menu skid openings, load packaging, rack heights, etc.,
section of this chapter to clear the logged events. Refer throughout a given site need to be considered at all
to the Event Codes section of this chapter to view times.
Event Code details and troubleshooting information.
User Rack
NOTE
User Rack is available only if Rack Select (F12) and
Once Level 2 or 3 is entered, the truck must be keyed
User Rack (F13) are enabled. Accuracy is extremely
OFF and back ON to exit the Service Menu.
dependent on the height feedback calibration and re-
peatability. If it is not desired for operators to change,
Service delete or add rack heights, use F13 to disable this fea-
ture.
This menu allows service technicians to enter the Ser-
vice Menus Level 2 and Level 3. Refer to Service
Menus in this section for detailed information on each User Rack - Show/Delete
menu.
Press the up and down arrows to view all programmed
labels and heights. Preceding the height measurement
Performance = is an alphanumeric label. The labels are sorted first nu-
merically, then alphabetically. Press the right arrow to
This menu allows the operator to select one of three allow the deletion of an individual entry. Press enter to
desired truck performance levels based on pre-pro- confirm the deletion. The menu will return to Show/De-
grammed parameters. This option is available only if lete. Press the down arrow to continue.
User Performance = Enabled in F10 and if User Codes
in F11 are not otherwise programmed to limit perfor-
mance level selection by individual users. User Rack - Add
When using factory defaults: A maximum of 2S heights and labels may be pro-
grammed. Preceding the height measurement is an al-
• P1 - the maximum achievable performance level, phanumeric label. The labels can be alpha or numeric
balanced productivity and energy consumption. in either digit. For example, A1 or 1A are both accept-
able. The labels are sorted first numerically, then al-
• P2 - reduced performance and energy. Consistent phabetically. Press the right arrow. Press the up and
performance over the battery's state of charge. down arrows to enter the first digit of the desired label.
Press the right arrow, then enter the second digit.
• P3 - used where operational conditions require the
Raise the forks to the desired height level and press
lowest truck performance (Le., slick floors, novice
enter. Entering a label that already exists will return the
operators, traffic areas, etc.).
message Invalid #. Press enter to return to the Add
To enter Performance = _ , press the right arrow. Menu. Press the down arrow to continue.
Press the up and down arrows to select the desired
performance level. Press enter to select. To change the
factory default settings, refer to Performance Menus
within the Level 2 and 3 Service Menus.
M4.3-1457-004 Crown 2008 PF174294 Rev. 3110
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ELECTRICAL
CJ\owr. Access 1 2 3® Menus
User Rack - Modify Next: LL Height

Press the right arrow to modify existing labels or "LL" is a rack 10 that identifies the next available rack
heights. Press the up and down arrows to select the allowed to be targeted by the rack select system, in the
desired label. Raise the forks to the new height and direction of the requested hoist (or in the raise direction
press enter. The menu will return to Modify. Press the if no hoist is requested). "Height" is the height associ-
down arrow to continue. ated with the rack 10. The IDs and heights available are
configured via the User Rack Menu. If the operator se-
lects sideshift on the multi-task control handle, the next
User Rack - Loaded Offset available configured rack, based on direction, is dis-
played and targeted (see below). If there are no more
Press the right arrow to enter the Put Away Offset. An available racks in the direction of hoist, then "-" dashes
offset from 0 - 254 mm (0 - 10 in) is available from the are displayed instead of the rack 10 and Rack Select
programmed rack height. Press the up and down ar- targeting is aborted.
rows to edit the Loaded Offset. Press enter to confirm.
Target: LL Height
Rack Select JILL" identifies the rack that is targeted by the rack se-
User Rack is available only if Rack Select (F12) is en- lect system. The hoist system will stop at this config-
abled. Accuracy is extremely dependent on the height ured height when the fork height reaches the target
feedback calibration and repeatability. height. Then a raise cutout SRO will be displayed.
Lh CAUTION
Raise Only
This SRO appears when the target rack is a height
The User Rack and Rack Select features are primarily above the current mast height and the operator re-
intended to relieve operator strain by assisting in posi- quests the lower command instead of raise. Lower is
tioning the forks near a selected rack position. It is al- inhibited until the target is aborted or raise is re-
ways the responsibility of the operator, whether or not
quested.
Rack Select is used, to assure the forks are at the re-
quired height before inserting them into a load or be-
fore depositing a load into a rack. Variations in pallet or Remote Raise/Lower
skid openings, load packaging, rack heights, etc., Remote RaiselLower is available only if F20.8 is en-
throughout a given site need to be considered at all abled and' the truck is equipped with the optional re-
times. mote module. To activate, the operator is to scroll to the
Before operating the hydraulics, operators must also Set Remote Mode Menu and press the right arrow.
assure that a clear path exists for the forks and assure Press the up and down arrows to navigate to Enable
that sufficient overhead clearance is available in the and press enter. When enabled, all multi-task control
load handling area. The same level of operator atten- handle functions will be locked out. To disable, press
tion must be given to all aspects of driving and maneu- the up and down arrows to scroll to the Set Remote
vering whether Rack Select is used or not. Mode Menu. Press the right arrow, then press the up
and down arrows to navigate to Disabled. Press enter.
The following messages are displayed only during the
operation of rack select while in the Operator Mode,
Rack Select Disabled
Rack Select Menu:
This appears and hoist is inhibited when an event that
would cause Rack Select not to function properly is
present on the truck. The operator must back out of the
Rack Select Menu and hoist may function again (de-
pending on what event is present), but the Rack Select
Menu will no longer be available.
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193
ELECTRICAL
Access 1 2 3® Menus CJ\OWI'
Service Menus NOTE
Service Menus are available for several functions, in- There must be an operator present in the seat in order
cluding truck setup and troubleshooting. The service to view any Analyzer Menu items.
technician has access to various portions of the follow-
ing Service Menus depending on the service level se- Level 2:
lected. A 1 - Truck Status, view only
1. Key the truck ON. A2. - ACCESS 123 Module Inputs
2. Navigate to the Service Menu by pressing the A3 - ACCESS 123 Module Outputs
down arrow.
A4 - Not available in Level 2
3. At the Service Menu, press the right arrow to enter
Level 2. ##If:#. will be displayed. Truck functions are enabled in Level 2 with the operator
present in the seat.
4. Press the up and down arrows to scroll to the first
digit. Press the right arrow to advance to the next Level 3:
digit.
A 1 - Truck status, view only
5. Continue step four until the last digit has been en-
tered. Press enter to accept the service level pass- A2. - ACCESS 123 Module Inputs
word. A3 - Not available in Level 3
If Level 3 is desired, press the down arrow from Level A4 - ACCESS 123 Module Output Tests.
2 on the display.
Truck functions are disabled in Level 3.
1. Press the right arrow again to enter the service
level password. ##If:#. will be displayed.
2. Press the up and down arrows to scroll to the first
digit. Press the right arrow to advance to the next
digit.
3. Continue step two until the last digit has been en-
tered. Press enter to accept the service level pass-
word.
NOTE
Once Level 2 or 3 is entered, the truck must be keyed
OFF and back ON to exit the Service Menu.
Within the menu structures, the display may scroll from
right to left if the message is too long to be displayed at
once. To stop the scrolling display or move to the next
menu level, press the right arrow. Press the up and
down arrows to scroll through the menus. To return to
the previous menu level, press the left arrow.
Analyzer
The Analyzer Menu descriptions give further detail to
the menu structure shown on the previous pages. The
Analyzer Menu displays the different system compo-
nents available for viewing or testing.
Crown 2008 PF174~ Rev. 5110

M4.3-1457-006
02 Rev. 5/10
194
ELECTRICAL
Operator Menus
User Code 1 lOOI #### I

00
Message Mode 2 1001 Weight & Height 10
00 00
01 Model 10
00
01 Timer 1001 Stop 10
00 00
01 Start 10
00
01 Reset 10
01 Trip 1001 Reset lO
00 1 Visible only if F11 is enabled
01 Height 10 2 Determined by F8 selection in the
00 3
Features Menu
Visible only if H1 is enabled in F9
01 Hours 10 4 Visible only if H2 is enabled in F9
00 5 DC Hydraulic trucks only
01 Odometer 10 6 Electronic Power Steering only
00
01 Speed lO
Hour Meters 100 IH1 Truck Runtime1 = #.# Hr 31 0 0 I #.#Hr
00 00
continued on next page 01 H2 Truck Runtime2 = #.# Hr 41 0 0 I #.#Hr
00
01 H3 Odometer = #.# Mile 1001 #.#Mile
00
01 H4 Traction Motor = #.# Hr I001 #.#Hr
00
01 H5 Lift Motor 1 = #.# Hr 1001 #.#Hr
00
01 H6 Lift Motor 2 = #.# Hr 5 1001 #.# Hr
00
01 H7 Steer Motor = #.# Hr 6 1001 #.# Hr
Figure 22243..Q1
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195
ELECTRICAL
Access 1 2 3® Menus CROW"
Operator Menus
continued from previous page
00
_---:E::.,:v-=;;en.;.:..t-=Co~d.=.:es:-.-_l 00 1 Last = ### 1001 ###
00 00
Ol Last-1 = ### 1001 ###
00
01 Last-2 - Last-14 = ### 1001 ###
00
01 Last-15 = ### 1001 ###
,--_S:.::e;.:..;rv..:.;::,ice=-1_ _10 0 I Level 2 1001 Service Level Password

00 00
Ol Level 3 1001 Service Level Password
performance = "Value" 2100 I P1 10

00 00
continued on next page 0I P2 10
00
01 P3 10
Menu Selections:
Analyzer see page -011
Calibration see page -037
Features see page -054
Hour Meters see page -068
Events see page -072
Performance see page -074
Utilities see page -086
2 Visible only if enabled in F10 and F11
Figure 22244-01
M4.3-1457-008 Crown 2008 PF17429-8 Rev. 5110
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ELECTRICAL
Operator Menus
00 loocontinued on next page

User Rack 1 100l Show/Delete
00 00 1 0 0continued on next page
Ol Add
00 IOOcontinued on next page
Ol ModifY
00
01 Loaded Offset 1001 ###2 10
Rack Select 1001 Next: LL Height 3 I
00
Target: LL Height 3
Ol
00
01 Raise Only I
00
01 Rack Select Disabled I
00
01 Remote Raise/Lower 1001 Disable
00
01 Enable
1 Visible only if F12 and F13 are enabled

2 Use the up and down arrows to select the
desired offset value 0 - 254 mm (0 - 10 in)
3 LL is alpha numeric rack label, height is
programmed lift height
Figure 22245
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ELECTRICAL
Access 1 2 3® Menus CJ\OW"
Operator Menus
continued from 001 ### IN/MM 1001 Delete? Y 10

previous page
00
01 ### IN/MM 1001 Delete? Y 10
00
01 ### IN/MM 1001 Delete? Y 10
continued from 001 ### 1 1001 ### 1 I
previous page
00
o IRaise Forks to Desired HeightlO
continued from
001 ### 100 IRaise Forks to Desired HeightlO
previous page
00
00
Use the up and down arrows to select the
desired value, press Enter to confirm
Figure 22246
M4.3-1457-010 Crown 2008 PF17429-10 Rev. 3110
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ELECTRICAL
Analyzer Menus
continued from page -086
I
Analyzer Analyzer Analyzer
1 - - - - - - - - - to 0 t--_----'-A-'-1---:S...;.:ta....:..tu-'-s_'_ _- t 00 t----;:F::-u~1Is"')p-leA-e~....·~-.-I~--;(dr-a--;ul.,.-ics---t
. Enabled/Disabled
00 00
continued on page -037 continued on page -013
00
Analyzer
A1.3
0 Sideshift
Menu Selections: Enabled/Disabled
A1 Status
A2 Inputs see page -013
A3 Outputs see page -014
00
Analyzer
A4 Test Outputs see page -015 A1.4
2 Menu Selections:
A1.1 Full Speed Hydraulics
0 Tilt
Enabled/Disabled
A1.2 Extend/Retract
A1.3 Sideshift
A1.4 Tilt
00
A1.5 Lower
Analyzer
A1.5
A1.6 Raise
A1.7 Full Traction 0 Lower
A1.8 Limp Traction see next page Enabled/Disabled
A1.9 Steering see next page
A1.10 ED see next page
A1.11 Module see next page
00
0
00
Analyzer
A1.7
0 Full Traction
Enabled/Disabled
00
continued on next page
Figure 22247
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ELECTRICAL
Analyzer Menus
00
Analyzer
A1.8
(0 Limp Traction
Enabled/Disabled
00
Analyzer
A1.9
(0 Steering
Enabled/Disabled
00
Analyzer
A1.10
(0 ED
Enabled/Disabled
00
Analyzer
A1.11
(0 Module
Enabled/Disabled
Figure 22248
Crown 2008 PF17429-12 Rev. 3110

M4.3-1457-012
01 Rev. 3/10
200
ELECTRICAL
Analyzer Menus
00
Analyzer Analyzer
0
A2lnputs
00
A2.1 ,
Access 1 DM
00 continued on page -016
00
00
Analyzer
0 A2.2
Access 2 HCM 2
00
Analyzer
0 A2.2
Access 2 HDMJ
00
Analyzer
0
A2.3
Access 3 rCM 00 continued on page -019
00
Analyzer
Menu Selections:
A2.1 Access 1 OM 0 A2.4
Access 4 VCM
A2.2 Access 2 HCM
A2.2 Access 2 HOM
A2.3 Access 3 TCM
A2.4 Access 4 VCM
00
Analyzer
A2.5 Access 5 SCM
2 AC Hydraulic trucks only 0 A2.5
Access 5 SCM 4
3 OC Hydraulic trucks only
4 Electronic Power Steering trucks only
Figure 22249
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ELECTRICAL
Analyzer Menus
00
Analyzer Analyzer
0
A3 Outputs
00 A3.1 1
Access 1 DM
00 00
continued on next page Analyzer
0 A3.2
Access 2 HCM 2
00
Analyzer
0 A3.2
Access 2 HDM ~
00
Analyzer
0 A3.3
Access 3 TeM 00 continued on page -027
Menu Selections:
A3.1 Access 1 OM
A3.2 Access 2 HCM
o J-----.------r'1l""TX"'ll...----4 00 continued on page -028
A3.2 Access 2 HOM

A3.3 Access 3 TCM
A3.4 Access 4 VCM Analyzer
2
A3.5 Access 5 SCM
AC Hydraulic trucks only o I - - - - .,.-c-ce--'t'--"s3:;:-S5:;'S=C'-'M-'4---I
A 00 continued on page -032
Figure 22250
M4.3-1457-014 Crown 2008 PF17429-14 Rev. 3110
01 Rev. 3/10
202
ELECTRICAL
Analyzer Menus
00
Analyzer AnalyZer
0 A4 Test outputs
00 A4.1 1
Access 1 DM
00
Analyzer
0 A4.2
Access 2 HCM 2
00
Analyzer
0 A4.2
Access 2 HDM 3
00
Analyzer
0
A4.3
Access 3 TCM
Menu Selections:
A4.1 Access 1 OM
A4.2 Access 2 HCM
A4.2 Access 2 HOM
00
AnalyZer
A4.3 Access 3 TCM
A4.4 Access 4 VCM 0 A4.4
Access 4 VCM 00 continued on page -034
2 AC Hydraulic trucks only
Figure 22251
Crown 2008 PF17429-15 Rev. 3/10 M4.3-1457-015

01 Rev. 3/10
203
ELECTRICAL
Analyzer Menus
ACCESS 1 Inputs
continued from page -013 0 to t--.............,"""''>T""i''''-=''T':'T"==---1
Analyzer
~.1.2
O
~ 1---;C.""A"'-;4;-;;OCFS--71~3:;'D.r-'ig::;"iit--;al"ln-p-u"""'t
---i
Switch Open/Switch Closed
00
Analyzer
~.1.3
O
~ t--"C""iA,...4""OS,,---.....,14......D"'"'"ig=lit:-a"l'-np-Iu""""t---i
Figure 22252
M4.3-1457-016 Crown 2008 PF17429-16 Rev. 3110
01 Rev. 3/10
204
ELECTRICAL
Analyzer Menus
ACCESS 2 Inputs (AC Hydraulics)

Analyzer Analyzer
A2.2.1 A2.2.1.1
continued from
page -013
00 ECR6 M2 Speed 00 Tach
# RPM # RPM
00 00
Analyzer
A2.2.1.2
0 Counts
#Cnt
Analyzer
A2.2.2
0 Target Speed
# RPM
00
Analyzer Analyzer
A2.2.3 A2.2.3.1
0 Module Temp 00 Temp 1
# °C/F # °C/F
00 00
01 9af~IF
emp2
o
Analyzer
A2.2.4
0 M2Temp
#oC/F
Figure 22253
Crown 2008 PF1742S-17 Rev. 3/10

M4.3-1457-017
01 Rev. 3/10
205
ELECTRICAL
Analyzer Menus
ACCESS 2 Inputs (DC Hydraulics)
continued from page -013 01 OJ 1---=E=~~--r----1
Analyzer
A2.2.4
O
W 1-------.M...;;2,...:;:V:;.:.:o"'""lta'e
l--lg-- - - i
# Volts
Figure 22254
M4.3-1457-018 Crown 2008 PF17429-18 Rev. 3110
01 Rev. 3/10
206
ELECTRICAL
mowr. Access 1 2 3® Menus
Analyzer Menus
ACCESS 3 Inputs
na er
continued from page -013 00 t-r""""';"T'TT7"""'I-==-==:-7'.-::p-=-ee=-=d:r-i 00 1----....:..A2...::;T;;-::.:~~~....:..·1.:......---_i
Analyzer
1--_ _A2.: I<'-.;.,:",.3.. .,.;1.;.,:",.2- - - - - 1
O
~ Counts
#Cnt
AnalyZer
A2..3.1.3
Speed
# PH
Analyzer
A2..3.6 O~
O
~ POT4 Tilt Position Sensor ~ \WI t--------...==-=o-----t
1-------.rrF.7-----t
Figure 22255
Crown 2008 PF17429-19 Rev. 3110 M4.3-1457-019

01 Rev. 3/10
207
,--------------------~----~--------------------------------
ELECTRICAL
Analyzer Menus
ACCESS 4 Inputs
nal er
~o A2.4.1
continued from page -013 W W LMS Aux Limit Switch
Switch en witch losed
osed
Analyzer
~ A2.4.4
W J---.:S=R=E=S"-'1;-",~2";:S:":""att~R-es"""t-ra"""in"""t"7'"'""""i
1
00
1 Visible only if enabled

2 RRIRD 57005 series trucks only
Analyzer
~ A2.4.8
W I----iS
...R""S=2"U.-JP-Ple--r.....L-,eft.....P
...e--d;-a"'l£;-f
Figure 22256
Crown 2008 PF17429-20 Rev. 3110

M4.3-1457-020
01 Rev. 3/10
208
ELECTRICAL
l!J\OWr. Access 1 2 3® Menus
Analyzer Menus
ACCESS 4 Inputs
o OM
AnalyZer
A2.4.13
ret
~ 1-----;=O"'R""S"'L""jft.......,..C:-ut.--o-ut..-:s
.....w-.j.-:tcTh------i
AnalyZer
A2.4.17
ret
~ t--------rF......,SF"'"':,o="=rw-a-=-r:-.d....,..--
Slw.....it-.ch,----------i
00
Figure 22257
Crown 2008 PF174~21 Rev. 3110 M4.3-1457-021

01 Rev. 3110
209
ELECTRICAL
Analyzer Menus
ACCESS 4 Inputs
00
Analyzer
o t----.P""1U""T"71....T.-ra--'~~i~--~ .......
~;;....cc-e.....le-ra....,..to-r---l 0 0) 1---------...-:-:-:--.-----1
Analyzer
O
W
A2.4.19
POT2 Raise/Lower Accelerator W ¥
00 1-----~~..:.r-:------1
1--------:zrrl'::-l...-:---....:....-..---1
01----;=;--:-:-;-------1
Analyzer
00
Figure 22258
M4.3-1457-022 Crown 2008 PF17429-22 Rev. 3110
01 Rev. 3110
210
ELECTRICAL
Analyzer Menus
ACCESS 4 Inputs
00
Analyzer Analyzer
O
W
A2.4.21
RPS1 Steer Feedback Sensor
00 A2.4.21.1
wwt-----.....-=sllg=-na:T11-----f
t----#'IT'V
rT4o-.)lt.,....s-----i
01 ~Mir
00
Analyzer Analyzer
A2.4.22 A2.4.22.1
0 ECR7 Tiller Cmd Sensor' 00 Counts
#Cnt
00
0
Analyzer
00
DC Hydraulic trucks only
Figure 22259
Crown 2008 PF17429-23 Rev. 3110 M4.3-1457-023

01 Rev. 3/10
211
ELECTRICAL
Analyzer Menus
ACCESS 4 Inputs
I ~eer
Analyzer
A2.4.25
O
W t----;L;-;.S"'F;:-o-.rk-.L-o-'ad~Se-n-so-r--i
#ma
Analyzer
A2.4.26
O
W 1-------;:;8=D,::;1V-,o-7.lt-'ag-le-----t
# Volts
Analyzer Analyzer
A2.4.29 A2.4.29.1
0 Accelerometer 00 X Grade
#%
00
01 *1'f}
Figure 22260
M4.3-1457-024 Crown 2008 PF17429-24 Rev. 3110
01 Rev. 3/10
212
ELECTRICAL
Analyzer Menus
ACCESS 5 Inputs 1
001 !~{
Analyzer
continued from 0 OJ A2.5.1
ECR M4 Speed
page -013
00 00
Analyzer
A2.5.1.2
0 CHA Counts
#Cnt
00
Analyzer
A2.5.1.3
0 CHB Counts
#Cnt
00
0
Analyzer Analyzer
o 1----=St,.....:.e~-=r:.:.;~:..:....:~~:-lP-lS--~O OJ 1---nMA2.,T4·:.,;. i~:. . :. 3m:"~------t
#"C
:"·
00
Electronic Power Steering trucks only
Figure 22261
Crown 2008 PF174~25 Rev. 3110 M4.3-1457-025

01 Rev. 3/10
213
ELECTRICAL
Access 1 2 3® Menus CJ\own
Analyzer Menus
ACCESS 5 Inputs 1
r (00 t - - - - . . , . . - - - - , - - - - - - - - t
"""""""""""'''''''''--'''''---''''---''''-''''"e-n-so-i
00
(0 J--,,~~;...=:,;<-=-=-r-.,.,.e-n-so-r--I (0 0 I---~~...:....:....:.----I
Analyzer
A2.5.6.3
O
W 1----O~lut':;OB;.:.;C"'""~co.:..:u.=.n-;-ts-----f
# Counts
Figure 22262
M4.3-1457-026 Crown 2008 PF17429-26 Rev. 3110
01 Rev. 3110
214
ELECTRICAL
Analyzer Menus
ACCESS 1 Outputs
I k@f
continued from page -014 00 1----;-M=2,...-r-:-:-=~,...-~1-- ....,.t""'2"1----i
rren
# Amps
ACCESS 2 Outputs (DC)
Analyzer
continued from page -014 00 t-----;M,.....2"A7.:C3:...;.:~~::.:.·e..:...1n-:-t£...---------i
# Amps
00
Analyzer
o 1--- A~ ;~~.----.2-----I
.....
ACCESS 3 Outputs
continued from page -()14 to 4) I- - - - -=.A~. . :. pi. ; ro-:~-=·- r 1 to 4) II-------.D=~-;-~...,~=/-,-cfe-:----

00 00
Analyzer
O 1-_-=-:A~3.:..::.:3':,,:.:1'T-2- - - - - I
~ Current
limA
Analyzer
A3.3.2
O
¥ I------=-A.,....LM:-:=2.,;T~ra:..:..v:..;el;::.,A1,...,..a-r-m......3,...--~ 1 AC Hydraulic trucks only
2 DC Hydraulic trucks only
#%
3 Visible only if enabled
00
Figure 22263
Crown 2008 PF17429-27 Rev. 3110 M4.3-1457-027

01 Rev. 3/10
215
ELECTRICAL
Access 1 2 3® Menus CAOWI'
Analyzer Menus
ACCESS 4 Outputs
Analyzer Analyzer
continued from page -014 00 A3.4.1
PVL Lower 00 A3.4.1.1
Duty Cycle
# "10
00 00
Analyzer
A3.4.1.2
0 Current
#mA
Analyzer Analyzer
A3.4.5 A3.4.5.1
0 PVAAccy 00 Duty Cycle
#"10
00 00
Analyzer
A3.4.5.2
0 Current
#mA
Analyzer Analyzer
A3.4.8 A3.4.8.1
0 SVBY Bypass 00 Duty cycle
#"10
00 00
Analyzer
A3.4.8.2
0 Volts
# volts
Analyzer Analyzer
A3.4.9 A3.4.9.1
0 ScV Hoist 00 Duty Cycle
#"10
00
00
Analyzer
A3.4.9.2
0 Volts
# Volts
Figure 22264
M4.3-1457-028 . Crown 2008 PF17429-28 Rev. 3110
01 Rev. 3110
216
---- ----------------------------------------.,
ELECTRICAL
Analyzer Menus
ACCESS 4 Outputs
00
Analyzer
A3.4.10 O~
O
¥ 1-------,S~'V7i-L.:.,.:..Lo:....:....w=--er---1¥ 'WI I-------P<-'-'i--?~--___t
Analyzer
A:3.4,.:.:,..1~O=.2--_1
1----..:.....:.;..:,
O
¥ Volts
# Volts
o I- _- - ,;. <. ~T,r~,c-.:. ~r ~....:..11~-----4 0 ol!-----,;.,i..:..:,i.:....;.i:,.<-~...;..:.:T'"""~---

00
Analyzer
1--_----=-A..:..;3:.,:...4:rr-.1..:....:.:1.2=--_--1
O
¥ Volts
# Volts
Analyzer Analyzer
A3.4.12 O~ A3.4.12.1
O
¥ 1-------...
S"'V""'"R"'Rc-.:..
ea h-----1 ¥
..::..c.... ...u~tyC,...:;y::..:,(cl;-e-----1
'WI 1-------.D
#%
Analyzer
1--_---:....:A3-TJ.4.::=r.l~2=.2--__t
O
¥ Volts
# Volts
00
continued on next page Analyzer
1--_ _A--';~3,.,..,.4.....
1..:..;.3.2::...._._
O
¥ Volts
____i
# Volts
Figure 22265
Crown 2006 PF1742S-29 Rev. 3110 M4.3-1457-029

01 Rev. 3/10
217
ELECTRICAL
Analyzer Menus
ACCESS 4 Outputs
00
Analyzer Analyzer
O
¥
1--_------,A~3=-.4=.14:_:__-____iO
SVT Tilt ¥ W
0
1---_~A..::,:..3.4..:..;".1r;.4:....r_.1--__1
Duty Cycle
#%
o t-------....-rr----f
Analyzer
A3.4.15
0 FAN1 & FAN2 00
00
Malyzer
A3.4.15.2
0 Volts
# Volts
Analyzer
A3.4.16
0 HN 00
1 1
00 00
0
1
r;er
36i 2
Ot----,~---t
00
Figure 22266
M4.3-1457-030 Crown 2008 PF17429-30 Rev. 3110
01 Rev. 3/10
218
ELECTRICAL
Analyzer Menus
ACCESS 4 Outputs
00
Analyzer
A3.4.18 O~
O
~ 1------;:S::-ra"--7-::...:....;..:...
ke (o;"::;'ut-er....--)--t ~ W I------..,;.~~r:__---t
00
Analyzer
A3.4.18.3
O
~ I----R"'e....:..s-.-'is..-'-ta...:...nc--=e-----t
'II Ohm
Analyzer
A3.4.19 O~
O
~ I-------.S
......ra--r~k-le.,....
(In-n-er..---)--l ~ W 1------...::-:r-:-n:-:-:;c--------1
00
Figure 22267
Crown 2008 PF17429-31 Rev. 3110 M4.3-1457-031

01 Rev. 3/10
219
- -- ---------------------------
ELECTRICAL
Analyzer Menus
ACCESS 4 Outputs
Analvzer
00
A3.4.20 O~
O
W 1--=-Br--;akC-:-e'::'(ca--:-ste-n.--::'r------I W '¥' 1----;:;:-;--.."..--,-------1
Analyzer
1--_----:....;A3~.4~.2:...:..0.,=...2--__i
O
W Current
# Amps
00
Analyzer
A3.4.20.3
O
W t----'R..-le:-:s"T':ls:L"ta:-:n:-:c-=-e----t
#Ohm
ACCESS 5 Outputs
Analyzer
continued from page -014 00 J-----;M,.....4..,....-rm.:....As~3c~·5.:....~~'-re-n.t£..,.....----1
# Amps
1 RRIRD 57005 series trucks only

Figure 22268
M4.3-1457-032 Crown 2008 PF17429-32 Rev. 3110
01 Rev. 3110
220
ELECTRICAL
CROW" Access 1 2 3® Menus
Analyzer Menus
ACCESS 1 Test Outputs
Analyzer
continued from page -015 0 OJ A4.1.1
ALM1
00
Analyzer
A4.1.2
0 Lamps
ACCESS 2 Test Outputs (AC)

Analyzer Analyzer
M2 rms Current 00 A4.2.1.1
U
00
Analyzer
01 A4.2.1.2
V
00
Anr er
ACCESS 2 Test Outputs (DC)

01 A4.2.t.3
Analyzer
M2 Current
00
An~er
Aiz2
01
Figure 22269
Crown 2008 PF17429-33 Rev. 3110 M4.3-1457-033

01 Rev. 3/10
221
ELECTRICAL
Analyzer Menus

Analyzer
continued from page -015 OJ OJ A4.3.1
Travel Alarm 1
00
Analyzer Anal~er
OJ A4.3.2
M1 rms Current 001 A4.&=.1
00 00
Analyzer
01 A4.3.2.2
V
00
Ana~r'
01 A4.?.2.3
Analyzer
A4.3.3
OJ FAN3 & FAN4
continued from page -015 001 Anafer

#r.4..
1
Power
1
00
Analyzer
A4.4.5
OJ PVAAccy
00
Visible only if enabled
Figure 22270
M4.3-1457-034 Crown 2008 PF17429-34 Rev. 3/10
01 Rev. 3/10
222
ELECTRICAL
Analyzer Menus
Figure 22271
Crown 2008 PF17429-35 Rev. 3110 M4.3-1457-035

01 Rev. 3/10
223
ELECTRICAL
Analyzer Menus
RRIRD 57008 series trucks only
Figure 22272
M4.3-1457-036 Crown 2008 PF17429-36 Rev. 3110
01 Rev. 3/10
224
ELECTRICAL
Calibration Menus
00
Calibration
100 Calibration
C1 Handles 1 00 continued on next page
00 00
continued on page -054 Calibration
0 C2 Hvdraulics 00 continued on page -041

00
Calibration
(0 C3 HeiQht Cutouts
(00 continued on page -049
00
Calibration
(0 C4 SteerinQ Sensor
(00 continued on page -053
Menu Selections:
C1 Handles
C2 Hydraulics
C3 Height Cutouts
C4 Steering Sensor
Figure 22273
Crown 2008 PF17429-37 Rev. 3110 M4.3-1457-037

01 Rev. 3/10
225
ELECTRICAL
Calibration Menus
Calibration Calibration
(0 0 t--=Tr-a-ctc=:....i01:...:...~1.;-.,.H~-n--,d,..-le~ (0 0 J-----T-ra-c~ti~~~~·~~a-nd-Ie-~
continued Sure? N
from previ- L...--o=-fiNl~a-----J 0 0
ouspage W W W W
continued on next page Calibration
(0 I----=T-ra--,ct.,..:::i~:...:..~=:-::·~-an--'d"""le----I(0 0 . . . . =:-i-F==::===-r.:..::::-:.=.:..::....F"n=te-=-r-l
Sure? Y
Menu Selections:
C1.1 Traction Handle
C 1.2 Raise/Lower Handle see next page
C1.3 Accessory Handle see page -040
Calibration
o I--:C"'""a-.l,.,..ib.....:ra.:..;t~io:.::n:..::.a.:..:.c....:...ce.:..::~D::..;·t:..::.ed:.;:/;7fa.."i1:-e....,.d--l
A Traction Handle
Figure 22274
M4.3-1457-038 Crown 2008 PF17429-38 Rev. 3110
01 Rev. 3/10
226
ELECTRICAL
Calibration Menus
00
o I-,R=-a--:i-se--:/"....L~=w....:.;1~=~'-:-H-:-a-n--:d"....le--i 0 0 I---=R-a-:-is-e-=/L~~=--~:....:.;~2=-r
--:H--:a-nd-=I-e---t
Sure? N
00
00
O C1 2
~ t---;::R:-a..,..is-e-;;/L-'o:;....w;...:;~::..r ....
012 J--S=e--Tle~c=::t:.,;;R.:-:a:;.::is..:..:e....::.,
H'a-nd..'-e--t ~ ¥
Raise/Lower Handle
p':"'-r:"":'es=s":";E:-:n=-:-te-r---f
Sure? Y #.# Volts
00
Calibration
o
~ Raise/Lower Handle
J----:SO<""e-i-le~c-i-t:,.:L..:..:ow::..:....:.er.:....:,~
Plre":":s:"":'s....E,.'-n.,..-te-r~
#.#Volts
00
Calibration
o .-. ".,-
Cie"":'nt"':';e":":r:"';H~a=nd;";'I':"":e,":":p"':""r":":es:"":'s":;'E";"n"""t-er~
#.#Volts
00
Calibration
o
t---;C...a....li;-br--a7'tio--n-'a--c--c-ep-;1t..:...ed~/iT"fa-:;i1e-d-.---l
Figure 22275
Crown 2008 PF17429-39 Rev. 3/10 M4.3-1457-039

01 Rev. 3/10
227
ELECTRICAL
Calibration Menus
00
0) I--A:-c-ce-s--'sC:::"o~:..:.·3=:-H:-a-nd"""l-e-I 0 (0 I---A-:-c-c-e-ss-=~:....:.)~..:.::·37-:H-an-d-::-le---1
Sure? N
00
Calibration
O 1--::------"'C--'-"1.3~-:-:--__i
'WI Accessory Handle
0 0 ~~~.L-:....:..::::...:.=.,.;.-.,....----I
'WI ~
Sure? Y
Calibration
o
~ Accessory Handle
!----,C"a. .li,-;-br--a.....
tio-n--ac......c--e--;-P1te-:;d"'/fa"':"'iO':"le-:;d-l
Figure 22276
M4.3-1457-040 Crown 2008 PF1742940 Rev. 3110
01 Rev. 3/10
228
ELECTRICAL
Calibration Menus
o 0 I- - ,.H. ,. . e. ,. . ig~ h~;:. :, ·~~-ns-o-r
continued
...... ---f 00 I----,.H..,....e..,....ig.,.::;I~~2s:.-~-ns-o-:-r---f
Sure? N
~~03~ page 0 0 0 0
o J--.... H,....,ei,...,g~--.-t2"'s~--:n=so=r-----1 0
Sure?Y
0 1---o----:-.---;-:::"~=:-::::=:-;::::-==in=--1
00
Calibration
O ~--;---,--.......---,:;:C=,2:...;'1-.--:-:-:-::-:r==::-t
~ Raise to Max Height, press Enter
###If. counts
00
Calibration
C2.1
O
~ 1-------.E
--n""7te-r:-.F,;-o=.r\<-';H"e-::-;ii"::;glCL
ht------1
###If. counts
Menu Selections:
C2.1 Height Sensor
C2.2 Load Sense see next page
00
calibration
C2.3 Main Lower Valve see page -043 C2.1
C2.4 Accessory Valve see page -oM
C2.5 Accelerometer see page -046
O alr;[ib:": "ra=<1tT:io-=n""::a:=:c7ce=-=p:7te=-=dJ""lj/fT.:.,aTo"i1e=-=d:r--;
~ 1--e:"'="1
C2.6 Tilt Sensor see page - 047
C2.8 Steer Feedback see page -048
Figure 22277
Crown 2008 PF17429-41 Rev. 3110 M4.3-1457-041

01 Rev. 3/10
229
ELECTRICAL
Access 1 2 3® Menus
Calibration Menus
00
Calibration
o I-----:--Lo-a~:::;.:~==·~=--n-se---i 0 0 I-----.----.-:...-- ---i
00
o Cd",:2s''---I~-ns-e---1
I------;L-o-a--.
Sure? Y
00 '---'L-o-w-e-re-m----,;---'7.....:,.:~O=--r-e-ss--.=E~nt;-e-r---l
Calibration
O 1---..;=::-:r=-:=ACT2;;..2~~==....---1
~ Raise Forks 1", Stop Command
Visible once calibration completes and command #### psi
remains active
Calibration
~---.=o---..---.-"'=":;::
C:2.~2 --...-~-__i
O
~ Finding Load Sense Point
00
Calibration
O 1-_ _---;:=~C=-=2=.2=_::;_:r---__i
~ Stop Command 1
00
Calibration
C2.2
O
~ ..------,:C-=a-;:;lib;:-:r:-:-a:iTtio:-:n:-=a==c:-:c=:-e~pltr::-e-::rd/iLfa::iil;::e-::rd- - - 1
Figure 22278
M4.3-1457-042 Crown 2008 PF17429-42 Rev. 3110
01 Rev. 3/10
230
ELECTRICAL
Cl\OWI' Access 1 2 3® Menus
Calibration Menus
00
o .........,MC"':"a--:i-n-:-L.=:~w=.2:.::r~v-:-a-:-,v-e~ 00 I----,M,.-;-a:-in....,.L-=~-=~~::....r
Sure? N
VrT"""1
al' ve- - i
00 00
continued on next page Calibration Calibration
o ....a-,i'n-;""L-~-~-:r-,v....a--:I-ve--t
I---;M
Sure? Y
00 ..a--.,.is-e-t·o.....T;:-'~:..:;:....,·~i;-h-e-n·L-ow-er------t
1------,R
fFIRRt. em/in
Calibration
C2.3
O
~ I---oF""'in-d....i-ng-----==S-re-a-;""k-o'ut:-."'M'--a""'in-:-ta-'i'n~C""'"o-m-m-a-n-d.-t
#### rna
o Findin
Calibration
C2.3
O
~ J-----..,.S;-:-to-)p--:;C~o.=.m:..:.m-a-n ...
d...-
z------i
1 Will find for speed for 1 through speed 7

00
Calibration
2 Visible once calibration completes and command C2.3
remains active O
~ 1------,:;C'a=lib-r-at,.,-io-n--=a:..:cc:..:..:....ep--:1t-ed-;-/rT
fa...,.,i1-ed..--------t
Figure 22279
Crown 2008 PF17429-43 Rev. 3110 M4.3-1457-043

01 Rev. 3/10
231
ELECTRICAL
Calibration Menus
00
o I--7"Ac-c-e-'s~=;:":"rv.4-=-:v"""'a"""'lv-e-; 0 (0 l--"'Ac-c-e-s~-;-ry.4--;v"a--'lv-e---l
Sure? N
00 00
continued on page -046 Calibration Calibration
o t---:A-cc-e-s-~-;ry-.4~v7""a"""lv-e----i 0 (0
Sure? Y
t-----'L-o-w-e-r-em-l---:-ptyc....,,~-·~7""kS---:-to--;b-e-lg..,....iin--:1r----1
00
Calibration
C2.4
O
~ I-oE"'"xt-.-en-d......
Fo-r......k-s·N;-e..:..a..:..r""s7'"to-p,,---
plre-s-s"E:-n7'"te-r---l
00
Calibration
C2.4
O
~ t----=S-e:-le-ct~R=e-a.=;,;c'7h'-':C=o-m-m-a-nd-:-----t
00
Calibration
O
~
1--:::------,,......-::--:-_C==2=.4-'---.,-----,_,-;--____=_--1
Paused - Select Reach to continue 2
00
1 Visible only if forks are above staging

2 Visible only if command has been removed
Figure 22280-01
M4.3-1457-044 Crown 2008 PF17429-44 Rev. 5110
02 Rev. 5/10
232
ELECTRICAL
CJ\owra Access 1 2 3® Menus
Calibration Menus
00
Calibration
C2.4
0 Finding Breakout, Maintain Command
####ma
00
Calibration
C2.4
0 Retracting - Maintain Command
00
Calibration
C2.4
0 Finding flow point, Maintain Command
####ma
00
Calibration
C2.4
0 Stop Command 1
00
Calibration
C2.4
0 Calibration accepted/failed
Visible once calibration completes and command remains active
Figure 22281
Crown 2008 PF17429-45 Rev. 3110

M4.3-1457-045
01 Rev. 3/10
233
ELECTRICAL
Calibration Menus
00
o I---A""'c-c--:ef:":e~:.:.;~5=-m-e"""te-r
----i 0 '0 I---A"-c-c-'efr-:e~~~5':""m-e""'te-r
Sure7 N
--I
00
00
Calibration
o t--"'A--cc~ef--e~=~~:-:-e:-;-te:--r
Sure?Y
--I 0 '0 J-,,=~:":':T>'-=:==:;~:-=-i"':'"-=-==~
Calibration
(.;2.5
O
W J------;D"""e-;t;-e-rm--,I~n1.-:n:..=g:.rL.:....ev-e"""TI....T.....
ru-c"T'"k-----I
x.x 9
00
Calibration
(,;2.5
O
W J-"'P~o-=-'sl""'ti-:-on--=;=T--ru-c'--'-kln-O-p--p-o-'si"""te--;D""i'='"re--c7'tl-:-on---1
x.x 9
(.;alibratlon
o C2.5
J------,D"'le-:-:;t:-:-e=rm::"!I='n1.-=:n::=g~
L4eV--e:Tll.....T'=ru-:-:c~k---f
x.xg
00
Calibration
o J---~(.;iamlib:-::r:=-:at;;-:io:-::n:-=a:=:c:'-=::ce=:-:lp=-:ilt-=-ed::i'il/,lZ:fa:Tiil-=-ed::r------t
C2.5
Figure 22282
M4.3-1457-046 Crown 2008 PF1742946 Rev. 3110
01 Rev. 3/10
234
ELECTRICAL
Calibration Menus
00
C2.6 C2.6
0 Tilt Sensor 1 00 Tilt Sensor
Sure? N
00
00 calibration
Calibration
C2.6 C2.6
0 Tilt Sensor 00 Tilt fully back. press Enter
Sure1 Y
00
Calibration
1--_......."""..........,..,....-.,........:::C.=.2.:.::::6_----;::..--;-_ _~
O
~ Tilt fully down. press Enter
00
Calibration
O 1---="....,.--=-----;:~C2=.:..: . .6----.=-...----~
~ Tilt to Zero Degrees, press Enter
00
Calibration
O 1--........---=o_-=-----=.C2=.:.-=-6---.--=~=....---i
~ Use Zero Degrees as target, Yes?
00
Calibration
O
~
1--....---::;.-......-_C=2=.:..6=---.....-:-::-=-:-L--.r::.,.-------t
Use Zero Degrees as target, No?
00
Calibration
Visible only with TPA feature enabled and TPA O 1----;;-;-:---:-=7:"-:-:~C:=:2~.6=-=-=--=-=-=::-=7""---i
~ Using Zero Degrees as target
hardware installed
00
Calibration
C2.6
O
~ J------..T""ilt"""'t-o....,dr-e....,si-re-d,.....:a=-=n:..:....:;-glleprr-e-s-s"i=Er-nt"-e-r--I
-.-
00
calibration
1--_--=-....,."....----;-;-_.=.c:2=.:..: . .6---;--...,..".-.....--.-~
O
~ Calibration accepted/failed
Figure 22283
Crown 2008 PF17429-47 Rev. 3110 M4.3-1457-047

01 Rev. 3/10
235
ELECTRICAL
Calibration Menus
00
o I---s"'"'t-ee-r-=~~;::':';~~:;"b-a-:ck-1~ 0 0 I---':;S"""'te-e-rc;':F~=-:':"'d;;-ba-c"'k~
Sure? N
calibration Calibration
o I---:=S:-:""te-e-rC:-=/~e~-8d~b-a""'ck---1
Sure? Y
00 I------:=c,....e-nt,....e-r=S7""te-e-r, ",~:,:;:~:. :. ~8=-e" ,
'l plre-s-s-=E:-n""'te-r--f
-
Calibration
C2.8
ret
¥ ...h--e--e·1r="Fu-lIlr"ly....,C'"W~,p--r--es--s:-;E
I--..S.....te--e--r..W F
n::1t--er=----t
Calibration
C2.8
ret
¥ I--S=t,....e-er....,W~h-ee--:I-=F=-u..,;:lIy=.;<C;.C"'w,.,-p-lre-s-s-=E=-n...,...te-r---l
Calibration
C2.8
ret
¥ C,amlib'r-at""io-n--'a""'c:..:..c=-ep't:-e-r"dITrfca-;;i1;-"ed-.------1
1----,......
DC Hydraulic trucks only
Figure 22284
Crown 2008 PF17429-48 Rev. 3110

M4.3-1457-048
01 Rev. 3/10
236
ELECTRICAL
Calibration Menus
Calibration
continued from 00 C3.1 1
Height Cutout 1
00 continued on next page
page-03?
00
Calibration
0 C3.2
HeiQht Cutout 2 2
00
Calibration
0 C3.3
HeiQht Cutout 3 2
00
Calibration
0 C3.4
Height Cutout 4 2
00
Calibration
0 C3.5
Height Cutout 5 £
00
Calibration
0 C3.6
Height Cutout 6 £
00
C3.99 C3.99
0 Clear All Cutouts 00 Sure? N
Menu Selections:
C3.1 Height Cutout 1
00
Calibration
C3.99
0 Sure? Y
C3.99 Clear all cutouts
2 Cutout is same as C3.1 cutout; follow C3.1 steps to calibrate
Figure 22285
Crown 2008 PF17429-49 Rev. 3110 M4.3-1457-049

01 Rev. 3/10
237
ELECTRICAL
Calibration Menus
O
~0¥
J-----=---,--=.:.C3:::..:-;.1::::-:-:.
Cutout 1 TriQQer
1----I 00
~¥
C3.1.1.1
Cutout 1 Trigger Type ~ ¥
0 0 J-...-.....--:-oo;:...;::..:..:.::..:....,r.....:...:..>i!S!..~-.--------I
nter
continued
from previ-
ous page 00
A Cutout 1 Triaaer
G hS--e"le-c'tT~n:';:iQ:':::":Qle:':'r-i.-th~e":"':n:il.p>Lre:":'s-srE=-n"""te-r--l
FLS
Calibration
Cutout 1 Trigger
0 Select Triaaer then press Enter
HGTS1
00
-Calibration
Cutout 1 Trigger
0 Select Tnaa-er then press Enter
HGTS2
Calibration
RlL to Cutout then press Enter
0 00 ###.#mm/in
Visible only if Height Sensor trigger is selected
Figure 22286
Crown 2008 PF17429-50 Rev. 3110

M4.3-1457-050
01 Rev. 3/10
238
ELECTRICAL
Calibration Menus
00
C312 ~~ Cutout 1 Type
O~ t------;C....u......to-u......t·71 T~yple=------f
""T' 0 0
!--,S"e-'-Ie-c"'-t;'Ty:"='::":ple:"':;;th~e":""n"':""pU:lre:"'=s-s-'=E:-n"""te--fr
~ None
00
Calibration
CUIDut1Type
O
~ Select Type then press Enter
Latched Raise Cutout
Calibration
Cutout 1 Type
O
~ t-:S
. .e-.le-c-.t-==T=--yple--:-:-th-e-n.....p:...L.lre-s-s-.=E=-n-:-te---lr
Latched Lower Cutout
00
Figure 22287
Crown 2008 PF1742~51 Rev. 3110 M4.3-1457-051

01 Rev. 3/10
239
ELECTRICAL
Calibration Menus

00
o
A C31 4 A~
t------=C-ut,.....o..=ut-:=-17-'·-=Zo'-n-e-,1.----10 hS 0
..-e:7'"le=-c......
Cutout 1 Zone
t ""';Zo-=-n=-e'-;trhe--n-:-'' ':' plr--e'-ss--;E;=-n-''t-er-i
A
illliI##nll
Calibration
o I-:S"'""e~le-c~t-=Zi-o~n:"::'e":;:'thc-e":""n=p-=-lr:":"e=-ss--;=:E-nt:-e-lr
A Cutout 1 Zone
Calibration
oA Cutout 1 Zone
I Select Zone then press Enter
C
Calibration
o
A Cutout 1 Zone
Select Zone then press Enter
All
Visible only if F20.7 - Zone Switch is enabled
Figure 22288
M4.3-1457-052 Crown 2008 PF17429-52 Rev. 3110
01 Rev. 3/10
240
ELECTRICAL
CJ\OW" Access 1 2 3® Menus
Calibration Menus
Calibration l;alibratlon
C4 Steering Sensor 1 C4 Steering Sensor
00 00 Sure? N
continue a
from page
-037 00
Calibration
C4 Steering Sensor
0 Sure? Y 00 nter
Calibration
C4 Steering Sensor
O
¥ t--~Clen-'tc-e-=rs~lt'--e'-e-'-;rWrarr-h.....
ee'-;I,.-',--pr---e-'-ss--'=E-'ntc-e-r --t
#.#Volts
Calibration
C4 Steering Sensor
O
¥ ce'-~p-:"lte-d..,.,/crfa..,.i1e-d..,..----1
1---=C-al=ib-ra-;t.io-n-a-c.....
.
Figure 22289
Crown 2008 PF17429-53 Rev. 3110 M4.3-1457-053

01 Rev. 3110
241
ELECTRICAL
Access 1 2 3® Menus CJ\OWf'
Features Menus

00
100
Features Features
F1 Lanauaae 1
"Value" 00 nter
00
continued on page -068
00
0 nter
t-eatures
Languaae
0 Select then press Enter
French
Menu Selections:
F1 Language 00
F2 Metric= Features
F3 Truck Data Number see next page Language
F4 Truck Weight see page -oS8
F6 COM see page -oS8
Gennan
F7 Fans see page -oS9
F8 Message Mode see page -060
F9 Hour Meter Mode see page -061
00
Features
F10 User Performance see page -061
Language
F11 User Codes see page -061
F12 Rack Select see page -063
F13 User Rack see page -063
Dutch
F20 Options see page -063
00
Features
Lanquaae
Italian
Features t-eatures
~ =
G I---~"'::"':":='-=-----I ret
F2 Metric ~
~ 0 1--...,.........,
Metric
Slel-,ec"""'t.,....th..:..:.;len~p::...:.r=-es-s ......
B~nt:-er----i
Disable
00
Figure 22292
M4.3-1457-054 Crown 2008 PF1742~ Rev. 3110
01 Rev. 3/10
242
ELECTRICAL
CAOWr. Access 1 2 3® Menus
Features Menus

00 eatures
Features
0 F3 Truck Data Number

00 T ruck Model
0 WI
F_3... ,. . 1M-:-:o,...--d..,....el-:--_---t 0 1--=--"""----,:...,,~---'--;:.,..-,-----1
¥
" a ue
00
00
Features
Truck Model
5715
00
Features
Truck Model
5725
Features
00
Truck Model
5795
Features
0 F3.2 ;:::;-
Re;...;..a-"-;-ch-::;T;:,,-,,-,,e-.------I
F3.2 ReachT e
0 0
¥WI
1--7'l-=i::=-=n,~~~::'=::--i
00
continue d on next page Features
o
~ F3.2 Reach Type
J-'S---=leTle:O-=:c7=ttrrh:":=-e:: -:n===p=re:-::s-!-sJFE~nt'-::-e::-r ----i
RD
Visible only if Model 5725 or 5795 is selected
Figure 22293
Crown 2008 PF17429-55 Rev. 3110 M4.3-1457-055

01 Rev. 3/10
243
ELECTRICAL
Features Menus

00
Features
~
F3.3 Max Load Weight
O 0
'¥' 1--~~~~::"':;'-':~"77---f'¥' W t--""'S"'-le:-'e"""ct""':"ith-e-n-
plre-ss--,E=-n"':-te-r----f
1360 kg (3000 Lbs)
00
Features
F3.5 Lift HeiQht
0 "Value" 00
00
Features
F3.6 Collapsed Height
0 ''Value'' 00
00
Features
F3.7 Lift System
0 "Value" 00
00
continued on next page Features
F3.7 Lift System
AC
Figure 22294
M4.3-1457-056 Crown 2008 PF17429-66 Rev. 3110
01 Rev. 3/10
244
ELECTRICAL
CJ\owra Access 1 2 3® Menus
Features Menus

00
Features
F3.9 Steering Direction 1
0 "Value" 00
00
Features
F3.9 Steering Direction
Reverse
Features
F3.10 Sideshift
0 "Value" 00 nter
00
0
Features
~ t - -_ _F
....:3..,-.1,-1T-...ilt_ _---i ~ ~ t---....-....,...."...:--'-'--;.......-.----I
~ 'Value' ~ 'WI nter
Features
~ F3.11 Tilt
~ t--'S..--e......le=-=c......
t ...th--e-=-n--p-=-rre=-=s--srE=-=n......te=-=r---i
Enable
Figure 22295
Crown 2008 PF1742&-57 Rev. 3110 M4.3-1457-057

01 Rev. 3/10
245
ELECTRICAL
Features Menus
Features
t F4 Truck Wei ht
0 00 Select then ress Enter
''Value'' Lbs
00
Features
F6CDM
0 00
00
00
Features
Capacit y Data Monitor
select tt en press Enter
...nable
Features
F6.2
0 CDM Zones 1 00 nter
"Value"
00
Features Features
F6.3 CDM Height 1
0 CDM Hei ht 1 00 Select then press Enter
"Value" ###In
00
Features
F6A
0 CDM Wei ht 1 00
"Value"
00
Features
F6.5
1 Visible only if F6.1 is enabled 0 CDM Hei ht2 00
2 Visible only if F6.1 is enabled & F6.2 ''Value"
Zones are greater than 1
00
Features
F6.6
0 CDMWei ht2 00 nter
"Value"
00
Figure 22296
M4.3-1457-058 Crown 2008 PF17429-58 Rev. 3110
01 Rev. 3/10
246
ELECTRICAL
CJ\OWf\ Access 1 2 3® Menus
Features Menus
00
Features
F6.7
0 COM HeiQht 3 1 00
"Value"
00
Features
F6.8
0 COM Weight 3 1 00
"Value"
00 Features
Features
F6.9 t,;OM HeiQht 4
0 COM Height 4 2 00 Select then press Enter
"Value" fRRI.ln
00
Features
F6.10
0 COM Weight 4 :l 00 nter
continued from previous page "Value"
00
Features Features Features
F7 Fans F7.1 Module Fan
0 00 Module Fan 00 Select then press Enter
"Value" Thermal
00
00 00
0 nter
Features Features
O
W t - - - - ·M
F7.2 0 0
,...o--',t....:.or.:::;F.....a -n-----1 W ¥
I--..,.........,..~M:;.::.o.:.::to.:...:-:rF~a:.:...:.n......-:;~--1
Select then press Enter
''Value'' Disable
00
t-eatures
1 Visible only if F6.1 is enabled & F6.2 Zones are greater than 2
2 Visible only if F6.1 is enabled & F6.2 Zones are equal to 4 o
~ Motor Fan
"'-'S"'e:'Tle-=-c-:7t-ith':-=e:":'n::":o::-:lr=e7ss::-O=E=nt'-:=e-=-r---i
Thermal
t-eatures
o
~ Motor Fan
t--....,S.....le"'T~le-c....,..t 7rth. . :.le.:. :n:. :. .p---re.,-s---s.....E~ln....te:-:r,..----i
AlwavsOn
Figure 22297
Crown 2008 PF1742~59 Rev. 3110 M4.3-1457-059

01 Rev. 3/10
247
---------------------------------~
ELECTRICAL
Access 1 2 3® Menus CAOWI"
Features Menus

00
Features
~ Message Mode
O
¥ t------nrT.......-"'-.,.....-----1 0
¥ ¥' t--...,......,
Slelr-ec-.,.t-:Tth-e......
n'-- plr-e-ss-'E=-n"":"'"te-r---i
Timer
00
Features
Message Mode
Height
00
Features
Message Mode
Weight & Height
00
t-eatures
Message Mode
Hours
00
Features
Message Mode
Odometer
00
0
Features
o
~ Message Mode
I--"S'e'le":':'c:"'::'t....
th.:..:e""n<..::...,;.
plre":':'s':":s"EO-:n7"te-r---i
Model
00
Features
o
~ Message Mode
I--'S....e'le...;.;c7t .Tth--e'-'n.....p-'re-s-s·E=-n......te--r--t
All
Figure 22298
M4.3-1457-060 Crown 2008 PF1742~ Rev. 3110
01 Rev. 3/10
248
ELECTRICAL
continued from previous page Features Menus
00
Features
O
¥ ''Value''
0
I-------!F....:::9...:....H=ou=r~M;=_:etc=;;er-=..:M=0=de~
¥
~ I--~....:....:..,.:~:...:..:..c......:..:...c.:.....-:-:-_-I
W
00
Features Features
F10 User Performance User Performance
0 00 Select then press Enter
Disable
00 00
Features
User Performance
Enable

F11 User Codes F11.1 User Codes
0 00 User Codes 00 Select then press Enter
"Value" Disable
00
00 00
Features
User Codes
Enable
Features Features
F11.2 F11.2.1
0 Setup User Codes 1 00 User Code - ####
Performance Level =#
00
00
0
Visible only if User Codes is enabled
Figure 22299
Crown 2008 PF17429-61 Rev. 3110 M4.3-1457-061

01 Rev. 3/10
249
ELECTRICAL
Features Menus
00
Features Features
F11.3 1 Timeout
0 Timeout 00 Select then press Enter
''Value'' Never
00
Features
Timeout
1 Min
00
Features
Timeout
5Min
00
Features
Timeout
10 Min
00
Features
Timeout
15Mln
00
Features
Timeout
20 Min
00
Features
Timeout
30 Min
00
0 nter
Visible only if User Codes is enabled
Features
Timeout
O
'¥' t--'S--Ie..le-c.,.....tt""'h-en--pr--e""'ss~E-:;ntC:-e-:-r ---I
90 Min
Figure 22300
M4.3-1457-062 Crown 2008 PF174~2 Rev. 3110
01 Rev. 3/10
250
ELECTRICAL
Features Menus

00
Features eatures
O
W
I--__=_F__=_1=-2;....;.Ra=c:.:.:.k....=.S=el=ec:.:..t_1-----i 0 ~ t--""-:-;"":'""":7=a-:-ck-:-S-:-e:-:-le-:-:c..."t""='T:-:-----i
W W
R
Select then ress Enter
Features eatures
F13 User Rack 2 User Rack
0 00 Select then press Enter
Disab e
00
0 nter

O F20 Options
W t---.....:....::;;..;;........;~..;;;.,;,.;;,,;'-----i
~~
0 0 F20.1 ~ Chain 0 Slack Switch
J-----=Cc:-h..:....,ai;::.n::,:S:-i-la-cc:-k----I W W J--"""S,eTlec..:. :c7-'t :i-h":"en:":";":';plr":"e":"ss';";""=E"-;nt""-e-r--I
"Value" Disable
00
00
Features
Chain Slack Switch
O I----oo<--.----:--;r----=,-----!
Enable
1 Visible only if F25 is enabled

2 Visible only if F12 is enabled
Figure 22301
Crown 2008 PF17429-83 Rev. 3/10 M4.3-1457-063

01 Rev. 3/10
251
---------------------,------
ELECTRICAL
Features Menus

00
Features Features
F20.2 Battery Retainer
0 Battery Retainer 00 Select then press Enter
''Value'' Disable
00 00
Features
Battery Retainer
Coast
00
Features
Battery Retainer
Coast wi Horn
00
Features
Battery Retainer
Brake wI Horn
Features
F20.3
0 Travel Alarm 00 nter
"Value"
00
continued on next page Features
Travel Alarm
Forward
00
Features
Travel Alarm
Reverse
Figure 22302
M4.3-1457-064 Crown 2008 PF17429-64 Rev. 3110
01 Rev. 3/10
252
ELECTRICAL
Features Menus

00
Features
o
~ F20.4
::-'";p-lee-';-d~C:....:.,.uti-ba---;ck,.....-;1..---I
I----.S
~~
0 0
1--.,.......-r....:....;:...;,...::...:;-~~,.......,....----1
"Value"
Features Features
O
¥
F20.5 0 ~ Tilt Position Assist
T=ilt-:P::"'"o-s=:-,:iti;:.:o::..:;n=:A-s......,si,....st-:2=----t ¥
J..---- ¥ t--....,S"""le""Tlle-c-:"t"""'thr-"le-n-p-lr-e-ss---.=E-nt:-e-r---i
"Value" Disable
00
Features Features
F20.6 F20.6.1
0 Startup Interlock 00 Startup Interlock 00
"Value"
00
00
00
0
1 Visible only if both F20.7 & F20.8 are disabled

2 Visible only if F3.11 is enabled
Figure 22303
Crown 2008 PF17429-65 Rev. 3110 M4.3-1457-065

01 Rev. 3/10
253
ELECTRICAL
Features Menus

00
Features Features
(0 1-----=-i,...;:i~::.::~;.:.:::.;.~f;::,1::-----1(0 0 J----:s=-e-:-le-c....,.t..,.,t~.:....:~:..:.:~:.::~.::.~I~=..:~:....s-=E=-n...,...te-r~
''Value'' Never
00
Features
Timeout
O
'¥ I----'S'-le"""'e-c"""t""':th:"':':e~n=
Plre:..:s-s......E.-n..,...te-r~
5Min
Features
Timeout
(0 Select then press Enter
15Min
00
Features
Timeout
20 Min
00
Features
Timeout
30 Min
00
(0 nter
Visible only if F20.6 is enabled

(OI--.. . . . . . ---..,....,.,..:....:.:.:.:.::..::.=.:..-............,nt-er---l
Figure 22304
M4.3-1457-066 Crown 2008 PF174~ Rev. 3110
01 Rev. 3110
254
-----------------------------------------------------
ELECTRICAL
Features Menus
00
Features
F20.7
0 HeiQht Zone Switch 1 00 nter
"Value"
00 Features
Zone SWitch
Enable
Features Features
F20.8 Remote Raise/Lower
0 Remote Raise/Lower 2 00 Select then press Enter
''Value'' Disable
00
Features
Remote Raise/Lower
Enable
Features t-eatures
F20.9 Speed Zone Switch
0 Speed Zone Switch 3 00 Select then press Enter
"Value" Disable

3 Visible only if F20.4. F20.7 & F20.8 are all disabled
Figure 22305-01
Crown 2008 PF17429-67 Rev. 5110 M4.3-1457-067

02 Rev. 5/10
255
ELECTRICAL
Hour Meters Menus

00
Hour Meters Hour Meters
00 H1 Truck Runtime1
"Value" Hr
1
OJ OJ continued on page -070
1
00
00
Hour Meters
(0 H2 Truck Runtime2
"Value" Hr
2
00
Hour Meters
(0 H3 Odometer
#.# Mile/km
00
Hour Meters
(0 H4 Traction Motor
"Value" Hr
Menu Selections:
H1 Truck Runtime1
00
Hour Meters
H2 Truck Runtime2
H3 Odometer (0 H5 Lift Motor 1
''Value'' Hr
H4 Traction Motor
H5 Lift Motor 1
H6 Lift Motor 2
H7 Steer Motor
00
Hour Meters
H8 Access 1 see next page
(0 H6 Lift Motor 2
''Value'' Hr
3
H14 PM Timer see next page 00
Hour Meters
2 Visible only if F9 is set to H2
3 DC Hydraulic and 36 V trucks only (0 H7 Steer Motor 4
''Value'' Hr
00
Figure 22306
Crown 2008 PF1742~ Rev. 3110

M4.3-1457-068
01 Rev. 3/10
256
ELECTRICAL
mowr. Access 1 2 3® Menus
Hour Meters Menus
OJ 0 continued on page -071
OJ Ocontinued on page -071
ou r Meters
H14.1
Tag OJ o continued on page -071
Value"
o0
r - - - - : - :-
Hour Meters
OJ J------:-'I
H14.2
nterval
"Value"

2 Visible only if H14.1 (TAG) is set under Service Level 3
Figure 22307
Crown 2008 PF17429-69 Rev. 3110 M4.3-1457-069

01 Rev. 3/10
257
ELECTRICAL
Hour Meters Menus
Hour Meters
continued from page -068 0 0 L--S~el,:...ce~ct~t~he':"':n:::=Dlre~s'='s';:E'=n7:te:-:r--t
Truck Runtime1 1
"Value" Hr
Hour Meters
Hour Meters Truck Runtime21
continued from page -068 00 1---=T::-ru-c-;-k~~~~=:'~~~i=m:-:e"2"""
2---100 l-.....,S:-e...;le~c~t~th~e~n~p~lre:-:s~s::;;E=::n:-.:te::r:-i
"Value" Hr "Value" Hr
Hour Meters
o H2.2 2
~-----:T~im~e=o-=u7""t-----1
"Value" Min
Hour Meters
Odometer 1
continued from page -068 0 0 l-.....,S=-e...,.le-c-..;t~th~e~n~p::::lr~e-=-ss:r=E=ntr:e:::-r----i
"Value" Hr
Hour Meters
Traction Motor 1
continued from page -068 0 0 l--S:-e""'le~c~t::;;th~e'::::n:":"D":':lr':':e:":';ss::":"':E=ntr:e-::r---t
"Value" Hr
Hour Meters
Lift Motor 1 1
1 Visible only in Service Level 3 continued from page -068 0 0 I-.....,S;;-e..l-ec~t~th~e~n::::p~lr=e-:ss:r=E=nti:::e:::-r---1
2 Visible only if F9 is set to H2 "Value" Hr
3 DC Hydraulic and 36 V trucks only
4 Electronic Power steering trucks only Hour Meters
Lift Motor 21 3
continued from page -068 0 0 l-.....,S=-e...,.le~c~t~thPe~n~p=-:lr~e=:ss:r=E~nt<:::e:::-r---1
''Value'' Hr
Hour Meters
Steer Motor 1 4
continued from page -068 0 0 l--::S=-e....,.le....::c~t~th=-:e=-=n:.-=:p:::lr=e=ss:-EE~nt~e:;-r---1
''Value'' Hr
Figure 22308
M4.3-1457-070 Crown 2008 PF17429-70 Rev. 3110
01 Rev. 3/10
258
ELECTRICAL
Hour Meters Menus
Hour Meters
continued from page -069 00 Access l '
l--S=-e--:I-ec--:t!::;t~he~n~~pr:-:e~s=-sFE'=ni:te:":r---1
''Value'' Hr
Hour Meters
Access 2 1
continued from page -069 00 L-S~e""'le-c""!'t~th~e~n~D:::""lre~s--srE=:n:7te::r;----i
"Value" Hr
Hour Meters
Access 3 1
continued from page -069 00 L-S=-e....,l-ec....,t~th~e~n::.::D::::lr~e=:-ss:-;=E'=n.-:te::"r---1
"Value" Hr
Hour Meters
Access 41
continued from page -069 00 l-~S=-e....,.le-c....,.t~th~e~n::.::p~lr:-:e7ss:-;=E:::nt.-:e::-r---1
"Value" Hr
Hour Meters
Access 5 1 2
continued from page -069 00 L-S=-e....,l-ec..!,t~t~he~n~p:::....lr~e-=-s-=-sFE'=ni:te::"r--l
"Value" Hr
Hour Meters
Tao 13
continued from page -069 00 L -S
=-e--:l-ec""t""'th;-:e":::n:'2=-Plr=e-=-ss::-;::E'=ni:te:":r---1
"Value"
Hour Meters
Interval~
continued from page -069 00 L~S::-e"""le-c""'t':;;th~e~n~p~r:-:-e=-ss:r=E:::nt'-:e::-r---1
"Value"
1 Visible only in Service Level 3

3 Visible only if H14.1 (TAG) is set under Service Level 3
Figure 22309
Crown 2008 PF17429-71 Rev. 3110 M4.3-1457-071

01 Rev. 3/10
259
ELECTRICAL
Events Menus
00
f-----------1
Events I001 Events
. .--=:E: . .;.1.-: C. .:. ;,;hr;. =.on:. .:. .:o:. .:. .:lo.; L;.Qi .=. . cH:....:..:i=sto=..:..)rvL-l~ 0 (() t:~~~~~~=1
00
00
Menu Selections:
E1 Chronologic History
E2 Accumulated History see next page
E3 Clear History see next page
Figure 22290
M4.3-1457-072 Crown 2008 PF17429-72 Rev. 3110
01 Rev. 3/10
260
ELECTRICAL
Events Menus
Events
Accumulated History
0 00 Event ### = ### times
Scroll Event Code Cesc. 1
00 00
Events
E3.1
0 00 Clear Chronologie 00
00 . Events
E3.1
Clear Chronologie
Sure? Y
Events Events
o 1-----C~I;=;:..:.=~~7-,I;--1
---i 00 ~--C""'I='::;;:-:=/ATII;-I-----1
Sure? N
00
Events
~E::.::3:..::.27-rr-_ _--;
Use the up and down arrows to scroll O
~
I
r- Clear All
through other event codes
Sure?Y
Figure 22291
Crown 2008 PF174~73 Rev. 3110 M4.3-1457-073

01 Rev. 3/10
261
ELECTRICAL
Performance Menus
00
I
Performance Performance
- - - - - - 0 0 .----=-P1..:..-CS::....::e..::..::.tul:...,;pP~1_1 00
Performance
P1.1
_ __1 t-....-----.--.----:--o--:-;:"'-__1
Travel Acceleration 00
continued
"Value'
on page
00
00
00 -082
Performance
P1.2
Max Travel Soeeds 00
continued
00 on page
-082
Performance
P1.3
Load Weight 00
continued
''Value''
on page
Menu Selections: 00 -082
P1 Setup P1 Performance
P2 Setup P2 see next page P1.4
P3 Setup P3 see page -076
P4 BDI see page -077
Raise Speed 00
continued
''Value''
P5 Plug see page -077 on page
P6 Drive Brake see page -077
P7 Caster Brake see page -077
00 -082
Performance
P8 Coast see page -077 P1.5
P9 Accy Speed < FLS see page -077
P10 Accy Speed> FLS see page -077
Lower Speed 00
continued
P11 Accy Speed> 270 see page -077
"Value"
on page
P12 Travel Speed> FLS see page -078
-082
P13 Travel Speed> 270 see page -078
P14 Accy Ramp see page -078
P15 Hoist Ramp see page -078
P16 Speed Cutback see page -079
P99 Load Factory Defaults see page -081
Figure 22310
M4.3-1457-074 Crown 2008 PF17429-74 Rev. 3110
01 Rev. 3/10
262
ELECTRICAL
CJ\OWrl Access 12 3® Menus
Performa nce Menus
00
Performance e rformance
o I-------..:P-=2:....=S=et=uot::....:P-=2=___~ 00 t--"""'Tr-av---;e
P2.1
I Acceleration
'Value"
00
continued on next page r---~P~e
o0
rformance
P2.2
ravel Soeeds
o0
r---"'l":P:-"erformance
o P2.3
t-------.L-oa d Weight 00 continued on page -083
'Value"
r---.....- o0
Pe rformance
P2.4
ise Speed
'Value"
0
rtormance
P2.5
Ol---~L-OWer Speed 00 continued on page -083
'Value"
Figure 22311
Crown 2008 PF17429-75 Rev. 3110 M4.3-1457-075

01 Rev. 3/10
263
ELECTRICAL
Performance Menus
00 Performance
Performance
0 P3 Setuo P3
00
P3.1
Travel Acceleration
o Ocontinued on page -084
"Value"
00
00
Performance
0 P3.2
Max Travel Soeeds
o Ocontinued on page -084 .
00
Performance
0 P3.3
Load WeiQht
o Ocontinued on page -084
"Value"
00
Performance
0 P3.4
Raise Speed o Ocontinued on page -084
"Value"
00
Performance
0 P3.5
LowerSoeed o Ocontinued on page -084
"Value"
Figure 22312
M4.3-1457-076 Crown 2008 PF17429-78 Rev. 3110
01 Rev. 3110
264
ELECTRICAL
Cl\OWI' Access 1 2 3® Menus
Performance Menus
00
Performance
P4 BDI
0 ''Value" 00 nter
00
Performance
P5 PIUQ
0 "Value" 00 nter
00
P6 Drive Brake Drive Brake
0 ''Value'' 00 Select then press Enter
1-9 knob
00
P7 Caster Brake Caster Brake
0 ''Value" 00 Select then press Enter
1-9 knob
00
P8 Coast Coast
0 ''Value" 00 Select then press Enter
1-9 knob
00
Performance
P9 Accy Speed < FLS
0 ''Value'' 00
00
Performance
P10 Accy Speed> FLS
0 ''Value'' 00
00
Performance
P11 Accy Speed> 270
0 "Value" 00
00
Figure 22313
Crown 2008 PF17429-n Rev. 3110 M4.3-1457-077

01 Rev. 3/10
265
-- ----------
ELECTRICAL
Access 1 2 3® Menus CJ\OW~
Performance Menus
00
Performance
P12 Travel Speed> FLS
0 "Value 00
00
Performance
P13 Travel Speed> 270
0 "Value" 00
00
Performance Performance Performance
P14 Accy Ramp P14.1 Accel
0 00 Accel 00 Select then press Enter
"Value" 1-9 knob
00 00
P14.2 Decel
0 Decel 00 Select then press Enter
"Value" 1-9 knob
Performance Performance Performance

P15 Hoist Ramp P15.1 Raise Accel
0 00 Raise Accel 00 Select then press Enter
"Value" 1-9 knob
00
00
Performance
P15.2
0 Raise Decel 00
"Value"
00
Performance
P15.3
0 Lower Accel 00 nter
"Value"
00
Performance
P15.4
0 Lower Decel 00
"Value"
Figure 22314
M4.3-1457-078 Crown 2008 PF17429-78 Rev. 3110
01 Rev. 3/10
266
ELECTRICAL
mow" Access 1 2 3® Menus
Performance Menus
00
Pertormance Pertormance
O
W
J--,-P1.;...:6.-:S='P...::...lee:;..:;d.-:C:;..:;u;..:.:.:tb....:.;.ac.::..:..k'---f 00
W W
J--_..,.....--,,..-,P;-;-1......6..,....1__- - - - i 0 0
Height Triggers W W

00 00
Performance
o
~ P16.2
I - - - - -,.-or....-k..,.-,H-om-e---.T--ri.-·gg
F 0 0
-le-r- - - - I
~~
...--....--T-~,..:...::..:.:.:..::.....:..~::..:,-~
"Value"
00
Figure 22315
Crown 2008 PF1742S-79 Rev. 3110 M4.3-1457-079

01 Rev. 3/10
267
ELECTRICAL
Performance Menus

00
Performance
o I---""""W"""'e""':"iig~, . .;-i 6-=-T~=:-ig-gle-r----i 00 1--..,............--'-i--7~....;,.,;",;,,~,.-,----i
"Value"
00
Performance
~ Weight Trigger
G th"'-e-n-p-Ire~s"'-s-;:E=-n·te-r---i
t--'S....e·le-c·t....
> 454 Kg (1000 Ibs)
00
Figure 22316
M4.3-1457-080 Crown 2008 PF17429-80 Rev. 3110
01 Rev. 3/10
268
ELECTRICAL
CAOWI' Access 1 2 3® Menus
Performance Menus
00
0
00
Performance
P16.4
0 Cutback Speed 00
continued from page -079 "Value"
00
P99 Load Factory Defaults
0 Load Facto Defaults 00 Sure?Y
00
Performance
Load Factory Defaults
0 Sure? N
Figure 22317
Crown 2008 PF17429-81 Rev. 3110 M4.3-1457-081

01 Rev. 3/10
269
ELECTRICAL
Performance Menus
Performance
~~ Travel Acceleration
continued from page -074 0 0 J--"""'S"""e....;,l..:....:ec::..;t-7th;-:.e~n..:....:p:....:r..:....:e:..:..ss.::.:..:;;,;E:..:..nt;....e-r~
1-9 knob
Performance
continued from page -074 (00 hF--lo-rw-a-rd-'-'T-r:-v·~-.·t..."'~=-m-1P-'-ty'FFo-r"k~s-l( 0 0 ~~:r-=-,...:.,.r.::....:....::..:~..:..:..c.,;~=..:..:.::....t
"Value"
00
Pertormance
(0 . . R"'"""e-v-er-se-----Tr-:-:e....,.·~--;·~=-m-p....,.)ty--=Fo-r
. ks--f (0 0 t--..,..-:"T":"'"":";....-r:-:-'--:-:-::-'o=~-'---'-'-I
..
"Value"
00
Performance
O P1.2.3
~ Forward Travel Loaded Forks ~ W J--....,.,...~:771c::-:-':-__-.=--..,---I
00
"Value" t-------,TITJ1,....:.---r----__f
00
Performance e ormance
O P1.2.4 Reverse Travel, Loaded Forks 00
~ Reverse Travel, Loaded Forks ~ W Select then ress Enter
"Value" m
continued from page -074 (00 t---=--:--....,..,.,.--"'><--=-..,....---1
Performance
continued from page -074 (0 0 t----::S:-e-:"le-c-:"~-:-::h-i:-~_~....L)I~-:4s-es-dE=-'"'"'nt""e-r---I
1-9 knob
Performance
Lower Speed
O0
continued from page -074 ~ W J--.S"e--.le-c--.t-7.thc-e:-n-p-=-"r":"e-ss:-i="E-:nt;-:"e"":'"r---t
1-9 knob
Figure 22318
M4.3-1457-082 Crown 2008 PF17429-82 Rev. 3110
01 Rev. 3/10
270
ELECTRICAL
CAOWI) Access 1 2 3® Menus
Performance Menus
Performance
continued from page -075 00 Travel Acceleration
1-9 knob
continued from page -075 00 P2.2.1
Forward Travel, Empty Forks 00
Forward Travel, Empty Forks
select then press Enter
"Value" ### mph
Performance
00
P2.2.2
0 Reverse Travel, Empty Forks 00
"Value"
00
Performance
P2.2.3
0 Forward Travel Loaded Forks
"Value"
00 Performance
Performance
P2.2.4 Reverse Travel, Loaded Forks
0 Reverse Travel, Loaded Forks 00 Select then press Enter
"Value" '### mph
Performance
Load Weight
continued from page -075 ¥ ret 0
W t--'S"e:Ole-:-c:Ot""';';thLe--n-p-lr-e"'-ss-'=E"-nt:-e-r---i
#### Lbs
Performance
Raise Speed
continued from page -075 ¥ ret 0
W t-'S"e.....le-c.....t7.th.. . :e. . :.n-p:. .£'r:. . : e. . .:ss.. . :.;. E"""'nrt'e----i
1-9 knob
Performance
Lower Speed
continued from page -075 ¥ ret 0W J-....,S;::-e....,.le-c..:::;t~th;..:..e-=.n:.-p=-lrl:..e::...:ss==E,....n.,....te-r~
1-9 knob
Figure 22319
Crown 2008 PF17429-83 Rev. 3/10 M4.3-1457-083

01 Rev. 3/10
271
ELECTRICAL
Performance Menus
Performance
A ~ Travel Acceleration
continued from page -076 0 0 ....e....:,l..:...:ec::..;:t..;thc-:e....:n.:...:p=-=lr~e:..:..ss=.:;;.:E:..:..nt;-e-r---l
..-""""S
1-9 knob
continued from page -076 (00 I-.z------,...,=----,-.........-----,--=o-r.,....ks-l (0 0 t-:--=~:=..,.;~~=~,..=:..~
Performance
A 1-=--_..,........:...P3:..:..;:.2~.2--:---=---r---l A
~ Reverse Travel, Empty Forks ~W
~~~~~..;....::.:.:.~ 0
''Value"
Performance
A P3.2.3 A
~ Forward Travel. Loaded Forks ~ W
~~~-rr:-:-~~~~:...:..:=.J 0
"Value"
Performance
A P3.2.4
~ Reverse Travel, Loaded Forks
"Value"
Performance
A ~ Load WeiQht
continued from page -076 0 0 "-""""S"""e-:"le-c"':;:t:';th=-e=-n"':"p":"':lr::';"es;z,;s":":=E""""nt:-e-r---I
#### Lbs
Performance
A ~ Raise Soeed
continued from page -076 0 0 I-""'S"""e-:"le-c"':"t:;;th::':e:"::n:"':p::..llr:':e:"::ss~E-nt:-e-r---l
1-9 knob
Performance
A ~ Lower Soeed
continued from page -076 0 0 I-""'S=-e--=l-ec"::;t::;th;':"e=n:""p=.Jrl:.:e:":ss=-=-=E-nt"-e-r---l
1-9 knob
Figure 22320
M4.3-1457-084 Crown 2008 PF17429-M Rev. 3110
01 Rev. 3/10
272
ELECTRICAL
Performance Menus
Performance
continued from page -079 0 <0 1------:;:T,....,;ri~_g1;...:.1:-'-:~~:;:-r~--Ple ---i 0 0) 1--......-~~~~~n::7te:-::r---f
''Value''
Performance
Trigger Type
O
¥ "'-""'S"'"""e-:-Ie-c';";tt:-:>hl.>Oent...:.'-Plr":""eU:ss-'o=E""""nt"'-e-r--i
HGTS1
Performance
Trigger Type
O
¥ .-'S..--e.....le:-:cTttithz.>ie:=n~
pire~s::::sr=E~nt.-::-e-=-r - i
HGTS2
Performance
o I----..:..,..~.;-:=.,~,..:...;g.~I~·t~-----t 0 0) 1--7'i"":T::-=TLr=~==:r="="ntr=:er:---i
"Value"
Figure 22321
Crown 2008 PF17429-85 Rev. 3110

M4.3-1457-085
01 Rev. 3/10
273
ELECTRICAL
Access 1 2 3® Menus CRown
Utilities Menus
00
00 00
00
continued on page -011 Utilities
o t-------:"A.....:::C~:....:.:~~""'-~-,....1----100
t---..:....:..=.='-=-'-----tcontinued
on page
O 0
r--_ _~~~W....;;;;..._ _-,-088
Utilities
o t-------:A--=C~::....:..~S::.=..·~-=2-----t 0 0
J----~==.=::'------t continued
on page
O 0
......_ _~~~~W~_ _.....,-088
Utilities
o t-------:"A.....:::C~:....:.:~~'-=-~-::-3----10 0
t---"-==:=-='------t continued
on page
00
-088
Menu Selections:
U1 Part Numbers
U2 Tow Mode see next page
U3 Truck Lockout see next page
Figure 22322
M4.3-1457-086 Crown 2008 PF17429-86 Rev. 3110
01 Rev. 3110
274
ELECTRICAL
Utilities Menus
Utilities Utilities
o 1----A-:-C..:~-'-'~~=~--,.4----tO 0 I-------.M...-:~-:r~~--.·~-:-·~ ....N :-;------i
Utilities
U1.5.2
O s,o.....)ftw;:-:...:-:,ar=e=..Pcn-
~ 1----...... N ----f
Utilities utilities
o 1-----,A:-C-=~:....:..~=·;-=-5....,....1---100 I-------.-M.-~:..,d~....,:·~---;·~=N...--------t
00
Utilities Utilities
O
~
de:::"""------I
.----=U=2....:,..To::...:.;w,-,-M:.:..:0c.::.. 0~ ,--,:,"""""",:,,:,--=U:=2-;To:: . :.w.:. . .;M:=-;.:o: . =;d-=-;e~-----I
~W Activate Tow Mode? No
Utilities
U2 Tow Mode
O
~ t-A-;:-c-:-ti;-va....:::t=e':::T:-=ow-=+M~o~d=-=:e?=-'. y=-=-e-s---i
Utilities Utilities Utilities

U3 Truck Lockout
~ I-----=":::""':":''=:''''='='='::'':'----f 0 0
O ~~ U3 Truck Lockout
t---..=..;;;......:..::'
..
0 ~ Truck Lockout
V=::'a"""lu-=e""..= .=..:.....--t ~ W I--...,.S,...-er-le-,ct,...,.tr-he-n-p-lre-s-s......Eo-n-:-te- r ---i
Disable
Electronic Power Steering Trucks only utilities

o~ Truck Lockout
t--"'S;-:"eT":"le-::;ct"thL'""e=-=n-=p:-::"lre':"":s:-::"s""E"=nLte-=-r---i
Enable
Figure 22323
Crown 2008 PF17429-87 Rev. 3/10 M4.3-1457-087

01 Rev. 3/10
275
· ELECTRICAL
Utilities Menus
Utilities
continued from page -086 00 t----.M..~:-~;-·1~.-:~•~
. '"N~---i
00
Utilities
U1.2.2
G
~ 1-------.,.S:-oftwr.-:-:.(a=re=P=N...---~
Utilities
continued from page -086 00 t----""TMi"T'"~-)dr-~Ir-I~I.....
· ~=)N"""----f
00
Utilities
U1.3.2
G
~ 1----;:;S,-oftw~a..:...;re..:::;P=N,......-----I
JJ/llIlSiP;;-###-##
utilities
continued from page -086 00 t----Tr-MI~......~I......~~_·~.......-rN-----i
Figure 22324
M4.3-1457-088 Crown 2008 PF17429-88 Rev. 3110
01 Rev. 3/10
276
ELECTRICAL
Analyzer Access Disabled indicates the raise function is not allowed.

This could be due to a system issue. Press the left ar-
Key the truck ON. Navigate to the Service Menu by row to return to A1. Press the down arrow to continue.
pressing the down arrow. At the Service Menu, press
A1.7 Full Traction - The display will show Enabled or
the right arrow to enter Level 2. Press the right arrow
Disabled. Enabled indicates full traction is allowed.
again to enter the user code. Press the up and down
Disabled indicates full traction is not allowed. This
arrows to scroll to the first digit. Press the right arrow to
could be due to a system issue. Press the left arrow to
advance to the next digit. Continue these steps until the
return to A1. Press the down arrow to continue.
last digit has been entered. Press enter to accept the
user code. Press the down arrow to navigate to the An- A 1.8 Limp Traction - The display will show Enabled or
alyzer Menu, then press the right arrow. The message Disabled. Enabled indicates limp traction is allowed.
displayed will be A1 Status. Disabled indicates limp traction is not allowed. This
could be due to a system issue. Press the left arrow to
Analyzer Menu Descriptions return to A1. Press the down arrow to continue.
A1 Status - View the status of the monitored truck sys- A1.9 Steering - The display will show Enabled or Dis-
tems. This information can be used to troubleshoot ser- abled. Enabled indicates steering functions are al-
vice conditions by identifying common circuits for en- lowed. Disabled indicates steering functions are not al-
abled or disabled functions. The Status Menu includes lowed. This could be due to a system issue. Press the
multiple submenus as explained below. Press the right left arrow to return to A1. Press the down arrow to con-
arrow to enter the submenus. Press the up and down tinue.
arrows to navigate to the desired submenu. A1.10 ED - The display will show Enabled or Disabled.
A1.1 Full Speed Hydraulics - The display will show Enabled indicates the ED contactor is enabled. Dis-
Enabled or Disabled. Enabled indicates full speed hy- abled indicates the ED contactor is not enabled. Press
draulic functions are allowed. Disabled indicates full the left arrow to return to A1. Press the down arrow to
speed hydraulics are not allowed. Press the left arrow continue.
to return to A1. Press the down arrow to continue. A1.11 Module - The display will show Enabled or Dis-
A1.2 Extend/Retract - The display will show Enabled abled, reflecting the system status of all modules on
or Disabled. Enabled indicates extend and retract func- the CAN. Press the left arrow to return to A1. Press the
tions are allowed. Disabled indicates extend and re- down arrow to continue.
tract functions are not allowed. This could be due to a A2 Inputs - View the inputs of ACCESS 123 monitored
system issue. Press the left arrow to return to A1. components. This information can be used to trouble-
Press the down arrow to continue. shoot service conditions. If necessary, refer to the
A 1.3 Sideshift - The display will show Enabled or Dis- Componentry section to identify the component desig-
abled. Enabled indicates sideshift functions are al- nators displayed.
lowed. Disabled indicates sideshift functions are not al- From the A1 menu, press the down arrow to scroll to
lowed. This could be due to a system issue. Press the A2. Press the right arrow to view input submenus.
left arrow to return to A1. Press the down arrow to con- Press the up and down arrows to navigate through the
tinue. multiple submenus as explained below.
A1.4 Tilt - The display will show Enabled or Disabled. A2.1 ACCESS 1 OM - View the inputs monitored by the
Enabled indicates tilt functions are allowed. Disabled ACCESS 1 display module. Press the right arrow to
indicates tilt functions are not allowed. This could be view the inputs. Press the up and down arrows to scroll
due to a system issue. Press the left arrow to return to through the submenus.
A1. Press the down arrow to continue.
A2.1.1 CA405-o1 Digital Input - Switch open (switch
A 1.5 Lower - The display will show Enabled or Dis- not activated); switch closed (SWitch activated). Moni-
abled. Enabled indicates the lower function is allowed. tors the digital input to CA40S-Q1. Input is designated
Disabled indicates the lower function is not allowed. as Trigger Type HGTS1 for feature F20.4 Speed Cut-
This could be due to a system issue. Press the left ar- back and Calibration C3.1 Lift/Lower Cutout, as Zss A
row to return to A1. Press the down arrow to continue. Zone 1 select feature F20.7, and used for Remote
A1.6 Raise - The display will show Enabled or Dis- Raise when feature F20.8 = Enabled.
abled. Enabled indicates the raise function is allowed.
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Access 1 2 3® Menus CAOW"
A2.1.2 CA405·13 Digital Input· Switch open (switch greater than 85°C (185°F). Press the right arrow to dis-
not activated); switch closed (switch activated). Moni- play the value. Press the up and down arrows to scroll
tors the digital input to CA405-13. Input is designated through the submenus.
as Trigger Type HGTS2 for feature F20.4 Speed Cut-
A2.2.3.1 Temp 1 = _ °C/F • View the ACCESS 2
back, and Calibration C3.1 Lift/Lower Cutout, as Zss B
module temperature 1 in degrees Celsius if F2 = En-
Zone 2 select feature F20.7, and used for Remote
abled or in degrees Fahrenheit if F2 = Disabled. Press
Lower when feature F20.8 = Enabled.
the down arrow to continue or press the left arrow to
A2.1.3 CA405·14 Digital Input • Switch open (switch return to the A2.2.3 menu.
not activated); switch closed (switch activated). Moni-
A2.2.3.2 Temp 2 = _ °C/F • View the ACCESS 2
tors the digital input to CA405-14. Input is designated
module temperature 2 in degrees Celsius if F2 = En-
as Fork Home switch for feature F20.4 Speed Cutback
abled or in degrees Fahrenheit if F2 = Disabled. Press
and as Zss C Zone 3 select feature F20.7.
the left arrow to return to the A2.2.3 menu.
AC Hydraulic Lift Trucks· Available only when an AC
A2.2.4 M2 Temp =_ °C/F • View the hydraulic pump
truck model is configured.
motor (M2) temperature in degrees Celsius if F2 = En-
A2.2 ACCESS 2 HCM • View the inputs monitored by abled or in degrees Fahrenheit if F2 = Disabled. Event
ACCESS 2 hydraulic control module. Press the right code 228 will log if M2 temperature exceeds 165°C
arrow to view the inputs. Press the up and down arrows (329°F). Press the right arrow to display the value or
to scroll through the submenus. ACCESS 2 is different press the down arrow to continue.
in AC Hydraulic Lift Trucks and DC Hydraulic Lift
Trucks. Be sure to view the correct description.
A2.2.5 Module Voltage =_ Volts· View the current
ACCESS 2 module voltage. Event code 234 or 236 will
A2.2.1 ECR6 M2 Speed· View the hydraulic pump mo- log if the ACCESS 2 module voltage is not within the
tor (M2) speed inputs. Press the right arrow to view the correct operating range, which is 10.0 to 63.0 Vdc at
inputs. Press the up and down arrows to scroll through ACCESS 2 B+ and BNEG Press the right arrow to dis-
the submenus. Press the down arrow to continue. play the value or press the down arrow to continue.
A2.2.1.1 Tach = _ RPM· View the hydraulic pump A2.2.6 Key Voltage = _Volts· View the current key
motor (M2) speed in revolutions per minute. Event voltage which should be the same as the battery volt-
code 232 will log if the speed exceeds 4000 RPM, or age. Event code 238 or 239 will log if the ACCESS 2
event code 231 will log if stalled or there is no motor module voltage is not within the correct operating
speed feedback. To view the target speed, see A2.2.2. range which is 7.0 to 100.00 Vdc at CA402-01. Press
Press the right arrow to display the value. Press the left the right arrow to display the value or press the down
arrow to return to A2.2.1. Then, press the down arrow arrow to continue.
to continue or press the left arrow again to return to
DC Hydraulic Lift Trucks - Available only when a DC
A2.2.
truck model is configured.
A2.2.1.2 Counts =_ Cnt • View the hydraulic pump
A2.2 ACCESS 2 HDM • View the inputs monitored by
motor (M2) speed counts. Press the right arrow to dis-
the ACCESS 2 hydraulic control module. Press the
play the value. Press the left arrow to return to A2.2.1.
right arrow to view the inputs. Press the up and down
Then, press the down arrow to continue or press the
arrows to scroll through the submenus. ACCESS 2 is
left arrow to return to A2.2.1. Press the left arrow again
different in AC Hydraulic Lift Trucks and DC HydraUlic
to return to A2.2.
Lift Trucks. Be sure to view the correct description.
A2.2.2 Target Speed = _ RPM· View the lift pump
motor (M2) target speed in rotations per minute based
A2.2.1 ECR3 M2 Speed =_ RPM· View the hydrau-
lic pump motor (M2) speed in revolutions per minute.
on the position of the multi-task control handle position.
Event code 609 will log if the M2 motor is stalled or
Press the right arrow to display the value or press the
there is no motor speed feedback. To view the target
down arrow to continue.
speed, see A2.2.2. Press the right arrow to display the
A2.2.3 Module Temp = _ °C/F • View the value or press the down arrow to continue.
ACCESS 2 module temperature in degrees Celsius if
A2.2.2 Target Speed = _ RPM • View the hydraulic
F2 = Enabled or in degrees Fahrenheit if F2 =
Dis-
pump motor (M2) target speed in revolutions per min-
abled. Event code 226 or 224 will log if the ACCESS 2
ute. Press the right arrow to display the value or press
module temperature is not within the correct operating
the down arrow to continue.
temperatures which are less than -25°C (-13°F) or
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A2.2.3 Module Temp =°C/F - View the A2.3.3 M1 Traction Motor Temp =_ °C/F - View the
ACCESS 2 module temperature in degrees Celsius if traction motor (M1) temperature in degrees Celsius if
F2 = Enabled or in degrees Fahrenheit if F2 = Dis- F2 = Enabled or in degrees Fahrenheit if F2 = Dis-
abled. Lift performance is reduced proportionally be- abled. Event code 328 will log if the M1 temperature
tween 75°C (167°F) and 105°C (221°F). Press the right exceeds 165°C (329°F). Press the right arrow to dis-
arrow to display the value or press the down arrow to play the value or press the down arrow to continue.
continue.
A2.3.4 Module Voltage =_ Volts - View the current
A2.2.4 M2 Voltage = _ Volts - View the hydraulic ACCESS 3 module voltage. Press the right arrow to
pump motor (M2) voltage. Press the right arrow to dis- display the value or press the down arrow to continue.
play the value or press the down arrow to continue. Event code 334 or 336 will log if the ACCESS 3 module
Event code 604 will log when the current =
0 when voltage is not within the correct operating range which
speed is commanded and event code 615 will log when is 10.0 to 63.0 Vdc at ACCESS 3 B+ and BNEG Press
the current is out of range. the right arrow to display the value or press the down
arrow to continue.
A2.2.5 Module Voltage =_ Volts - View the hydrau-
lic pump motor (M2) voltage. Press the right arrow to A2.3.5 Key Voltage = _ Volts - View current key
display the value or press the down arrow to continue. voltage which should be the same as the battery volt-
Event code 602 will log when M2 voltage is too low for age. Event code 338 or 339 will log if the ACCESS 3
command requested and event code 603 will log when module voltage is not within the correct operating
it is too high. range which is 7.0 to 100.00 Vdc at CA401-01. Press
the right arrow to display the value or press the down
A2.3 ACCESS 3 TCM - View the inputs monitored by
arrow to continue.
the ACCESS 3 traction control module. Press the right
arrow to view the inputs. Press the up and down arrows A2.3.6 POT4 Tilt Position Sensor - Press the right ar-
to scroll through the submenus. row to view the tilt position sensor inputs. Press the up
and down arrows to scroll through the submenus.
A2.3.1 ECR1 M1 Traction Speed - View the traction
motor (M1) speed inputs. Press the right arrow to view A2.3.6.1 Signal =_ Volts - View the tilt position sig-
the inputs. Press the up and down arrows to scroll nal in volts. Tilt position assist must be active to view.
through the submenus. Press the down arrow to con- Press the down arrow to continue. Press the left arrow
tinue. to return to A2.3.6.
A2.3.1.1 Tach = RPM - View the traction motor A2.3.6.2 Supply = _ Volts - View the tilt position
(M1) speed in revolutions per minute. Event code 332 supply in volts. Tilt position assist must be active to
will log if the speed exceeds 4000 RPM. Press the right view. Press the left arrow to return to A2.3.6.
arrow to display the value or press the down arrow to
A2.4 ACCESS 4 VCM - View the inputs monitored by
continue.
the ACCESS 4 vehicle control module. Press the right
A2.3.1.2 Count = Cnt - View the traction motor arrow to view the inputs. Press the up and down arrows
(M 1) speed counts. Press the right arrow to display the to scroll through the submenus.
value or press the down arrow to continue.
A2.4.1 LMS Aux Limit Switch = _ - Switch open
A2.3.1.3 Speed =_kmh/mph - View the traction (switch is not activated); switch closed (switch is acti-
motor (M1) speed in kilometers per hour if F2 = En- vated). Used as an optional digital input for Features
abled or in miles per hour if F2 = Disabled. Press the F20.4 Speed Cutback and Calibration C3.1 Lift/Lower
right arrow to display the value or press the down arrow Cutout. Press the down arrow to continue.
to continue.
A2.4.2 HGTRS2 Height Reset Switch = _ - Switch
A2.3.2 Module Temp = _ °C/F - View the open (switch is not activated); switch closed (switch is
ACCESS 3 module temperature in degrees Celsius if activated, forks are in the lowered position). Used as
F2 = Enabled or in degrees Fahrenheit if F2 = Dis- an optional digital input for Features F20.4 Speed Cut-
abled. Event code 324 or 326 will log if the ACCESS 3 back and Calibration C3.1 Lift/Lower Cutout. Press the
module temperature is not within the correct operating down arrow to continue.
temperatures which are less than -25°C (-13°F) or
A2.4.3 HNS Horn Switch = _ - Switch open (hom
greater than 85°C (185°F). Press the right arrow to dis-
button is not depressed); switch closed (hom button is
play the value or press the down arrow to continue.
depressed). Press the down arrow to continue.
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A2.4.4 BRES1, 2 Batt Restraint =_ - Switch open function is not selected, switch is held in the closed po-
(battery retainer is not installed); switch closed (battery sition). Press the down arrow to continue.
retainer is in place). Press the down arrow to continue.
A2.4.16 RS Reverse Switch =_ - Optic switch open
A2.4.5 BRS1 Left Brake Pedal = _ - Switch open (reverse travel direction is selected, 0 V output to
(pedal is not depressed); switch closed (pedal is de- ACCESS 4); optic switch closed (reverse travel direc-
pressed). Press the down arrow to continue. tion is not selected, 5 V output to ACCESS 4). Press
A2.4.6 TDS Tilt Down Switch = _ - Switch open (tilt
down is selected); switch closed (tilt down is not se- A2.4.17 FS Forward Switch = _ - Optic switch open
lected, switch is held in the closed position). Press the (forward travel direction is selected, 0 V output to
down arrow to continue. ACCESS 4); optic switch closed (forward travel direc-
tion is not selected, 5 V output to ACCESS 4). Press
A2.4.7 TBS Tilt Back Switch = _ - Switch open (tilt
back is selected); switch closed (tilt back is not se-
lected, switch is held in the closed position). Press the A2.4.18 POT1 Traction Accelerator - Press the right
down arrow to continue. arrow to view the traction accelerator potentiometer in-
puts. Use the up and down arrows to scroll through the
A2.4.8 BRS2 Upper Left Pedal = _ - (Upper Left
submenus.
Pedal Switch available on RR5795 models only)
Switch open (pedal is not depressed); switch closed A2.4.18.1 POT1 Signal = _ Volts - View the signal
(pedal is depressed). Press the down arrow to con- voltage from the traction accelerator potentiometer.
tinue. Range: 1.0 V (Full Forward), 2.5 V (Neutral), and 4.3 V
(Full Reverse). Press the down arrow to continue.
A2.4.9 BRS3 Upper Center Pedal = _ - (Upper
Press the left arrow to return to A2.4.18.
Center Pedal Switch available on RR5795 models
only) Switch open (pedal is not depressed); switch A2.4.18.2 POT1 Supply =_ Volts - View the supply
closed (pedal is depressed). Press the down arrow to voltage from the traction accelerator potentiometer.
continue. Nominal value: 5.3 V. Press the left arrow to return to
A2.4.18.
A2.4.10 DMS1 & DMS2, Right Deadman Pedal=_
- (Right Foot Presence Switch; DMS2 available on A2.4.19 POT2 Raise/Lower Accelerator - Press the
RR5795 models only) Switch open (operator is not right arrow to view the raise/lower accelerator potenti-
present); switch closed (operator is present, foot is on ometer inputs. Press the up and down arrows to scroll
the pedal). Press down arrow to continue. through the submenus.
A2.4.11 ENS Entry Bar = _ - Switch open (switch is A2.4.19.1 POT2 Signal = _Volts - View the signal
not activated); switch closed (operator's foot is resting voltage from the raise lower accelerator potentiometer.
on the power unit skirt area along the operator com- Range: 1.0 V (Full Raise), 2.5 V (Neutral), and 4.0 V
partment). Press the down arrow to continue. (Full Lower). Press the down arrow to continue. Press
the left arrow to return to A2.4.19.
A2.4.12 FLS Free Lift Switch = _ - Switch open
(mast is not in the free lift range); switch closed (mast A2.4.19.2 POT2 Supply =_ Volts - View the supply
is within the free lift range). Press the down arrow to voltage from the raise/lower accelerator potentiometer.
continue. Nominal value: 5.3 V. Press the left arrow to return to
A2.4.19.
A2.4.13 ORS Lift Cutout Override = - Switch
open (switch is not activated); switch closed (switch is A2.4.20 POT3 Accessory Pot - Press the right arrow
activated when the operator initiates momentary con- to view the accessory potentiometer inputs. Press the
tact toggle to override a lift cutout). Press the down ar- up and down arrows to scroll through the submenus.
row to continue.
A2.4.20.1 POT3 Signal = _ Volts - View the signal
A2.4.14 CHS Chain Slack Switch =_ - Switch open voltage from the accessory potentiometer. Range:
(switch is not activated); switch closed (switch is acti- 1.0 V (Full Reach), 2.7 V (Neutral), and 4.6 V (Full Re-
vated). The input is used when feature F20.1 Chain tract). Press the down arrow to continue. Press the left
Slack is enabled. Press the down arrow to continue. arrow to return to A2.4.20.
A2.4.15 SSS Sideshift Switch = _ - Switch open
(sideshift function is selected); switch closed (sideshift
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A2.4.20.2 POT3 Supply =_

Volts - View the supply A2.4.24 BDI Current =_ Amps - View the approxi-
voltage from the accessory potentiometer. Nominal mate battery current. Press the down arrow to con-
value: 5.3 V. Press the left arrow to return to A2.4.20. tinue.
A2.4.21 RPS1 Steer Feedback Sensor - This menu is A2.4.25 LS Fork Load Sensor = mA - View the
active only when truck is configured for hydraulic steer- fork load sensor current in milliamps. Nominal value: 4
ing. Range: 0.5 V (Full Clockwise) and 4.2 V (Full rnA while empty. Press the down arrow to continue.
Counter-Clockwise). Press the right arrow to view the
RPS1 inputs. Press the up and down arrows to scroll
A2.4.26 BDI Voltage =_ Volts - View the current
battery voltage. Press the down arrow to continue.
through the submenus.
A2.4.21.1 RPS1 Signal =_
Volts - View the signal
A2.4.27 Traction Speed Setpolnt =_ kmh/mph -
View the traction speed set point in kilometers per hour
voltage from the steer feedback sensor. Range: 0.5 V
if F2 = Enabled or in miles per hour if F2 = Disabled in
(Full Clockwise) and 4.2 V (Full Counter Clockwise).
relation to the position of the multi-task control handle.
Press the down arrow to continue. Press the left arrow
Press the down arrow to continue.
to return to A2.4.21.
A2.4.29 Accelerometer - Press the right arrow to view
A2.4.21.2 RPS1 Supply Voltage =_ Volts - View
the desired grades of the accelerometer. Press the up
the supply voltage from the steer feedback sensor.
and down arrows to scroll through the submenus.
Nominal value: 5.3 V. Press the down arrow to con-
tinue. Press the left arrow to return to A2.4.21. A2.4.29.1 Accelerometer X Grade = % - View the
X grade percentage for the accelerometer. Press the
A2.4.21.3 RPS1 Angle =_
Deg - View the angle of
0 down arrow to continue. Press the left arrow to return
the RPS1 sensor in degrees. Range: 105 (Full Clock-
to A2.4.29.
wise) and 80 0 (Full Counter-Clockwise). Press the left
arrow to return to A2.4.21. A2.4.29.2 Accelerometer Y Grade = % - View the
Y grade percentage for the accelerometer. Press the
A2.4.22 ECR7 Tiller Command Sensor - Press the
left arrow to return to A2.4.29. Press the down arrow to
right arrow to view the tiller command sensor inputs.
continue at A2.4.1 or press the left arrow to return to
Active only when the hydraulic steer truck model is
A2.4.
configured.
A2.5 ACCESS 5 SCM - View the inputs monitored by
A2.4.22.1 ECR7 Counts =
Cnt - View the counts
the ACCESS 5 steer control module. Press the right ar-
for the tiller command sensor. Value Range: 0 to 4096.
row to view the inputs. Press the up and down arrows
to scroll through the submenus. All A2.5 menus are ac-
tive only when the truck is configured with Electronic
A2.4.22.2 ECR7 Supply = _ Volts - View the voltage Power Steering.
of the tiller command sensor. Nominal value: 5.3 V.
A2.5.1 ECR4 M4 Speed - View the steer motor (M4)
speed inputs. Press the right arrow to view the inputs.
A2.4.23 ECR2 Height Sensor - Press the right arrow Press the up and down arrows to scroll through the
to view the height sensor inputs. Press the up and submenus. Press the down arrow to continue.
down arrows to scroll through submenus.
A2.5.1.1 Tach =_ RPM - View the steer motor (M4)
A2.4.23.1 ECR2 Counts =
Cnt - View the counts speed in revolutions per minute. Range: 0 to 3500
for the height sensor to measure the height of the forks RPM. Press the down arrow to continue. Press the left
beyond free lift. Press the down arrow to continue. arrow to return to A2.5.1.
A2.5.1.2 CHA Counts = Cnt - View the steer mo-
A2.4.23.2 ECR2 Supply =_
Volts - View the input tor (M4) channel A counts. Press the down arrow to
voltage of the height sensor. Nominal value: 5.3 V. continue. Press the left arrow to return to A2.5.1.
A2.5.1.3 CHB Counts = Cnt - View the steer mo-
tor (M4) channel B counts. Press the left arrow to return
A2.4.23.3 ECR2 Height =_
mmlln - View the fork to A2.5.1.
height in millimeters if F2 = Enabled or in inches if F2 =
A2.5.2 M4 rms Current = _ Amps - View the steer
Disabled. Press the left arrow to return to A2.4.23.
motor (M4) current in amps. Press the down arrow to
continue.
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A2.5.3 Steer Temps - Press the right arrow to view the A3 Outputs - A3 is not available in the Level 3 Service
temperature inputs monitored by ACCESS 5. Press Menu. Press the right arrow to view the outputs moni-
the up and down arrows to scroll through the sub- tored by the ACCESS 123 modules. Press the up and
menus. down arrows to scroll through the submenus.
A2.5.3.1 M4 Temp =_ °C - View the steer motor A3.1 ACCESS 1 OM - Press the right arrow to view the
(M4) temperature in degrees Celsius (regardless of F2 outputs monitored by ACCESS 1.
setting). Range: ambient temperature to 150°C. Exces-
sive temperature will log event code 506 and disables
A3.1.1 ALM1 =_ - (Status Alarm) 0% = Off (status
alarm is off); 100% = On (status alarm is sounding).
traction and steering. Press the down arrow to con-
Press the left arrow to return to A3.1.
tinue. Press the left arrow to return to A2.5.3.
A2.5.3.2 Module Temp =_ °C - View the ACCESS 5
A3.2 ACCESS 2 HCM (AC), HOM (DC) - Press the
right arrow to view the outputs monitored by the
module temperature in degrees Celsius (regardless of
ACCESS 2 hydraulic control module. The ACCESS 2
F2 setting). Range: ambient temperature to >125°C.
module is different on AC hydraulic lift and DC hydrau-
Current is limited to 60% maximum for temperature < -
lic lift trucks. Be sure to view the correct menu descrip-
20°C. Output has a linear rollback starting at 85°C to 0
tion below.
amps at 125°C. Event code 507 will log if the module is
over temperature and traction and steering will shut A3.2.1 M2 rms Current =_Amps - (AC Trucks)
down. Press the left arrow to return to A2.5.3. View the M2 current in amps. Press the left arrow to
return to A3.2.
A2.5.4 Module Voltage =_ Volts· View the current
ACCESS 5 module voltage. Value shows the battery A3.2.1 M2 Current =_ Amps - (DC Trucks) View
voltage, which should be 36 Vdc ± 1.5 Vdc. Press the the current present in M2 in amps. Press the down ar-
right arrow to view the value or press the down arrow row to continue. Press the left arrow to return to A3,
to continue. then press the down arrow to continue.
A2.5.5 RPS1 Steer Feedback Sensor - Press the right A3.2.2 P2 =_ ON/OFF - (DC Trucks - M2 Pump
arrow to view the RPS1 inputs. Press the up and down Contactor). Press the right arrow to view the current
arrows to scroll through submenus. status of P2. ON = contactor is energized. OFF = con-
tactor is not energized. Press the left arrow to return to
A2.5.5.1 Counts = Cnt - View the steer feedback
A3.2, then press the down arrow to continue.
sensor position in counts. Range: 100 to 800 counts.
Press the down arrow to continue. A3.3 ACCESS 3 TCM - Press the right arrow to view
the outputs monitored by the ACCESS 3 traction con-
A2.5.5.2 Angle =_ Deg - View the steer feedback
trol module. Press the up and down arrows to scroll
sensor position in degrees. Range: -80° to -107°. Press
through submenus.
the left arrow to return to A2.5.5.
A3.3.1 ED - Press the right arrow to view the ED out-
A2.5.6 RPS2 Tiller Command Sensor - Press the
puts. Press the up and down arrows to scroll through
right arrow to view the RPS2 inputs. Press the up and
the submenus.
down arrows to scroll through submenus.
A2.5.6.1 Cmd Counts =_ Cnt - View the computed
A3.3.1.1 Duty Cycle =_ % - (Status ED) Press the
right arrow to view the percentage of DC voltage; 0% =
command counts based on both channels. Range: 0 to
Open, 50% = Closed. Press the down arrow to con-
32000 counts. Press the down arrow to continue.
tinue.
A2.5.6.2 OutA Counts = Cnt - View the sensor
A3.3.1.2 Current =_ mA - (Status ED) Press the
channel A raw Adc counts. Range: 150 to 1000 counts.
right arrow to view the ED current in milliamps; 0 mA =
Channels are about }'4 turn out of phase from one an-
Open, 700 mA = Closed. Press the left arrow to return
other. Press the down arrow to continue.
to A.3.3.1.
A2.5.6.3 OutB Counts = Cnt - Sensor channel B
A3.3.2 ALM2 Travel Alarm - Press the right arrow to
raw Adc counts. Range: 150 to 1000 counts. Channels
view the percentage of power applied to the travel
are about }'4 turn out of phase from one another. Press
the down arrow to continue at A2.5.6.1 or the left arrow
= =
alarm. 0% Off (travel alarm is off), 100% On (travel
alarm is sounding). Press the down arrow to continue.
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A3.3.3 M1 rms Current = Amps - View the Traction A3.4.9 SCV Holst - Press the right arrow to view the
Motor (M1) rms phase current in amps. Press the down hoist solenoid valve (SCV) outputs. Press the up and
arrow to continue. down arrows to scroll through the submenus.
A3.3.4 FAN3 & FAN4 =_
% - View the percentage A3.4.9.1 Duty Cycle =_ % - Press the right arrow to
of power applied to the ACCESS 2 and ACCESS 3 view the duty cycle of the valve voltage. The duty cycle
=
cooling fans (FAN3 & FAN4). 0% Off (fans are off); (A3.4.9.1) multiplied by the battery voltage (A2.4.26),
100% = On (fans are running). Press the down arrow then divided by 100% is the voltage applied across the
to continue at A3.3.1 or press the left arrow key to re- valve. Press the down arrow to continue.
turn to A3.3.
A3.4.9.2 Volts = _ Volts - Press the right arrow to
A3.4 ACCESS 4 VCM - Press the right arrow to view view the valve voltage. Press the left arrow to return to
the outputs monitored by the ACCESS 4 vehicle con- A3.4.9. Press the down arrow to continue.
trol module. Press the up and down arrows to scroll
A3.4.10 SVL Lower - Press the right arrow to view the
solenoid valve lower (SVL) outputs. Press the up and
A3.4.1 PVL Lower - Press the right arrow to view the down arrows to scroll through the submenus.
Proportional Lowering Valve (PVL) outputs. Press the
up and down arrows to scroll through the submenus.
A3.4.10.1 Duty Cycle =_ % - Press the right arrow
to view the duty cycle of the valve voltage. The duty
A3.4.1.1 Duty Cycle =_ % - Press the right arrow to cycle (A3.4.1 0.1) multiplied by the battery voltage
view the duty cycle of the valve voltage. The duty cycle (A2.4.26), then divided by 100% is the voltage applied
(A3.4.1.1) multiplied by the battery voltage (A2.4.26), across the valve. Press the down arrow to continue.
then divided by 100% is the voltage applied across the
valve. Press the down arrow to continue.
view the valve voltage. Press the left arrow to return to
A3.4.1.2 Current =_
mA - Press the right arrow to A3.4.10. Press the down arrow to continue.
view the valve current in amps. Press the left arrow to
A3.4.11 SVA Accy - Press the right arrow to view the
return to A3.4.1. Press the down arrow to continue.
accessory solenoid valve (SVA) outputs. Press the up
A3.4.5 PVA Accy - Press the right arrow to view the and down arrows to scroll through the submenus.
proportional accessory valve (PVA) outputs. Press the
A3.4.11.1 Duty Cycle = _ % - Press the right arrow
A3.4.5.1 Duty Cycle =_ % - Press the right arrow to cycle (A3.4.11.1) multiplied by the battery voltage
A3.4.5.2 Current = _ rnA - Press the right arrow to A3.4.11. Press the down arrow to continue.
view the valve current in amps. Press the left arrow to
A3.4.12 SVR Reach - Press the right arrow to view the
return to A3.4.5. Press the down arrow to continue.
reach solenoid valve (SVR) outputs. Press the up and
A3.4.8 SVBY Bypass - Press the right arrow to view down arrows to scroll through the submenus.
the bypass solenoid valve (SVBY) outputs. Press the
A3.4.8.1 Duty Cycle =_
% - Press the right arrow to cycle (A3.4.12.1) multiplied by the battery voltage
A3.4.8.2 Volts = _ Volts - Press the right arrow to A3.4.12. Press the down arrow to continue.
A3.4.13 SVS Sideshift - Press the right arrow to view
A3.4.8. Press the down arrow to continue.
the sideshift solenoid valve (SVS) outputs. Press the
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A3.4.13.1 Duty Cycle =_ % - Press the right arrow A3.4.18.1 Duty Cycle =_ % - Press the right arrow
to view the duty cycle of the valve voltage. The duty to view the duty cycle. The duty cycle (A3.4.18.1) mul-
cycle (A3.4.13.1) multiplied by the battery voltage tiplied by the battery voltage (A2.4.26), then divided by
(A2.4.26), then divided by 100% is the voltage applied 100% is the voltage applied. Press the down arrow to
across the valve. Press the down arrow to continue. continue.
A3.4.13.2 Volts = _ Volts - Press the right arrow to A3.4.18.2 Current =_ Amps - Press the right arrow
view the valve voltage. Press the left arrow to return to to view the current in amps. Press the down arrow to
A3.4.13. Press the down arrow to continue. continue.
A3.4.14 SVT Tilt - Press the right arrow to view the tilt A3.4.18.3 Resistance = Ohm - View the outer
solenoid valve (SVT) outputs. Press the up and down brake resistance in ohms. Press the left arrow to return
arrows to scroll through the submenus. to A3.4.18. Press the down arrow to continue.
A3.4.14.1 Duty Cycle =_ % - Press the right arrow A3.4.19 Brake (inner) - Press the right arrow to view
to view the duty cycle of the valve voltage. The duty the brake inner coil outputs. Press the up and down
cycle (A3.4.14.1) multiplied by the battery voltage arrows to scroll through the submenus.
(A2.4.26), then divided by 100% is the voltage applied
across the valve. Press the down arrow to continue.
to view the duty cycle. The duty cycle (A3.4.19.1) mul-
A3.4.14.2 Volts = _ Volts - Press the right arrow to tiplied by the battery voltage (A2.4.26), then divided by
view the valve voltage. Press the left arrow to return to 100% is the voltage applied. Press the down arrow to
A3.4.14. Press the down arrow to continue. continue.
A3.4.15 FAN1 & FAN2 - Press the right arrow to view A3.4.19. 2 Current = _ Amps - Press the right arrow
the motor compartment cooling fan (FAN1 & FAN2) to view the current in amps. Press the down arrow to
outputs. Press the up and down arrows to scroll continue.
A3.4.19.3 Resistance =_ Ohm - Press the right ar-
A3.4.15.1 Duty Cycle =_ % - Press the right arrow row to view the resistance in ohms. Press the left arrow
to view the duty cycle. The duty cycle (A3.4.15.1) mul- to return to A3.4.19. Press the down arrow to continue.
tiplied by the battery voltage (A2.4.26), then divided by
A3.4.20 Brake (caster) - Press the right arrow to view
100% is the voltage applied across the component.
the caster brake outputs. Press the up and down ar-
rows to scroll through the submenus.
A3.4.20.1 Duty Cycle = _ % - Press the right arrow
view the valve fan voltage. Press the left arrow to return
to view the duty cycle. The duty cycle (A3.4.20.1) mul-
to A3.4.15. Press the down arrow to continue.
A3.4.16 HN - Press the right arrow to view the 'horn 100% is the voltage applied. Press the down arrow to
(HN) outputs. Press the up and down arrows to scroll continue.
A3.4.20. 2 Current =_ Amps - Press the right arrow
A3.4.16.1 Duty Cycle =_ % - Press the right arrow to view the current in amps. Press the down arrow to
to view the duty cycle. The duty cycle (A3.4.16.1) mul- continue.
A3.4.19.3 Resistance =_ Ohm - Press the right ar-
100% is the voltage applied across the valve. Press the
row to view the resistance in ohms. Press the left arrow
twice to return to A3.4.
A3.5 ACCESS 5 SCM - Press the right arrow to view
view the component voltage. Press the left arrow to re-
the outputs monitored by the ACCESS 5 steer control
turn to A3.4.16. Press the down arrow to continue.
module. Press the up and down arrows to scroll
A3.4.17 ED =_ - Press the right arrow to view the through the submenus.
ED value. Press the left arrow to return to A3.4.17.
A3.5.1 M4 rms Current = _ Amps - Press the right
arrow to view the steer motor (M4) rms current in amps.
A3.4.18 Brake (outer) - Press the right arrow to view Press the left arrow to return to A3.5.
the outer brake outputs. Press the up and down arrows
to scroll through the submenus.
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A4 Test Outputs - A4 is only available in the Level 3 A4.3.2 M1 rms Current - Press the right arrow to view
Service Menu. Press the right arrow to test the outputs the M1 test outputs. Press the up and down arrows to
monitored by the ACCESS 123 modules. Press the up scroll through the submenus. Press the left arrow to re-
and down arrows to scroll through the submenus. turn to A4.3.
A4.1 ACCESS 1 OM - Press the right arrow to view the A4.3.2.1 U - Applies 200 DC amps to the Phase U lead
test outputs controlled by ACCESS 1. Press the up and on the M1 motor. Press enter to test. Press the down
down arrows to scroll through the submenus. arrow to continue. Press the left arrow to return to
A4.3.2. Press the left arrow again to return to A4.3.
A4.1.1 ALM1 - (Status Alarm) Press enter to test the
status alarm. Press the down arrow to continue. Press A4.3.2.2 V - Applies 200 DC amps to the Phase V lead
the left arrow to return to A4.1. on the M1 motor. Press enter to test. Press the down
arrow to continue. Press the left arrow to return to
A4.1.2 Lamps - Press enter to turn on all display lights.
Press the left arrow to return to A4.1.
A4.3.2.3 W - Applies 200 DC amps to the Phase W
A4.2 ACCESS 2 HCM - (AC trucks) Press the right ar-
lead on the M1 motor. Press enter to test. Press the left
row to test the outputs controlled by ACCESS 2. Press
arrow to return to A4.3.2. Press the left arrow again to
the up and down arrows to scroll through the sub-
return to A4.3.
menus.
A4.3.3 FAN3 & FAN4 - Drives controller fans FAN3
A4.2.1 M2 rms Current - Press the right arrow to enter
and FAN4. Press enter to test. Press the left arrow to
the M2 test outputs. Press the up and down arrows to
return to A4.3.
scroll through the submenus. Press the left arrow to re-
turn to A4.2. A4.4 ACCESS 4 - Press the right arrow to view the test
outputs controlled by ACCESS 4. Press the up and
A4.2.1.1 U - Applies 200 DC amps to the Phase U lead
down arrows to scroll through the submenus.
on the M2 motor. Press enter to test. Press the down
arrow to continue. Press the left arrow to return to A4.4.1 PVL Lower - Press enter to test. Press the
A4.2.1. Press the left arrow again to return to A4.2. down arrow to continue. Press the left arrow to return
to A4.4.
A4.2.1.2 V - Applies 200 DC amps to the Phase V lead
on the M2 motor. Press enter to test. Press the down A4.4.5 PVA Accy - Press enter to test. Press the down
arrow to continue. Press the left arrow to retum to arrow to continue. Press the left arrow to return to A4.4.
A4.4.8 SVBY Bypass - Press enter to test. Press the
A4.2.1.3 W - Applies 200 DC amps to the Phase W down arrow to continue. Press the left arrow to return
lead on the M2 motor. Press enter to test. Press the to A4.4.
down arrow to continue. Press the left arrow to return
A4.4.9 SCV Holst - Press enter to test. Press the down
to A4.2.1. Press the left arrow again to return to A4.2.
arrow to continue. Press the left arrow to return to A4.4.
A4.2 ACCESS 2 Test Outputs (DC) - Press the right
A4.4.10 SVL Lower - Press enter to test. Press the
arrow to view the test outputs controlled by ACCESS 2.
Press the up and down arrows to scroll through the
to A4.4.
submenus.
A4.4.11 SVA Accy - Press enter to test. Press the
A4.2.1 M2 Current - Press enter to test. Press the
to A4.4.
toA4.2.
A4.4.12 SVR Reach - Press enter to test. Press the
A4.2.2 P2 - Press enter to test. Press the left arrow to
return to A4.2.
to A4.4.
A4.3 ACCESS 3 - Press the right arrow to view the test
A4.4.13 SVS Sideshift - Press enter to test. Press the
outputs controlled by ACCESS 3. Press the up and
toA4.4.
A4.3.1 Travel Alarm - Sounds the travel alarm (ALM2)
A4.4.14 SVT Tilt - Press enter test. Press the down
if it is equipped. Press enter to test. Press the down
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A4.4.15 FAN1 & FAN2 • Press enter to test. Press the - Main Lower Valve (C2.3)
- Accessory Valve (C2.4)
toA4.4.
- Accelerometer (C2.5)
A4.4.16 HN • Press enter to test. Press the down arrow
to continue. Press the left arrow to return to A4.4. - Steer sensor feedback on hydraulic steer truck
models (C2.8)
A4.4.17 Brake (outer) • Press enter to test. Press the
down arrow to continue. Press the left arrow to return • Replacement of ACCESS 5 requires calibration of
toA4.4. steering sensor on Electronic Power Steering truck
A4.4.18 Brake (inner) • Press enter to test. Press the models (C4).
• Movement or replacement of any potentiometer,
toA4.4.
switch or component used to mount potentiome-
A4.4.19 Brake (caster) • Press enter to test. Press the ters (POT1, POT2, POT3) or switches (FS or RS)
down arrow to continue. Press the left arrow to return in the multi-task control handle (C1.1, C1.2 and
to A4.4. C1.3).
• Replacement, movement or adjustment of Steer

Calibration Feedback Sensor (RPS1). Refer to C4 for Elec-
The calibration menu description is shown on the fol- tronic Power Steering or C2.8 for hydraulic steer
lowing pages. The level of the menu shows the differ- trucks.
ent area of calibration for this truck. If calibration proce- • Replacement, movement or adjustment of Height
dures are not performed correctly or features settings
Sensor (ECR2) (C2.1 and C2.3).
are not entered correctly, unsatisfactory truck perfor-
mance may result. • Replacement, movement or adjustment of Fork
Load Sensor (LS) (C2.2).
• C1 Handles
• C2 Hydraulics
• Replacement of hydraulic manifold, even if reusing
existing proportional valves (PVL and PVA) (C2.3
• C3 Cutouts and C2.4).
• C4 Steering - Available only when Electronic

• Replacement of PVL (C2.3).
Power Steering truck is calibrated. • Replacement of PVA (C2.4).
When to Calibrate Calibration Access

• Replacement of ACCESS 1 requires calibration of Key the truck ON. Navigate to the Service Menu by
steering sensor on Electronic Power Steering truck pressing the down arrow. At the Service Menu, press
models (C4). the right arrow to enter Level 2. Press the right arrow
again to enter the user code. Press the up and down
• Replacement of ACCESS 3 requires calibration of arrows to scroll to the first digit. Press the right arrow to
tilt sensor feedback on trucks equipped with Fea- advance to the next digit. Continue these steps until the
ture F20.5 enabled (Refer to C2.6). For trucks last digit has been entered. Press enter to accept the
equipped with Electronic Power Steering, recali- user code. Press the down arrow to navigate to the
brate steering sensor (C4). Calibration Menu, then press the right arrow. The mes-
sage displayed will be C1 Handles.
• Replacement of ACCESS 4 requires calibration of
the following:
- All potentiometers in the multi-task control han-
dle (C1.1, C1.2 and C1.3)
- Height Sensor (C2.1)
- Load Sensor (C2.2)
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Calibration Procedures C1.2 Raise/Lower Handle • Calibrates the hydraulic

position potentiometer (POT2) in the multi-task control
A full explanation of the display messages and calibra- handle. POT2 controls raise and lower requests.
tion procedures for each menu level follows.
1. Press the right arrow.
C1 Handles - Press the right arrow to enter handle cal-
ibrations. Press the up and down arrows to scroll 2. Press the up and down arrows to select "Sure? Y".
through the submenus. Press the left arrow to return to Press enter to confirm the choice (selecting "Sure?
the main menu. Upon returning to C1, you will be N" will return to C1.2).
prompted to save the calibration. Press the up and 3. Do not move the handle in the forward or reverse
down arrows to select "Sure? N" (to cancel the direction while calibrating hoist.
changes) or "Sure? Y" (to save the calibration). Press
enter to confirm the choice. 4. "Select Raise, press Enter" - Select and hold the
raise command on the multi-task control handle (to
NOTE view POT2 voltage, press the right arrow). Press
enter.
C1 Calibration results can be saved after the calibra-
tion of individual or multiple calibrations. After calibrat- 5. "Select Lower, press Enter" - Select and hold the
ing, press the left arrow to exit. Select "Sure? Y" with lower command on the multi-task control handle
the up and down arrows, then press enter. (to view POT2 voltage, press the right arrow).
Press enter.
C1.1 Traction Handle· Calibrates the traction position
potentiometer (POT1) in the multi-task control handle. 6. "Center Handle, press Enter" - Center the multi-
task control handle (to view POT1 voltage, press
POT1 controls forward and reverse travel.
the right arrow). Press enter.
7. "Calibration accepted" or "Calibration failed" will be
2. Press the up and down arrows to select "Sure? Y". displayed. Press the left arrow to return to C1.2. If
Press enter to confirm the choice (selecting "Sure? calibration fails, it will return to the failure point in
N" will return to C1.1). the process.
3. Do not move the handle in the raise or lower direc- C1.3 Accessory Handle • Calibrates the accessory
tion while calibrating traction. position potentiometer (POT3) in the multi-task control
4. "Select Forward, press Enter" - Move and hold the handle. POT3 controls accessory function.
multi-task control handle to the full forward position 1. Press the right arrow.
(to view POT1 voltage, press the right arrow).
Press enter. 2. Press the up and down arrows to select "Sure? V".
Press enter to confirm the choice (selecting "Sure?
5. "Select Reverse, press Enter" - Move and hold the N" will return to C1.3).
multi-task control handle to the full reverse position
(to view POT1 voltage, press the right arrow). 3. "Select Reach, press Enter" - Select and hold the
Press enter. full speed reach command on the multi-task control
handle thumbwheel (to view POT3 voltage, press
6. "Center Handle, press Enter" - Center the multi- the right arrow). Press enter.
task control handle (to view POT1 voltage, press
the right arrow). Release the handle and allow it to 4. "Select Retract, press Enter" - Select and hold the
come to rest at no less than half of the full stroke full speed retract command on the multi-task con-
position. Press enter. trol handle thumbwheel (to view POT3 voltage,
press the right arrow). Press enter.
7. "Calibration accepted" or"Calibration failed" will be
displayed. Press the left arrow to return to C1.1. If 5. "Center Handle, press Enter" - With the thumb-
calibration fails, it will return to the failure point in wheel ofthe multi-task control handle in the neutral
the process. position (to view POT3 voltage, press the right ar-
row), press enter.
displayed. Press the left arrow to return to C1.3. If
calibration fails, it will return to the failure point in
the process.
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C2 Hydraulics - Press the right arrow to enter hydrau- 7. "Calibration accepted" or "Calibration failed" will be
lic calibrations. Press the up and down arrows to scroll displayed. Press the left arrow to return to C2.1. If
through the submenus. Press the left arrow to return to calibration fails, it will return to the failure point in
the main menu. Upon returning to C2, you will be the process.
prompted to save the calibration. Press the up and
C2.2 Load Sense - Calibrates the load sense trans-
down arrows to select "Sure? N" (to cancel the
ducer (LS) to determine the approximate weight mea-
changes) or "Sure? Y" (to save the calibration). Press
surement on the forks for the capacity data monitor and
enter to confirm the choice.
traction functions. Lower the empty forks below staging
prior to calibration. The forks must be level prior to
NOTE starting.
C2 Calibration results can be saved after the calibra- 1. Press the right arrow.
tion of individual or multiple calibrations. After calibrat-
ing, press the left arrow to exit. Select "Sure? Y" with 2. Press the up and down arrows to select "Sure? Y".
the up and down arrows, then press enter. Press enter to confirm the choice (selecting "Sure?
N" will return to C2.2).
C2.1 Height Sensor - Calibrates the height sensor en-
coder (ECR2) to provide the measured height of forks 3. "Lower empty forks 12", press Enter" - Appears if
beyond free lift. Lower the forks below staging prior to the forks are above staging. Lower the empty forks
calibration. to continue.
1. Press the right arrow. 4. "Set empty forks 12", press Enter" - Use the multi-
task control handle to position the empty forks at
2. Press the up and down arrows to select "Sure? Y". 305 mm (12.0 in). Press enter.
N" will return to C2.1 ). 5. Wait to be prompted to raise the forks.
3. "Lower below staging to begin" - Appears if the 6. "Raise forks 1", Stop Command" - Use the multi-
forks are above staging. Lower the forks to con- task control handle to raise the empty forks 25.4
tinue. Press the right arrow to view the ECR2 value mm (1.0 in). Stop command.
in counts. 7. "Paused, Raise above staging" - Appears if raise
4. Verify the tilt is level. Clamp a tape measure to the command has been removed.
end of one of the forks. 8. "Finding Load Sense Point" - Wait to be prompted.
9. "Stop Command" - Appears once the calibration is
~ CAUTION complete and the command remains active.
Check for adequate overhead clearance before con- 10. "Calibration accepted" or "Calibration failed" will be
tinuing. displayed. Press the left arrow to return to C2.2. If
5. "Raise to Max Height, press Enter" - Raise the
the process.
forks to the desired maximum height. Press the
right arrow to view the ECR2 value in counts. Press C2.3 Main Lower Valve - Calibrates the main lower
enter. valve (PVL). Raise the forks as high as possible before
beginning.
6. "Enter Fork Height" - The current fork height will be
displayed in inches. Use the up and down arrows 1. Press the right arrow.
to adjust the displayed height to match the tape
2. Press the up and down arrows to select "Sure? V".
measure reading. Press enter.
NOTE
3. "Raise to Top, then Lower" - From the full raise po-
Aftersetting the maximum height value, lift slows down sition, command the hoist to the full lower position.
approximately 305 mm (12 in) prior to the calibrated
height. When the maximum height is reached, the Op- 4. Continue to hold the multi-task control handle at
erator Error icon will illuminate, ALM1 will beep and the full lower position as the forks begin to lower.
Height Cutout Stop will be displayed.
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5. "Paused - Raise to Top, then Lower" - When 11. "Calibration accepted" or "Calibration failed" will be
prompted, return the forks to their fully raised posi- displayed. Press the left arrow to return to C2.4. If
tion, then command the hoist again to the full lower calibration fails, it will return to the failure point in
position. the process.
6. "Finding Breakout, Maintain Command" - Wait for C2.5 Accelerometer - Calibrates the accelerometer.
the system to sense a valve breakout. Place the truck on a flat surface with empty forks prior
to calibration.
7. Finding Speed X - Maintain Command" - Will find
for speed 1 through speed 7. Calibration on a slope will cause incorrect values and
reduce truck performance. Verify the proper undercar-
8. "Stop Command" - Appears once the calibration is
riage articulation adjustment prior to calibration.
complete and the command remains active.
displayed. Press the left arrow to retum to C2.3. If & WARNING
calibration fails, it will return to the failure point in Do not operate the truck if ACCESS 4 is not mounted
the process. securely and properly calibrated.
C2.4 Accessory Valve - Calibrates the accessory 1. Press the right arrow.
valve (PVA). The forks should be lowered and level
prior to starting the calibration. 2. Press the up and down arrows to select "Sure? yo.
1. Press the right arrow. N" will return to C2.5).
2. Press the up and down arrows to select "Sure? Y". 3. Set the brakes by releasing the left pedal.
N" will return to C2.4). 4. "Truck Level? press Enter to continue" - Press en-
ter to begin the calibration.
3. "Lower empty forks to begin" - Appears if the forks
are above staging. Lower the empty forks to con- 5. "Determining Level Truck" is displayed.
tinue. 6. "Position Truck in opposite Direction" - To compen-
4. "Extend Forks Near Stop, press Enter" - Use the sate for any variation in surface grade, reverse the
multi-task control handle to position the empty truck position. Refer to Figure 21535.
forks at 51-76 mm (2-3 in) from the end of the
stroke. Press enter.
5. "Select Reach command" - Command full reach to
the multi-task control handle accessory thumb-
wheel.
6.
7.
"Paused - Select Reach to continue" - Appears if
the reach command has been removed.
"Finding Breakout, Maintain Command" - Wait for
the system to sense a valve breakout.
-- - ,---"- II
8. "Retracting - Maintain Command" - Continue to
command full extension while the forks cycle in
and out. -------
9. "Finding flow point, Maintain Command" - Continue
to command full extension while the forks cycle in
and out. Figure 21535
10. "Stop Command" - Appears once the calibration is 7. "Set Truck Level, then apply brake" - Set the truck
complete and the command remains active. level then apply the brake.
8. Repeat steps 4 and 5.
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9. "Calibration accepted" or "Calibration failed" will be 4. "Steer Wheel Fully CW. press Enter" - Tum the til-
displayed. Press the left arrow to return to C2.S. If ler to rotate the drive wheel fully clockwise. Press
calibration fails, it will return to the failure point in enter.
the process.
5. "Steer Wheel Fully CCW, press Enter" - Turn the
C2.6 Tilt Sensor· Calibrates the tilt sensor on trucks tiller to rotate the drive wheel fully counter-clock-
equipped with the tilt position assist feature. wise. Press enter.
1. Press the right arrow. 6. "Calibration accepted" or "Calibration failed" will be
2. Press the up and down arrows to select "Sure? Y".
the process.
C3 Height Cutout • Customizes the raise and lower
3. "Tilt fully back, press Enter" - Tilt the forks fully
cutouts.
back. Press enter.
4. "Tilt fully down, press Enter" - Tilt the forks fully NOTE
down. Press enter.
The truck must be keyed OFF and ba'ck ON to enable
5. "Tilt to Zero Degrees, press Enter" - Tilt the forks to traction after the cutouts are entered or modified. Press
zero degrees. Press enter. the right arrow to enter the height cutout calibrations.
6. "Use Zero Degrees as targer - If the zero degree Press the up and down arrows to scroll through the
point is the TPA auto target, scroll to "Yes" and submenus. A total of six cutouts (C3.1 through C3.6)
press enter. The process will advance to step nine can be programmed, one at a time, all by following the
and "Using Zero Degrees as targer will be dis- same calibration procedures outlined below. Press the
played. left arrow to return to the main menu. Upon returning to
C3, you will be prompted to save the calibrations.
7. If the zero degree point is not the TPA auto target, Press the up and down arrows to select "Sure? Nil (to
scroll to "No" and press enter. cancel the changes) or "Sure? Y" (to save the calibra-
8. "Tilt to desired angle, press Enter" - Tilt the forks to tion). Press enter to confirm the choice.
the desired angle and press enter.
NOTE
displayed. Press the left arrow to return to C2.6. If C3 Calibration results can be saved after the calibra-
calibration fails, it will return to the failure point in tion of individual or multiple calibrations. After calibrat-
the process. ing, press the left arrow to exit. Select "Sure? Y" with
the up and down arrows, then press enter.
C2.8 Wheel Position Sensor· Calibrates the wheel
position sensor (RPS1). C3.X Cutout X • Calibrates the associated cutout re-
strictions. Press the right arrow to continue.
2. Press the up and down arrows to select "Sure? Y".
C3.X.1 Cutout X Trigger =_ . Press the right arrow
to select the input that "triggers" the cutout selected in
C3.X.2. Press the up and down arrows to select the
type, then press enter to confirm the choice.
3. "Center Steer Wheel, press Enter" - Turn the tiller
C3.X.1.1 Cutout X Trigger Type·
to rotate the drive wheel to within one degree of
center. This procedure may require two people to • Height Sensor - This trigger type causes the cutout
complete. To confirm the wheel is centered, use a to occur when the height entered at C3.x.1 is
carpenter's square or other right angled tool to reached.
align the wheel with the truck. Place one edge of
the tool against the back of the tire, aligning the • FLS - This trigger type causes the cutout to occur
other edge along the battery box. Turn the tiller un- when the Free Lift Switch (FLS) on the fork car-
til the wheel and battery box are aligned. Press en- riage actuates. If this trigger is selected. the sys-
ter. tem will ignore any height entered at C3.X.1.
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• HGTRS2 - This trigger type causes the cutout to effect. For example, setting C3.X.5 to 1.61 kph (1.0
occur when the magnetic proximity height reset mph) will cause the cutout set in C3.X.2 to occur only if
switch (HGTRS2) on the side of the mast actuates. the truck is traveling at or above 1.61 kph (1.0 mph). If
If this trigger is selected, the system will ignore any C3.X.5 is set to 0.0 kph/mph, the cutout will be effective
height set in C3X1. at all travel speeds. Press the up and down arrows to
select the speed in kilometers per hour if F2 =Enabled
• HGTS1 - This trigger type causes the cutout to oc- or miles per hour if F2 = Disabled.
cur when an optional switch is installed. If this trig- C3.99 Clear All Cutouts - Press the right arrow, then
ger is selected, the system will ignore any height press the up and down arrows to select "Sure? N" (to
set in C3X1. cancel clearing all cutouts) or "Sure? Y" (to confirm
clearing all cutouts). Press enter to confirm the choice.
• HGTS2 - This trigger type causes the cutout to oc-
cur when an optional switch is installed. If this trig- C4 Electronic Power Steering Calibration - Press
ger is selected, the system will ignore any height the right arrow to enter Electronic Power Steering cali-
set in C3X1. brations. Press the up and down arrows to scroll
through the submenus. Press the left arrow to return to
C3.X.1.2 Cutout X Height - Press the right arrow to set
the main menu. Upon returning to C4, you will be
the cutout height.
prompted to save the calibration. Use the up and down
• "R/L to Cutout then press Enter" • Raise or lower arrows to select "Sure? N" (to cancel changes) or
the forks to the desired cutout position. The height "Sure? Y" (to save the calibration). Press enter to con-
=
is displayed in centimeters if F2 Enabled or in firm the choice.
inches if F2 = Disabled. Press enter.
NOTE
C3.X.2 Cutout X Type =_ -
Press the right arrow to
select the appropriate cutout type. Press the up and C4 Calibration results can be saved after the calibra-
down arrows to select the type, then press enter to con- tion of individual or multiple calibrations. After calibrat-
firm the choice. ing, press the left arrow to exit. Select "Sure? Y" with
the up and down arrows, then press enter.
• None - No cutout.
C4 Wheel Position Sensor - Calibrates the wheel po-
• Raise Cutout - This type of cutout takes affect dur- sition sensor on trucks equipped with Electronic Power
ing raise only. If height above the cutout is desired, Steering.
the operator must press and hold the override 1. Press the right arrow.
switch before raise is selected again.
2. Press the up and down arrows to select "Sure? yo.
• Latched Raise Cutout - This type of cutout is the Press enter to confirm the choice (selecting "Sure?
same as the raise cutout, except the override N" will return to C4.1).
switch can be released once the mast begins to
3. "Steer Wheel Fully CW, press Enter" - Tum the til-
raise.
ler to rotate the drive wheel fully clockwise. Press
• Raise Stop - This type of cutout will cause the mast enter.
to stop during raise when the mast reaches the cut- 4. "Steer Wheel Fully CCW, press Enter" - Tum the
out. The mast cannot be raised above a raise stop. tiller to rotate the drive wheel fully counter-clock-
wise. Press enter.
• Lower Cutout - This type of cutout will take affect
during lower only. If height below cutout is desired, 5. "Center Steer Wheel, press Enter" - Tum the tiller
the operator must press and hold the override to rotate the drive wheel to within one degree of
switch before lower is selected again. center. This procedure may require two people to
complete. To confirm the wheel is centered, use a
• Latched Lower Cutout - This type of cutout is the carpenter's square, or other right angled tool to
same as the lower cutout, except the override align the wheel with the truck. Place one edge of
switch can be released once the mast begins to the tool against the back of the tire, aligning the
lower. other edge along the battery box. Tum the tiller un-
til the wheel and battery box are aligned. Press en-
C3.X.3 Cutout X Speed - Press the right arrow to se-
ter.
lect the travel speed at which the C3.x.2 cutout takes
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6. "Calibration accepted" or "Calibration failed" will be for your truck. Incorrect settings can affect proper truck
displayed. Press the left arrow to return to C4.1. If performance.
F3.1 Truck Model - Press the right arrow to view the
the process.
model number. The model number displayed should
match the model number on the data plate. Ifthe model
Features displayed is correct, press enter to continue. If the
model displayed is incorrect, press the up and down
The Features Menu activates available truck hardware arrows to select the correct model number. Press enter
and, in some cases, sets up parameters as to when to to confirm the choice, then press the down arrow to
use that hardware. continue to F3.2.
F3.2 Reach Type· This feature is visible only if Model
NOTE 5725 or 5795 is selected in F3.1. Press the right arrow
If any truck functions are in operation, Features will not to view the reach type, RR or RD. The reach type dis-
be displayed until the drive motor brake sets. played should match the reach type listed as part of the
model number on the data plate. If the reach type dis-
The Features Menu descriptions are shown on the fol- played is correct, press enter to continue. If the reach
lowing pages. The first level of the menu shows the type displayed is incorrect, press the up and down ar-
various setup menus for the truck. rows to select the correct reach type. Press enter to
confirm the choice, then press the down arrow to con-
Features Access tinue to F3.3.
Key the truck ON. Navigate to the Service Menu by F3.3 Max Load Weight - Press the right arrow to view
pressing the down arrow. At the Service Menu, press the load capacity. The capacity displayed should match
the right arrow to enter Level 2. Press the right arrow the capacity given as part of the model number on the
again to enter the user code. Press the up and down data plate. If the load capacity displayed is correct,
arrows to scroll to the first digit. Press the right arrow to press enter to continue. If the load capacity displayed
advance to the next digit. Continue these steps until the is incorrect, press the up and down arrows to select the
last digit has been entered. Press enter to accept the correct max load weight. Capacity choices will be de-
user code. Press the down arrow to navigate to the termined by the reach type selected in F3.2. Press en-
Features Menu, then press the right arrow. The ED ter to confirm the choice, then press the down arrow to
contactor will open until the Features Menu is exited. continue to F3.4.
The message displayed will be F1 Language = _ . If
changes are made in Features, then key the truck OFF
F3.5 Lift Height =_ - Press the right arrow to view
the lift height setting. The lift height displayed should
and back ON to allow travel.
match the lift height listed as part of the truck data num-
F1 Language =_ . Determines the languages dis- ber on the data plate. If the lift height displayed is cor-
played on ACCESS 1. The default setting is English. rect, press enter to continue. If the lift height displayed
Press the down arrow to continue to F2 or press the is incorrect, press the up and down arrows to enter the
right arrow to select a different language. Press the up correct lift height. This value is important for proper
and down arrows to select the desired language. Press raise cutout, slowdown and hoist operation. Press en-
enter to confirm the choice. ter to confirm the choice, then press the down arrow to
continue to F3.6.
F2 Metric = - Determines the units of measure dis-
played throughout all the menus. Default setting is Dis- F3.6 Collapsed Height =_ - Press the right arrow to
abled, which means units of measure are displayed in view the collapsed height setting in millimeters if F2 =
standard units (Le., inches, degrees Fahrenheit, etc.). Enabled or inches if F2 = Disabled. The value shown
Press the down arrow to continue to F3 or press the initially is the standard value for the lift height entered
right arrow to change the setting. Press the up and in F3.5. Use a tape measure to measure the actual col-
down arrows to change the selection. Press enter to lapsed height of the truck and verify it matches the
confirm the choice. value displayed. If not, press the up and down arrows
to enter the correct collapsed height. This value is im-
F3 Truck Data Number - Press the right arrow to enter
portant for proper raise cutout, slowdown and hoist op-
the truck data number setups. Use information pro-
eration. Press enter to confirm the choice, then press
vided on the truck data plate and in the Introduction
the down arrow to continue to F3.7.
chapter of this manual to determine the proper settings
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F3.7 Lift System =_ -

This feature is visible only if F6.1 Capacity Data Monitor = _ - Press the right
Model 5725 or 5795 is selected in F3.1. Press the right arrow to view the capacity data monitor setting. Press
arrow to view the lift system setting, DC (contactor) lift the up and down arrows to select Disabled or Enabled.
or AC (ACCESS 2) lift. The lift system displayed should Press enter to confirm the selection. Press the down
match the lift system listed as part of the truck data arrow to continue.
number on the data plate. If the lift system setting dis-
played is correct, press enter to continue. If the lift sys-
F6.2 CDM Zones =_ - Press the right arrow to select
the appropriate number of zones. Press the up and
tem setting displayed is incorrect, press the up and
down arrows to set the number of zones from the ca-
down arrows to select the correct lift system. Press en-
pacity data plate. The default for this setting is one. The
ter to confirm the choice, then press the down arrow to
maximum for this setting is four. Press enter to confirm
continue to F3.9.
the choice. Press the down arrow to continue.
F3.9 Steering Direction =__ - This feature is visible
F6.3 CDM Height 1 = _ in/mm - Press the right ar-
only if AC Lift system is selected in F3.7. Press the right
row. The display shows the first (highest) height listed
arrow to view the steering direction setting - Forward or
on the capacity data plate. If the value does not match
Reverse. The setting should match the steering direc-
the capacity data plate, press the up and down arrows
tion listed as part of the truck data number on the data
to enter the correct value one digit at a time. Press the
plate. If the steering direction displayed is correct,
right arrow to continue to the next digit. Once all .the
press enter to continue. If the steering direction dis-
digits are entered, press enter to confirm the chOice.
played is incorrect, press the up and down arrows to
select the correct steering direction. Press enter to con-
firm the choice, then press the down arrow to continue F6.4 CDM Weight 1 =_ kgllb - Press the right ar-
to F3.10. row. The display shows the first (lightest) weight listed
on the capacity data plate. If the value does not match
F3.10 Sideshift = _ - Press the right arrow to view
the capacity data plate, press the up and down arrows
the sideshift setting. If the truck is equipped with side-
to enter the correct value one digit at a time. Press the
shift, select Enabled. If the truck is not equipped with
right arrow to continue to the next digit. Once all digits
sideshift, select Disabled. Press enter to confirm the
are entered, press enter to confirm the choice. Press
choice, then press the down arrow to continue to F3.11.
F3.11 Tilt = - Press the right arrow to view the tilt F6.5 CDM Height 2 = _ mm/in - Press the right ar-
setting. If the truck is equipped with tilt, select Enabled.
row. The display shows the second height listed on the
If the truck is not equipped with tilt, select Disabled.
capacity data plate. If the value does not match the ca-
Press enter to confirm the choice, then press the left
pacity data plate, use the up and down arrows t~ enter
arrow to return to F3. Press the down arrow to con-
the correct value one digit at a time. Press the right ar-
tinue.
row to continue to the next digit. Once all digits are en-
F4 Truck Weight =_ -
Press the right arrow to view tered, press enter to confirm choice. Press the down
the truck weight with the battery and without the load arrow to continue.
listed on the truck data plate. The weight is displayed
=
in kilograms if F2 Enabled or as pounds if F2 Dis- = F6.6 CDM Weight 2 =_ kg/lb - Press the right ar-
row. The display shows the second weight listed on the
abled. Press the up and down arrows to select each
digit of the weight in sequence. Press the right arrow to
pacity data plate, press the up and down arrows to .en-
continue to the next digit. After entering all digits, press
ter the correct value one digit at a time. Press the right
enter to accept the weight. Press the left arrow to return
arrow to continue to the next digit. Once all digits are
to F4, then the down arrow to continue.
entered, press enter to confirm the choice. Press the
F6 CDM - (Capacity Data Monitor) Press the right ar- down arrow to continue.
row to select the capacity data monitor settings. Press
F6.7 CDM Height 3 = _ mm/ln - Press the right ar-
the up and down arrows to scroll through the sub-
row. The display shows the third height listed on the
menus. All settings will be displayed in metric if F2 =
Enabled or as standard units if F2 = Disabled. Use this
pacity data plate, press the up and down arrows to .en-
feature to set the height a particular load can safely be
lifted. A warning alarm will sound if the load is lifted
above the set height.
down,arrow to continue.
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F6.8 CDM Weight 3 = _ kgllb - Press the right ar- ter reading), Odometer (total distance the truck has
row. The display shows the third weight listed on the traveled in miles), Speed (speed in mph), model (truck
capacity data plate. If the value does not match the ca- model), or All (scrolls through all messages). Press the
pacity data plate, press the up and down arrows to en- up and down arrows to navigate through the choices.
ter the correct value one digit at a time. Press the right Press enter to confirm the selection. Press the down
arrow to continue to the next digit. Once all digits are arrow to continue.
F9 Hour Meter Mode = _ - Press the right arrow.
This feature determines the hour meter displayed dur-
F6.9 CDM Height 4 = _ mmlln - Press the right ar- ing operation - H1 or H2. Refer to Hour Meter Menu in
row. The display shows the fourth height listed on the this section for H1 and H2 descriptions. Press the up
capacity data plate. If the value does not match the ca- and down arrows to select H1 or H2. Press enter to
pacity data plate, press the up and down arrows to en- confirm the selection. Press the down arrow to con-
ter the correct value one digit at a time. Press the right tinue.
F10 User Performance - Press the right arrow. When
enabled, this feature allows the operator to select dif-
ferent truck performance levels (P1, P2 or P3). Press
F6.10 CDM Weight 4 =_ kg/lb - Press the right ar- the up and down arrows to select Disabled or Enabled.
row. The display shows the fourth weight listed on the Press enter to confirm the selection. Press the down
capacity data plate. If the value does not match the ca- arrow to continue.
pacity data plate, press the up and down arrows to en-
F11 User Codes - Use this feature to enter up to 25
four-digit user codes (0000 to 9999) which can be ap-
plied to various performance levels. If no user codes
are entered, the Status will be disabled. The Timeout
feature, which requires the user code to be reentered a
F7 Fans - Press the right arrow to access the fan set- specific time limit after the operator leaves the seat, is
tings. Press the up and down arrows to scroll through adjustable with times from one to 90 minutes. Selecting
the submenus. o for the Timeout feature disables it. The time selected
in this menu item is applied to all user codes. This is not
F7.1 Module Fan = _ - Press the right arrow to se-
available if F20.6.1 is active. Press the right arrow to
lect the ACCESS 2 cooling fan (FAN4) and ACCESS 3
begin setup.
cooling fan (FAN3) settings. Press the up and down ar-
rows to select fan operation - Thermal or Always On.
Selecting Thermal will cause the fan to only operate NOTE
when the compartment reaches a pre-set temperature. If F11 Status = Enabled, operators cannot change the
Selecting Always On will cause the fan to run whenever performance levels in the F10 menu. The truck will be
the truck is ON. Press enter to confirm the choice. limited to the performance level assigned to the user
Press the down arrow to continue. code.
F7.2 Motor Fan =_ - Press the right arrow to select F11.1 Disabled/Enabled =_ - Press the right arrow.
the motor cooling fan(s) (FAN1 & FAN2) settings. Press Press the up and down arrows to select Disabled (user
the up and down arrows to select fan operation - Off, codes are not active) or Enabled (user code is re-
Thermal or Always On. Off will disable the fan(s), Ther- quired). Press enter to confirm the selection. The menu
mal will cause the fan(s) to only operate when the com- will return to F11.1. Press the down arrow to continue.
partment reaches a pre-set temperature, and Always
On will cause the fan to run whenever the truck is ON. F11.2 Setup User Codes - F11.1 must be enabled.
Press enter to confirm the choice. Press the down ar- Press the right arrow. Press the up and down arrows to
row to continue. input the first digit of the first four-digit user code. Press
the right arrow to move to the second digit. Continue
F8 Message Mode =_ - This feature determines doing this until all four digits have been entered. Press
what information is displayed during truck operation. enter to confirm the user code. Press the up and down
Select from: Timer (stopwatch in seconds), Trip (total arrows to select the desired performance level for that
distance the truck has traveled since the last reset in user. Press enter. Press the down arrow to enter the
feet), Height (current fork height displayed in inches), next code. Up to 25 user codes can be entered. Press
Height & Weight (displayed in in/lbs), Hours (hour me- the left arrow to return to F11.2.
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F11.3 Timeout =_.Press the right arrow. Press the • Coast - Travel request causes the traction motor
up and down arrows to set the desired user code time- brake to release, but the truck will not travel and
out function in minutes. This sets the number of min- "No Battery Restraint" appears on ACCESS 1.
utes the truck can sit idle (key switch turned ON with no
pedals pressed) before the truck must be restarted. • Coast with hom - Travel request causes the trac-
Press enter to confirm the selection. If timeout is not tion motor brake to release, but the hom will sound,
desired, select Never. The menu will return to F11.3. the truck will not travel and "No Battery Restraint"
Press the down arrow to continue. appears on ACCESS 1.
F12 Rack Select • This feature is available only if • Brake - Travel request will not cause the traction
F20.5 Tilt Position Assist is enabled and the truck is
motor brake to release, the truck will not travel and
equipped with a tilt position sensor and COM. Press the
"No Battery Restraint" appears on ACCESS 1.
right arrow. Press the up and down arrows to select
Disabled to turn this feature off, or Enabled to tum this Press the up and down arrows to make the selection.
feature on. Press enter to confirm the selection. Press Press enter to confirm the selection. The menu will re-
the down arrow to continue. turn to F20.2. Press the down arrow to continue.
F13 User Rack· This feature is available only if F12 = F20.3 Travel Alarm = .
This feature determines
Enabled. Press the right arrow. Press the up and down when the travel alarm (ALM2) will sound, if the truck is
arrows to select Disabled to turn this feature off, or En- equipped. Press the right arrow. Press the up and
abled to turn this feature on. Press enter to confirm the down arrows to select from the following:
selection. Press the down arrow to continue. Rack
heights can be programmed from the Operator Menu. • Disabled - No alarm.
• Forward - Alarm sounds only when the truck is in

NOTE
the forward travel direction.
After programming rack heights, protect the system
from unauthorized changes by disabling F13. • Reverse - Alarm sounds only when the truck is in
the reverse travel direction.
F20 Options Menu· Press the right arrow to enter the
Options Menu. Press the up and down arrows to navi- • Both - Alarm sounds whenever the truck travels
gate through the submenus. forward or reverse.
F20.1 Chain Slack Switch =_ .
Press the right ar- Press enter to confirm the selection. The menu will re-
row. The chain slack switch and associated hardware turn to F20.3. Press the down arrow to continue.
are required for this feature to work. It is designed to
detect lift chain slack when lowering. If chain slack is
F20.4 Speed Cutback =_ . This feature is only
detected, lowering will be disabled, ALM1 will sound, available if F20.6 and F20.8 are disabled. If speed cut-
and "Chain Slack" will be displayed on ACCESS 1 until back is enabled, use P16 for the setup of customized
weight, height trigger, fork home and speed conditions.
the situation is corrected. Press the up and down ar-
rows to select Disabled to turn this feature off, or En- When enabled, F20.4 limits vehicle speed in both di-
abled to turn this feature on. Press enter to confirm the rections to P16.4 speed based on fork load condition
selection. The menu will return to F20.1. Press the (P16.3) and height trigger condition (P16.1), or if en-
down arrow to continue. abled in the fork home position (P16.2). If F3.3 is
2495 kg (5500 Ib) capacity, F20.4 is automatically en-
F20.2 Battery Retainer =_.
Press the right arrow. abled and F20.4, F20.6 and F20.8 will all be blank as
Used in conjunction with the battery gate switches these trucks require fork home and 305 mm (12 in)
wired normally open to ACCESS 4 CA411-14, F20.2 height switches. Press the right arrow. Press the up
will display one of four selectable options when any and down arrows to select Disabled or Enabled. Press
gate is removed: enter to confirm the selection. The menu will return to
F20.4. Press the down arrow to continue.
• Disable - Beep and set the traction speed to zero.
(This setting is used for trucks without optional
switches.
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Access 1 2 3® Menus CJ\OWI)
F20.5 Tilt Position Assist = _ - This feature, if the and down arrows to select Disabled or Enabled. Press
truck is so equipped, enables the tilt position assist, al- enter to confirm the selection. The menu will return to
lowing the fork tilt to stop automatically at the horizontal F20.9. Press the down arrow to continue.
position. F3.11 must be enabled. Press the right arrow.
Press the up and down arrows to select Disabled or
Enabled. Press enter to confirm the selection. The Hour Meters
menu will return to F20.5. Press the down arrow to con- The Hour Meters Menu descriptions are shown on the
tinue. following pages. Hour meters are viewed only in the
F20.6 Startup Interlock - This feature is only available Operator Message Menu (as configured) and in the
if F20.4 and F20.7 are both disabled. Used in conjunc- Service Level 2 Menu. Adjustment ofthe PM Timer me-
tion with the override switch (ORS), wired normally ters must be completed in the Service Level 3 Menu.
open to ACCESS 4 CA411-21, it locks the operation of
the truck and displays "Invalid" unless the vehicle is Hour Meters Access
keyed ON while holding ORS closed. Press the right
arrow to view the startup interlock options. Press the up Key the truck ON. Navigate to the Service Menu by
and down arrows to scroll through the submenus. pressing the down arrow. At the Service Menu, press
the right arrow to enter Level 2. Press the right arrow
F20.6.1 Startup Interlock = _ - Press the up and again to enter the user code. Press the up and down
down arrows to select Disabled or Enabled. Press en- arrows to scroll to the first digit. Press the right arrow to
ter to confirm the selection. The menu will return to advance to the next digit. Continue these steps until the
F20.6. Press the down arrow to continue. last digit has been entered. Press enter to accept the
F20.6.2 Timeout = _ - Press the up and down ar- user code. Press the down arrow to navigate to the
rows to set the desired timeout function in minutes. Hour Meters Menu, then press the right arrow. The
This sets the number of minutes the truck can sit idle message displayed will be H1 Truck Runtime1 = _
(key switch turned ON with no pedals pressed) before Hr.
the truck must be restarted. Press enter to confirm the If Level 3 is desired, press the down arrow from Level
selection. If timeout is not desired, select Never. The 2 on the display. Press the right arrow again to enter
menu will return to F20.6. Press the down arrow to con- user code. Press the up and down arrows to scroll to
tinue. the first digit. Press the right arrow to advance to the
F20.7 Height Zone Switch = _ - This feature is next digit. Continue these steps until the last digit has
available only if F20.4 and F20.8 are both disabled. been entered. Press enter to accept the user code.
Press the right arrow. Press the up and down arrows to Within the submenus, the hour meter number will ap-
select Disabled or Enabled. Press enter to confirm the pear first and then text will display and scroll if neces-
selection. The menu will return to F20.7. Press the sary. This will repeat. To stop the scroll and advance
down arrow to continue. the display to the meter value only, press the right ar-
F20.8 Remote Raise/Lower = - This feature is row. To advance to the next meter, press the down ar-
only available if F20.4 and F20.7 are both disabled. row.
When enabled, it allows the operator to remotely raise H1 Truck Runtime1 = Hr - The H1 hour meter
and lower the forks at reduced speeds by use of the runs when the key switch is ON and the operator is in
available option control module. All multi-task control the seat. H1 resides in ACCESS 1. If ACCESS 1 is re-
commands are locked out when the user enables Re- placed, H1 can only be increased. Press the down ar-
mote Raise/Lower. Press the right arrow. Press the up row to continue.
and down arrows to select Disabled or Enabled. Press
enter to confirm the selection. The menu will return to H2 Truck Runtime2 = Hr - The H2 hour meter
F20.8. Press the left arrow twice to return to the Fea- runs when the key switch is ON and the operator is in
tures Menu. the seat. H2 resides in ACCESS 1. If ACCESS 1 is re-
placed, H2 can only be increased. Press the right arrow
F20.9 Speed Zone Switch = _ - This feature is avail- to view the values. Press the up and down arrows to
able only if F20.4, F20.7 & F20.8 are all disabled. For scroll through the submenus.
speed zone select, empty speeds under P1, P2 & P3
are used as the maximum travel speeds for this fea- H2.1 Truck Runtime 2 = Hr - View the number of
ture. The other performance settings under P1 will be truck runtime hours. This feature is available only if F9
used for P2 & P3. Press the right arrow. Press the up is set to H2. Press the down arrow to continue.
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H2.2 Timeout =_Min • Programmable timeout down arrows to select the desired meter. Press enter to
which will continue to increment for the timeout period confirm the selection.
after the operator has exited the seat. This feature is
available only if F9 is set to H2. Press the left arrow to
H14.2 Interval =_. This setting indicates the inter-
val between alerts. Press the right arrow. Press the up
return to H2. Press the down arrow to continue.
and down arrows to change the value. The value can
H3 Odometer = kmlmlle • View the total accumu- be set from one hour up to 65,535 hours. Example: In-
lated truck travel distance in kilometers if F2 = Enabled terval = 250, when the monitored hour meter increases
or miles if F2 = Disabled. Press the down arrow to con- 250 hours from the current reading an alert will be
tinue. given to the operator. Press enter to confirm the selec-
tion.
H4 Traction Motor =
Hr • View the total accumu-
lated traction motor (M1) hours. Press the down arrow
to continue. Events
H5 Lift Motor 1 =
Hr • View the total accumulated The Events Menu allows access to view logged event
hydraulic pump motor (M2) hours. Press the down ar- codes on ACCESS 1. Descriptions are shown on the
row to continue. following pages.
H6 Lift Motor 2 = Hr • This feature is available on
36 V DC Hydraulic trucks only. View the total accumu- Events Access
lated DC hydraulic pump motor (M3) hours. Press the
down arrow to continue. Key the truck ON. Navigate to the Service Menu by
pressing the down arrow. At the Service Menu, press
H7 Steer Motor =
Hr - This feature is available on the right arrow to enter Level 2. Press the right arrow
Electronic Power Steering trucks only. View the total again to enter the user code. Press the up and down
accumulated steer motor (M4) hours. Press the down arrows to scroll to the first digit. Press the right arrow to
arrow to continue. advance to the next digit. Continue these steps until the
H8 ACCESS 1 =
Hr • View the total accumulated last digit has been entered. Press enter to accept the
user code. Press the down arrow to navigate to the
ACCESS 1 display module hours. Press the down ar-
row to continue. Events Menu, then press the right arrow. The message
displayed will be E1 Chronologic History.
H9 ACCESS 2 =
Hr • View the total accumulated
E1 Chronologie History • Press the right arrow to
ACCESS 2 hydraulic control module hours. Press the
down arrow to continue. view a chronological listing of the last 16 event codes
beginning with the most recent event code logged.
H10 ACCESS 3 =
Hr· View the total accumulated Press the up and down arrows to scroll through the
ACCESS 3 traction control module hours. Press the event codes. Press the right arrow for more information
down arrow to continue. on each event code.
H11 ACCESS 4 =
Hr· View the total accumulated E1.1 Last· Press the right arrow to "Code = _ " to
ACCESS 4 vehicle control module hours. Press the display the event code. Press the down arrow to view
down arrow to continue. the hour meter reading "Hour = _ Hr" when the event
H12 ACCESS 5 =
Hr· This feature is available on was logged. Press the down arrow again to view the
battery state of charge "SOC = _ %" when the event
Electronic Power Steering trucks only. View the total
accumulated ACCESS 5 steer control module hours. was logged. Press the left arrow to return to E1.1, then
Press the down arrow to continue. press the down arrow to continue.
H14 PM Timer =_.

This feature is only available in
Service Level 3. Press the right arrow to enter values.
Press the up and down arrows to scroll through the
submenus.
H14.1 Tag = _ • The tag setting indicates which hour
meter will be monitored for planned maintenance inter-
vals. It can be tied to any of the hour meters, H1
through H13. Press the right arrow. Press the up and
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ELECTRICAL
Access 1 2 3® Menus cnOWl'
E1.2 Last-1 through E1.16 Last-15 - These event Performance Access
codes follow the same pattem as E1.1, with each code
going further into the chronological history. Follow the Key the truck ON. Navigate to the Service Menu by
instructions given in E1.1 to view the event code, the pressing the down arrow. At the Service Menu, press
hour meter reading and the state of battery charge the right arrow to enter Level 2. Press the right arrow
when the event occurred. Press the left arrow to return again to enter the user code. Press the up and down
to E1. arrows to scroll to the first digit. Press the right arrow to
advance to the next digit. Continue these steps until the
E2 Accumulated History - Press the right arrow to last digit has been entered. Press enter to accept the
view the number of times a specific event has oc- user code. Press the down arrow to navigate to the
curred. Press the up and down arrows to scroll through Performance Menu, then press the right arrow. The
the events. message displayed will be P1 Setup P1. The setup
E3 Clear History - Press the right arrow to view the structure is identical for each of the three performance
clear logged event history menu. Press the up and levels. Press the up and down arrows to select the de-
down arrows to scroll through the submenus. sired performance level to be viewed or modified.
E3.1 Clear Chronological - Press the right arrow to P1 Setup P1 - Enter the parameters for the P1 level in
clear the chronological event code log history (E1). this submenu. Press the right arrow to view or modify
Press the up and down arrows to select "Sure? Nil (to the current P1 settings.
cancel) or "Sure? Y" (to clear the chronological event P2 Setup P2 - User Performance (F10) or User Code
code log history) and press enter to confirm. The menu (F11 ) features must be enabled to view or modify this
will return to E3.1. Press the down arrow to continue. menu item. Enter the parameters for the P2 level in this
E3.2 Clear All - Press the right arrow to clear all stored submenu. Press the right arrow to view or modify the
event history. Press the up and down arrows to select current P2 settings.
"Sure? Nil (to cancel) or "Sure? Y" (to clear all stored P3 Setup P3 - User Performance (F10) or User Code
event history) and press enter to confirm. The menu (F11) features must be enabled to view or modify this
will return to E3.2. Press the left arrow twice to return menu item. Enter the parameters for the P3 level in this
to the Events Menu. submenu. Press the right arrow to view or modify the
current P3 settings.
Performance PX.1 Travel Acceleration =_ - Press the right arrow
to view the travel acceleration setting. PX.1 determines
The Performance Menus determine the adjustable the acceleration rate (time for the truck to go from stop
ranges for several truck performance items. Verifica- to top speed). Range: 1 for the longest acceleration
tion of the proper features settings is recommended time to 9 for the shortest acceleration time. The default
prior to setting up the performance levels. setting is 9. Press the up and down arrow to change the
P1, P2 and P3 - Select from three performance levels value. Press enter to confirm the selection. The menu
when in the operator mode. These settings affect for- will return to PX.1. Press the down arrow to continue.
ward and reverse travel speed and acceleration rate. PX.2 Max Travel Speeds - Press the right arrow to
Refer to F10 User Performance in the Features Menu view or modify the travel speed setup submenus.
to enable or disable user performance. The operator These speeds indicate the maximum traction speed
will not be able to change the performance level if a that the truck is permitted to travel under specific con-
performance level is assigned to user code. ditions (Le., loaded or empty, forward or reverse). Val-
Settings for each performance level can be higher, ues are displayed in kilometers per hour if F2 = En-
lower, or the same as the setting under any other per- abled or in miles per hour if F2 = Disabled. Press the
formance level. For example, traction speeds and for- up and down arrows to select the desired submenu.
ward and reverse can be the same for all performance PX.2.1 Forward Travel, Empty Forks =_ kph/mph
levels, while the acceleration rate can be different for - Press the right arrow to view or modify the maximum
all performance levels. forks empty forward (forks first) traction speed. Press
the up and down arrows to select the desired speed.
Range: 1.61 km/h (1.0 mph) to the maximum allowable
according to the F3.1 and F3.3 settings. Press enter to
confirm the selection.
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ELECTRICAL
l!J\owra Access 1 2 3® Menus
PX.2.2 Reverse Travel, Empty Forks =_ kph/mph into deeper discharge prior to lift lockout, to 9, which
- Press the right arrow to view or modify the maximum disables the lift function earlier in the battery discharge
forks empty reverse (power unit first) traction speed. cycle. The default setting is 5. Press enter to confirm
Press the up and down arrows to select the desired the selection. The menu will return to P4. Press the
speed. Range: 1.61 km/h (1.0 mph) to the maximum down arrow to continue.
allowable according to the F3.1 and F3.3 settings.
Press enter to confirm the selection. NOTE
PX.2.3 Forward Travel, Loaded Forks kphlmph - = If this setting is set too low, an event code indicating
Press the right arrow to view or modify the maximum low battery voltage may result.
forks loaded (PX.3 weight) forward (forks first) traction
speed. Press the up and down arrows to select the de- P5 Plug =_ - Press the right arrow to view or modify
sired speed. Range: 1.61 km/h (1.0 mph) to the maxi- the plugging distance setting. This feature allows the
mum allowable according to the F3.1 and F3.3 set- operator to control the amount of plugging distance
tings. Press enter to confirm the selection. with the multi-task control handle position. The longest
plugging distance occurs with the multi-task control
PX.2.4 Reverse Travel, Loaded Forks =_ kphl handle near the neutral position (P5 is 1). The shortest
mph - Press the right arrow to view or modify the max- plugging distance occurs with the multi-task control
imum forks loaded (PX.3 weight) reverse (power unit handle is at full command position (P5 is 9). The default
first) traction speed. Press the up and down arrows to setting is 9. Press the up and down arrows to select the
select the desired speed. Range: 1.61 km/h (1.0 mph) desired value. Press enter to confirm the selection. The
to the maximum allowable according to the F3.1 and menu will return to P5. Press the down arrow to con-
F3.3 settings. Press enter to confirm the selection. The tinue.
menu will return to PX2. Press the down arrow to con-
tinue.
PX.3 Load Weight =_ kg/lb - This is the weight to
be used as loaded for the PX.2.3 and PX.2.4 travel
speed limit. Press the right arrow to view or modify the
load weight performance setting. Press the up and
down arrows to select the desired weight in kilograms
if F2 = Enabled or pounds if F2 = Disabled. The mini-
mum weight in P1 is 227 kg (500Ib), and 454 kg
(1000 Ib) in P2 and P3. F3.3 determines the maximum
weight. Press enter to confirm the selection. The menu
will return to PX.3. Press the down arrow to continue.
PX.4 Raise Speed =_ - Press the right arrow to view
or modify the raise speed. Press the up and down ar-
rows to select the desired speed. Range: 1 for the
slowest raise speed to 9 for the fastest raise speed.
Press enter to confirm the selection. The menu will re-
turn to PX.4. Press the down arrow to continue.
PX.5 Lower Speed =_ -
view or modify the lower speed. Press the up and down
arrows to select the desired speed. Range: 1 for the
slowest lower speed to 9 for the fastest lower speed.
Press enter to confirm the selection. The menu will re-
turn to PX.5. Press the down arrow to continue.
P4 BDI =_ - Press the right arrow to view or modify
the battery discharge indicator (801). Changing this
setting will affect the battery discharge lift lockout level,
which disables the lift circuit when the battery is dis-
charged. Press the up and down arrows to select the
desired value. Range: 1 which allows the battery to go
J
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ELECTRICAL
Access 1 2 3® Menus Cl\own
stiff
I Stiffe~t Plug
I
9 Stiff plug
Short Plugging _ 1 - -' -..:- Shortest Plugging
8 Distance Distance
7 I
Plug 6 f--
I I-
Setting 5 f--
(P5)
4
3=t Stiff Plug
t==
.-
2 Softest Plug
Longest Plugging - - - ~ Short Plugging
1 Distance Distance
-
soft
near neutral Traction Command full command ..

(Multi Task Position)
At neutral the distance truck coasts is controlled by

performance setting P12.
Figure 9016
P6 Drive Brake = _ • Press the right arrow to view or lection. The menu will return to P7. Press the down ar-
modify the traction motor brake's braking effort. Press row to continue.
the up and down arrows to select the desired value.
Range: 1 (least braking power) to 9 (greatest braking
P8 Coast =_ .
Press the right arrow to view or mod-
ify the coast setting. This feature controls the amount
power). The default setting is 7. Press enter to confirm
of regenerative braking current applied to the traction
the selection. The menu will return to P6. Press the
motor when the operator returns the multi-task control
handle to neutral while the truck is in motion. The
P7 Caster Brake = . This feature is available for higher the setting, the lower the amount of regenerative
48" power unit trucks only. Press the right arrow to view braking current applied to the traction motor. Range: 1
or modify the caster brake's braking effort. Press the up (least braking power) to 9 (greatest braking power).
and down arrows to select the desired value. Range: 1 The default setting is 9. Press enter to confirm the se-
(least braking power) to 9 (greatest braking power). lection. The menu will return to P8. Press the down ar-
The default setting is 6. Press enter to confirm the se- row to continue.
9 .... ....
.... ....
.... ....
.... ....
.... ....
Coast .... .... .... ....
Setting .... .... .... ....
.... .... .... ....
(P12) .... .... .... ....
.... .... .... ....
.... .... .... ....
.... .... .... .... .... ....
.... .... .... .... .... ....
.... .... .... .... .... ....
1 .... .... .... .... ....
shOrt .. .long
Coast Distance
Figure 9017
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ELECTRICAL
CROWl' Access 1 2 3® Menus
P9 Accy Speed < FLS =_ .

Press the right arrow to P12 Travel Speed> FLS =_ kph/mph· Press the
view or modify the accessory speed when the forks are right arrow to view or modify the maximum travel speed
below free lift. Press the up and down arrows to select when the forks are above free lift. Press the up and
the desired value. Range: 1 (least speed) to 9 (greatest down arrows to select the desired speed in kilometers
speed). The default setting is 9. Press enter to confirm per hour if F2 = Enabled or miles per hour if F2 = Dis-
the selection. The menu will return to P9. Press the abled. The maximum speed and default setting is
down arrow to continue. 4.83 km/h (3.0 mph). Press enter to confirm the selec-
tion. The menu will return to P12. Press the down arrow
P10 Accy Speed> FLS =_.
Press the right arrow
to continue.
to view or modify the accessory speed when the forks
are above free lift. Press the up and down arrows to P13 Travel Speed> 270 =_ kph/mph • Press the
select the desired value. Range: 1 (least speed) to 9 right arrow to view or modify the maximum travel speed
(greatest speed). The default setting is 7. Press enter when the forks are above 69 mm (270 in). Press the up
to confirm the selection. The menu will return to P10. and down arrows to select the desired speed in kilome-
Press the down arrow to continue. ters per hour if F2 = Enabled or miles per hour if F2 =
Disabled. The maximum speed and default setting is
P11 Accy Speed> 270 =_ .
2.41 km/h (1.5 mph). Press enter to confirm the selec-
view or modify the accessory speed when the forks are
tion. The menu will return to P13. Press the down arrow
above 69 mm (270 in). Press the up and down arrows
to continue.
to select the desired value. Range: 1 (least speed) to 9
(greatest speed). The default setting is 7. Press enter P14 Accy Ramp. Press the right arrow to view the
to confirm the selection. The menu will return to P11. accessory ramp submenus. These adjustments affect
Press the down arrow to continue. the ramp time of the accessory valve. Increasing this
setting numerically makes the accessory hydraulic
functions more reactive.
Accessory (Reach & Sideshift) Response
more 9
reactive More Reactive-..... - - - ~ -More Reactive
8 and Slow -- - - - -- - - - and Fast
7 -1- - - - - - - - - - - - - --I
Accessory 6 -1- - - - - - - - - - - - - I
Ramp 5 .
(P13)
less : ~.::::======~
,----------------
--=-,-
2 Less Reactive_==-=-
reactive 1 and ~___________
_~ _Less Reactive
and Fast
1
slow (P15) fast
(Accy Speed)
Figure 8832
P14.1 Accel =_ .Press the right arrow to view or is 7. Press enter to confirm the selection. The menu will
modify the accessory ramp acceleration. Press the up return to P14.2. Press the left arrow to return to P14.
and down arrows to select the desired value. Range: 1 Press the down arrow to continue.
(less reactive) to 9 (most reactive). The default setting
P15 Holst Ramp • Press the right arrow to view the
is 7. Press enter to confirm the selection. The menu will
hoist ramp submenus. These adjustments affect the
return to P14.1. Press the down arrow to continue.
ramp time of the hoist valve. Increasing this setting nu-
P14.2 Decel =_ .Press the right arrow to view or merically makes the hoist hydraulic functions more re-
modify the accessory ramp deceleration. Press the up active.
and down arrows to select the desired value. Range: 1
(less reactive) to 9 (most reactive). The default setting
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ELECTRICAL
P15.1 Raise Accel =_ - Press the right arrow to P15.4 Lower Decel =_ - Press the right arrow to
view or modify the raise ramp acceleration. Press the view or modify the lower ramp deceleration. Press the
up and down arrows to select the desired value. up and down arrows to select the desired value.
Range: 1 (less reactive) to 9 (most reactive). The de- Range: 1 (less reactive) to 9 (most reactive). The de-
fault setting is 7. Press enter to confirm the selection. fault setting is 6. Press enter to confirm the selection.
The menu will return to P15.1. Press the down arrow to The menu will return to P15.4. Press the left arrow to
continue. return to P15. Press the down arrow to continue.
P15.2 Raise Decel =_ - Press the right arrow to P16 Speed Cutback - This feature is available only if
view or modify the raise ramp deceleration. Press the F20.4 = Enabled. Speed cutback allows the truck's
up and down arrows to select the desired value. travel speed to be optimized based on fork position and
Range: 1 (less reactive) to 9 (most reactive). The de- load weight. Press the right arrow to enter the speed
fault setting is 7. Press enter to confirm the selection. cutback submenus.
The menu will return to P15.2. Press the down arrow to
Examples: Customer "A" requires that operators do not
continue.
travel with loads greater than 1361 kg (3000 Ib) above
P15.3 Lower Accel =_ - Press the right arrow to free lift height or loads greater than 1361 kg (30001b)
view or modify the lower ramp acceleration. Press the with forks extended at any height. Customer "B" limits
up and down arrows to select the desired value. operator travel speeds to 3.2 kph (2.0 mph) when trav-
Range: 1 (less reactive) to 9 (most reactive). The de- eling empty with forks elevated more than 203.2 mm
fault setting is 7. Press enter to confirm the selection. (8.0 in) from the floor. P16 settings would be as follows:
The menu will return to P15.3. Press the down arrow to
continue.
P16.1 P16.2
Customer P16.3 Weight P16.4 Cutback Speed
Trigger Type Fork Home
kg Ib km/h mph
"A" FLS Enabled > 1361 kg > 3000 0.0 0.0
"B" HTS1 @8in Disabled Empty Forks Empty Forks 3.2 2.0
P16.1 Height Triggers - Press the right arrow to enter confirm the selection. The menu will return to P16.2.
height triggers submenus. Press the down arrow to continue.
P16.1.1 Trigger Type =_ - Press the right arrow to P16.3 Weight = _ - Press the right arrow to view or
view or modify the trigger type used to initiate speed modify the weight value that initiates speed cutback.
cutback. Press the up and down arrows to select the Values are as follows: Always On, Empty Forks,
desired trigger. Choices are as follows: Height, FLS, >227 kg (500 Ib), >454 kg (1000 Ib), >680 kg (1500 Ib),
HGTRS2, HGTS1, HGTS2, and LMS. The default set- >907 kg (20001b), >1134 kg (25001b), >1361 kg
ting is Height. Press enter to confirm the selection. The (3000 Ib), >1588 kg (3500 Ib), >1814 kg (4000 Ib). The
menu will return to P16.1.1. Press the down arrow to default setting is Always On. Press enter to confirm the
continue. selection. The menu will return to P16.3. Press the
P16.1.2 Height =_ cmlin - This feature is available
only If P16.6.1 = Height. Press the right arrow. Press P16.4 Cutback Speed = _kphlmph - The speed
the up and down arrows to select the desired speed cutback range is adjustable from 0 kmh (0 mph) to the
cutback height in centimeters if F2 = Enabled or inches maximum forward speed as defined by the PX.2 set-
=
if F2 Disabled. Press enter to confirm the selection. ting. In addition, F20.4 must be enabled. Press the up
The menu will return to P16.1.2. Press the left arrow to and down arrows to adjust the cutback speed in kilo-
return to P16.1. Press the down arrow to continue. meters per hour if F2 = Disabled or miles per hour if F2
= Enabled. Press enter to confirm the selection. The
P16.2 Fork Home Trigger =_ - Press the right ar-
menu will return to P16.4. Press the left arrow to return
row to view or modify whether or not the fork home po-
to P16. Press the down arrow to continue.
sition setting initiates cutback. Press the up and down
arrows to select Disabled or Enabled. Press enter to
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P99 Load Factory Defaults· Press the right arrow to U1.3.2 Software PN = _ • Press the right arrow to
enter the load factory defaults submenus. Press the up view the ACCESS 2 software part number. Press the
and down arrows to select "Sure? Y" to load factory left arrow twice to return to U1.3. Press the down arrow
settings or "Sure? N" to continue without loading fac- to continue.
tory settings. Press enter to confirm the selection. The
U1.4 ACCESS 3 • Press the right arrow to view the
menu will return to P99. Press the left arrow to return to
module and software part numbers for the ACCESS 3
the Performance Menu.
traction control module.
U1.4.1 Module PN =_ • Press the right arrow to view
Utilities the ACCESS 3 module part number. Press the left ar-
Utilities are viewed only from Service Level 2 and Level row to return to U1.4.1. Press the down arrow to con-
3 menus and are not available in the operator message tinue.
mode. U1.4.2 Software PN =_ . Press the right arrow to
view the ACCESS 3 software part number. Press the
Utilities Access left arrow twice to return to U1.4. Press the down arrow
to continue.
Key the truck ON. Navigate to the Service Menu by
pressing the down arrow. At the Service Menu, press U1.5 ACCESS 4 • Press the right arrow to view the
the right arrow to enter Level 2. Press the right arrow module and software part numbers for the ACCESS 4
again to enter the user code. Press the up and down vehicle control module.
arrows to scroll to the first digit. Press the right arrow to U1.5.1 Module PN =_ . Press the right arrow to view
advance to the next digit. Continue these steps until the the ACCESS 4 module part number. Press the left ar-
last digit has been entered. Press enter to accept the row to return to U1.5.1. Press the down arrow to con-
user code. Press the down arrow to navigate to the Util- tinue.
ities Menu, then press the right arrow. The message
displayed will be U1 Part Numbers. U1.5.2 Software PN = _ • Press the right arrow to
view the ACCESS 4 software part number. Press the
U1 Part Numbers - Press the right arrow to view the left arrow twice to return to U1.5. Press the down arrow
module and software part numbers. Press the up and to continue.
U1.6 ACCESS 5 • Press the right arrow to view the
U1.1 Vehicle PN • Press the up and down arrows to module and software part numbers for the ACCESS 5
scroll through the submenus to view the truck software steer control module.
part number.
U1.6.1 Module PN =_ • Press the right arrow to view
U1.2 ACCESS 1 • Press the right arrow to view the the ACCESS 5 module part number. Press the left ar-
module and software part numbers for the ACCESS 1 row to return to U1.6.1. Press the down arrow to con-
display module. tinue.
U1.2.1 Module PN =_ • Press the right arrow to view U1.6.2 Software PN = _ • Press the right arrow to
the ACCESS 1 module part number. Press the left ar- view the ACCESS 5 software part number. Press the
row to retum to U1.2.1. Press the down arrow to con- left arrow twice to return to U1.6. Press the down arrow
tinue. to continue.
U1.2.2 Software PN = _ • Press the right arrow to U2 Tow Mode • Press the right arrow to activate the
view the ACCESS 1 software part number. Press the truck tow mode. Press the up and down arrows to se-
left arrow twice to return to U1.2. Press the down arrow lect Activate Two Mode? "V" to release the brakes for
to continue. towing. Press enter to confirm the selection. In order for
U1.3 ACCESS 2 • Press the right arrow to view the the brakes to be released, the operator must remain on
module and software part numbers for the ACCESS 2 the truck with both feet in place to activate the operator
hydraulic control module. presence switches. If either foot is removed, the brakes
will be applied. Refer to the Control of Hazardous En-
U1.3.1 Module PN =_ . Press the right arrow to view ergy section for information on proper towing proce-
the ACCESS 2 module part number. Press the left ar- dures. Key the truck OFF and back ON to remove tow
row to retum to U1.3.1. Press the down arrow to con- mode.
tinue.
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ELECTRICAL
Access 1 2 3® Menus CJ\OW~
U3 Truck Lockout· Press the right arrow to view the
truck lockout submenus.
U3.1 Truck Lockout =_ . Press the right arrow.
Press the up and down arrows to select Disabled or
Enabled. Press enter to confirm the selection. The
menu will retum to U3. Press the left arrow to return to
the Utilities Menu.
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ELECTRICAL
Cf\owr. Capacity Data Monitor
Capacity Data Monitor • The truck's Capacity Plate provides information

concerning truck capacities.
The Capacity Data Monitor (COM) requires ACCESS 1
to be an Enhanced Display with COM. Further, it re-
quires a truck equipped with a hydraulic pressure
transducer (LS), Height Sensor (ECR2) and Capacity
Plate information correctly entered in the capacity (F6)
portion of the Features Menu (Refer to ACCESS 123®
Menus section).
• COM, located on ACCESS 1, provides the visual

indicators to the operator. Refer to Figure 21848.
• LS, located in the main manifold block, provides a

signal to the ACCESS 123 system to determine
Capacity Data Monitor (COM)
load weight.
Figure 21860
• ECR2 provides information to the ACCESS 123
system to determine actual lift height. Refer to
Height Sensor section for further information.
1 00b 3
Ob/ / /4
OOb~
J/5
Message Display
Figure 21848
1 Maximum Lift Height for Load 4 Forks Above Collapsed Height

2 Corresponds to Data Plate Icons 5 Forks Below Collapsed Height
3 Actual Fork Height 6 Operator Alert
7 Alarm (sounding)
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ELECTRICAL
Capacity Data Monitor CAOWI'
Data input from the monitoring devices are processed
by the ACCESS 123 system and the CDM displays the
results. Displays observed for various speed, load and
height conditions are shown as follows.
(~-)
Figure 21851
• Fork height below collapsed height
• Load weight and load center limits recommended

Figure 21849 lift height
• Power up self test
• Audible alarm continuous (self test is approxi-

mately 2 seconds)
Figure 21852
• Fork height above collapsed height
• Load weight and load center allows lift to full height

Figure 21850
• Traction speed less than creep speed 0.9 km/h
• Fork height below collapsed height (1.5 mph)
• Load weight and load center allows lift to full height
M4.3-1457-201 Crown 2009 PF17590-2
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ELECTRICAL
CAomr. Capacity Data Monitor
Db:,
o oOb:,
oOb:, oOb:,
OOb:, OOb:,
OO}' I I.; 00 f II.;
ct: tl:
( ()
) t ( ~ ) t
Figure 21855
Figure 21853
• Fork height above collapsed height • Fork height above collapsed height
• Load weight and load center allows lift to full height • Load weight and load center limits recommended
lift height
• Traction speed equal to or greater than creep
speed 0.9 km/h (1.5 mph)
Ob:,
o
oOb:,
OOb:,
OOb:,
~
( ()
CHECK LOAD ) t
Figure 21854
Figure 21856
• Fork height below collapsed height
• Load weight and load center limits recommended
lift height • Over capacity load for truck, based on 610 mm
(24 in) load center
(1.5 mph)
Crown 2009 PF17590-3 M4.3-1457-202
307
ELECTRICAL
Capacity Data Monitor CJ\OWI'
°Ob,
oOb,
OOb,
OOb,
tk
( 0
,-_ _C_H_E_C_K_L_OA_D_~
)
Figure 21857
• Over capacity load for truck, based on 610 mm

(24 in) load center

(1.5 mph)
°Ob,
OOt'I!;
./ "-
OO~
OOb,
tk
(,-_C_H_"~_CK_L_O_A_D_~)
Figure 21858
• Over capacity load for truck, based on 610 mm

(24 in) load center

M4.3-1457-203 Crown 2009 PF17590-4
308
ELECTRICAL
CJ\OWI' Camera Setup
Camera Setup 2. Auto (R)LCD Backlight Control/Day/Night Settings

Press this button to switch between the ABC mode, the
The camera system consists of a 12 Vdc camera mod-
0 (R)LCD backlight day and the (R)LCD backlight night
ule with a heater capable of operating in -40 - 85 C
settings. The ABC mode controls the backlight settings
(-40 - 1850 F) temperatures, as well as a 177.8 mm
between the minimum settings (which are adjustable,
(7 in) color LCD monitor. This section describes basic
see the service menu) and 100%, depending on the
monitor operation, navigation and standard setup pro-
amount of available ambient light. The day and night
cedures.
modes' brightness settings can be manually adjusted
by pressing the minus (6) or plus (7) buttons (the set-
Keyboard Operation tings will be saved). This setting is not camera specific
and will therefore function on all cameras.
3. Contrast
Press the contrast button once to enter the contrast ad-
justment mode. Use the minus (6) and plus (7) buttons
Buttons 1 2 3 4 5 6 1 8
to select the image contrast.
4. Brightness
Button No. 1= Camera selection
Button N.o. 2 :: Auto (R)LCD Backlight Press the brightness button once to enter the bright-
ness adjustment mode. Use the minus (6) and plus (7)
ControllDaylNight settings buttons to select the image brightness.
Button No.3 = Contrast 3. and 4. Saturation
Button No.4 =Brightness
Press the contrast button (3) and the brightness button
Button No.5 = Option (4) at the same time to enter the saturation adjustment
Button NO.6:: Selection/setting - mode. Use the minus (6) and plus (7) buttons to select
Button NO.7:: Selection/setting + the image saturation.
Button No.8 = Enter NOTE

Figure 22802
The following buttons are used to scroll through the
The keyboard on the monitor consists of eight buttons various setup menus.
that facilitate navigation through the various setup
5. Option
menus. The following is a description of each button
and its function. Press the option button to return to the previous menu.
1. Camera Selection 6. Selection/Setting-
Press the camera selection button once. The camera Press the selection/setting - button to go to the next
LED will blink, indicating the manual camera override is menu option.
active. Use the minus (6) and plus (7) buttons to select
7. Selection/Setting +
the camera. You can select a different camera by
switching off this function by pressing the plus and mi- Press the selection/setting + button to go to the previ-
nus buttons. ous menu option.
8. Enter
Press the enter button to select or activate the high-
lighted option.
Crown 2009 PF17774-1 M4.3-1457-500
309
ELECTRICAL
Camera Setup l!J\OWI'
Standby Mode Horizontal Bars
The horizontal bars should be turned on and should be
NOTE adjusted, which can be accomplished by performing
The blue wire should not be connected to +BV during the following procedures.
this procedure. Otherwise, it will not be possible to en- 1. Open the service menu. To open the service
gage standby. This can be accomplished by raising the menu, press the minus (6), plus (7) and camera
mast above staging. selection buttons (1) at the same time. Refer to Fig-
The monitor should already come in standby mode. If it ure 22804.
is not, perform the following procedures to put the mon-
itor in standby mode.
1. When the monitor is switched ON, press the enter
button (8) on the keypad. This will bring up a menu
where standby is already highlighted. Refer to Fig-
ure 22803.
Figure 22804
2. Use the option (5), minus (6), plus (7) and enter (8)
buttons to scroll through the service menu.
3. Press the enter button (8) to activate the camera
settings menu. When entering the menu, use the
minus (6) and plus (7) buttons to select the camera
Figure 22803 (C1) to configure and press the enter (8) button.
The yellow cursor will jump to the list of items. Use
NOTE the minus and plus buttons to select the item to ad-
If the standby menu cannot be toggled, ensure the just, and press the enter button. If the selection op-
forks are above staging. If the standby menu still can- tion is ON/OFF, it will toggle between on (repre-
not be toggled, go into the keyboard menu and ensure sented by a large dot) and off (represented by a
it is not locked out (represented by a large dot instead small dot). If the option is a numeric value, it is pos-
of a small one). sible to change the value with the minus and plus
buttons. Press the enter button to store the new
2. Press the enter button (8) a second time and the setting. Refer to Figure 22805.
monitor will go into standby. A black screen will
now be shown. When the blue wire is connected to
BNEG (above staging), the monitor will be acti-
vated and the camera picture will be shown on the
screen. When the blue wire is either disconnected
(open) or connected to +BV (below staging), the
monitor will go back to standby and show a black
screen again.
Figure 22805
M4.3-1457-501 Crown 2009 PF17n4-2
310
ELECTRICAL
CAOW" Camera Setup
4. Scroll to the horizontal marker option. Enable this

option to switch the marker on. The marker is dis-
played as a horizontal green line.
Menu
· Do not set.
5. Scroll to the marker position option. This option ad-

Camera Switch • Set this option so camera
selection cannot be toggled.
justs the horizontal position of the marker. 0 is the
top of the screen, 100 is the bottom of the screen. Camera Setting • Set this option so brightness
Adjust the marker with the minus (6) and plus (7) cannot be changed, etc.
buttons until it hits the tip of the forks with the forks
extended and level. Press the option button (5) to
Standby • Set this option so the operator
cannot get the camera out of
return to the previous menu. standby below staging, thus
having the camera on.
Locking the Keyboard
1. In the camera settings menu, scroll to the system Language and Default Settings
settings menu and press the enter button (8).
When entering the system settings menu, use the Language
minus (6) and plus (7) buttons to select the key-
board to configure and press the enter button. The This option under the system setting menu opens the
yellow cursor will jump to the list of items. language selection menu. The selected language will
Scroll down to keyboard and press the enter but- be used for all OSD (on screen display) menus. The
ton. This will bring up the keyboard menu. Press OSD menus are available in English, Dutch, German,
the enter button to get into the keyboard lock French, Czech, Hungarian, Italian, Polish, Portuguese,
menu. Refer to Figure 22806. Spanish, Turkish, Swedish, Finnish, Danish and Nor-
wegian. Refer to Figure 22807.
Figure 22806
Figure 22807
2. In the keyboard lock menu, the following options
can be toggled ON (represented by a large dot)
and OFF (represented by a small dot).
Crown 2009 PFlm4-3 M4.3-1457-502
311
---- -------------------,
ELECTRICAL
Camera Setup
NOTE
All user settings will be lost when the factory defaults
are reset.
Default Settings
This option under the system setting menu opens the
default settings menu. If the restore defaults option is
selected, the factory settings will be reset. The restore
defaults option can be used to get the service techni-
cian back to a known state. Refer to Figure 22808.
Figure 22808
M4.3-1457-503 Crown 2009 PF1m4-4
312
ELECTRICAL
CJ\OWI' AC Traction Drive
AC Traction Drive Each phase of the output is 120 degrees out of phase
as shown.
o 120 240 360
Figure 21863
Each phase is applied to separate windings in the mo-

tor stator, resulting in the rotating magnetic field which
causes rotation of the rotor. ACCESS 3 manages the
speed regulation and various system inputs and out-
puts.
Inherent to the design of AC motors is generated volt-
age when using motor braking. Without the need for
additional contactors or resistance, this voltage is ap-
Figure 21861
plied to the battery to extend the usable charge avail-
able.
Basics of System Operation
Motor torque is variable, making closed loop speed
The Traction Control Module (ACCESS 3) applies a regulation possible. This maintains vehicle speed,
variable frequency current and pulse width modulated within the limits of the motor and drive system, as de-
three phase AC voltage to the motor stator to generate termined by the speed request. The Traction Encoder
a rotating magnetic field. The rotating magnetic field in- (ECR1) mounted on top of the Traction Motor (M1) pro-
duces an opposing magnetic field in the rotor which vides a feedback signal to ACCESS 3 for control of the
causes the rotor to turn. Using this technology elimi- AC power convertor. Speed feedback is also provided
nates the need for motor brushes as well as forward to ACCES$ 3 for speed regulation.
and reversing contactors and the associated mainte-
nance. ACCESS 3 contains the power circuitry for con- The ACCESS 123® system instantly analyzes informa-
verting the DC input to three phase AC output and con- tion received from ECR1, RPS1 and the accelerometer
trols the Pulse Width Modulation (PWM) of the voltage in ACCESS 4 to reduce tire spin and provide maximum
and the frequency of the resultant current waveform. available traction.
The resulting output is shown (single phase shown).
Control Circuit Operation
1- .. 4 The control circuitry of the ACCESS 3 module is soft-
2 / \ t ware driven with the parameters set for the system in

the Features and Performance menus. Refer to
3~ V ACCESS 123 Menus section of manual for further set

up information.
ov
Figure 21862
1 Positive Battery Volts

2 1/2 of Battery Volts
3 Current Wavefonn
4 Voltage Modulation
Crown 2009 PF17694-1 M4.3-1457-600
313
-------------------_._----------------------------------
ELECTRICAL
AC Traction Drive CRown
Power Circuit Operation cal inputs occur on the U, V and W inputs spaced 120
degrees aparat for the three phase output required.
ACCESS 3 provides signals to the inputs of the power The upper bank of transistors produces the positive
transistors to switch battery voltage on and off to pro- pulses and the lower bank of transistors produce the
vide a pulse width modulated voltage output and con- negative pulses.
sequently the sinusoidal current waveform. The identi-
ACCESS 3 (TCM)
_____- - ~--.-...--+___e B+
I
ACCESS 4 Vector
-
-
(VCM) Generatore+
_----f-----+___'
Speed
~ ~
and
Regulator
&
10
Can Bus Current
Regulator (Gil (iiI i]l zr
Module
.+--~~I___t_--e-~-t-e-_____t
l---t--- B-
4 ,e+ -------t-----+---J
I
~ 4 4
Phase U Phase V PhaseW
Figure 21864
When the motor is acting as a generator. the combina-

tion of diodes and transistors convert the three phase
AC current to DC current that returns energy to the bat-
tery.
M4.3-1457-601 Crown 2009 PF17694-2
314
ELECTRICAL
l!J\OWI' Contactor
Contactor Contacts
110613-003 and 110613-008

• In normal operation, the contacts will become
blackened, discolored, and roughened. This will
not interfere with proper operation and cleaning is
not necessary.
• The contacts should be replaced before the silver

contact facing is completely eroded through to the
backing material. The silver contact facing may
transfer to either the moving or stationary contact
and cause buildup on one contact. This can be ex-
pected under certain conditions and does not re-
quire contact dressing or filing.
• It is recommended that contacts always be re-

placed in mating pairs.
Coil
The coil is nominally rated at 24 ohms. To check the
coil:
• Remove all electrical connections.

Figure 10554-01
• Resistance reading of the coil should be between
The purpose of this information is to instruct the techni- 16 and 30 ohms.
cian on proper care and maintenance to obtain satis-
factory service from these devices. Crown has tested
• If reading does not fall within the limits, replace coil.
and applied these contactors according to the require-
ments of our vehicle. No modifications or changes
should be made in the layout, physical arrangement or
electrical connections without permission from Crown.
it CAUTION
Before any inspection, adjustments, servicing, parts re-
placement or any other act is performed requiring
physical contact with the electrical working compo-
nents or wiring of these contactors, disconnect battery,
raise drive wheels clear of floor and place blocks under
truck frame.
Inspection
The following information is intended to assist during
periods of normal maintenance and to provide checks
for maintaining adjustments. As these devices are
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.
Crown 2009 PF17696-1 M4.4-1457-001
315
ELECTRIGAL
Contactor l!J\OWf'
Component Replacement Contact Replacement
Refer to Figure 21867 and the appropriate parts break- 1. Remove electrical connections to contacts (coils
down in Electrical Parts Section of manual when re- do not have to be disconnected for this procedure).
placing components.
2. Remove two screws (5) from top of contact and re-
move contact top cover (6).
1-@ 3. Remove and replace contacts (contacts always

should be replaced in pairs).
I
2-~ 4. Place contact assembly on coils and install top
3-~ cover and secure with two screws removed in step

2.
4--<@l 5. Connect electrical wiring removed in step 1.
.....
Coil Replacement
--6 1. Disconnect all electrical wiring.
2. Remove four mounting screws that secure contac-
tor to mounting bracket and remove contactor from
truck.
3. Remove two screws (5) and separate contact as-
sembly from coil assembly.
4. Select replacement coil and transfer plunger (9)
from existing coil to replacement coil.
5. Reassemble contact assembly to coil and secure
with two screws (5).
6. Mount contactor on truck and reconnect all electri-
10--- cal wiring removed in step 1.
Torque
Main terminal nuts (1) should be torqued to 8 - 9.5 Nm
(5.9 - 7.0 ft Ib).
Figure 21867
M4.4-1457-002 Crown 2009 PF17696-2
316
ELECTRICAL
l!J\OWr. Multi-Task Control Handle
Multi-Task Control Handle Task Control Handle. The handle harness contains the
sideshift switch (SSS), tilt back switch (TBS), tilt down
The truck utilizes a Multi-Task Control Handle that elim- switch (TDS) and the horn switch (HNS).
inates multiple hydraulic levers. The Multi-Task Control
Handle gives the operator complete control of travel
speed, direction, lift, lower, reach, side shift, tilt and Lubrication
hom functions. Refer to Figure 21868-01.
The Multi-Task Control Handle is located at the top and Remove the Multi-Task Control Handle cover (1) and
in the center of the power unit. The console must be the truck console. Tilt the handle down and lubricate
removed to perform maintenance on the Multi-Task the base (2) as shown by the arrow with clear silicone
Control Handle. Four micro switches, two optic sen- grease. Refer to Planned Maintenance for lubrication
sors, and three potentiometers are used in the Multi- type and frequency.
",," " sss

-6
"-
)
"
TBS ,- I
TDS~ . .1 1 _ 1
6-~~ ~ ,
6 v,, -~~~OT3 j,\
HNS 4-~$ci e"r~
(0) To",,,,, 2.82 ± 0.28 Nm (25 ± 2.5 Ie Ib) I~I
Figure 21868-01
Crown 2009 PF1743D-l Rev. 1/10 M4.5-1457-001

01 Rev. 1/10
317
ELECTRICAL
Multi-Task Control Handle CJ\OWI'
Handle Harness Replacement 6. Remove the cable ties as required.
7. Note the connection position of any wires to be dis-
Refer to Figure 21868-01.
connected. Use the appropriate extraction tool to
The handle harness includes HNS, SSS, TBS and
remove the wires from the connectors as needed
TDS.
to remove the potentiometer harness.
1. Lower forks completely and turn the key switch
8. Replace POT1 or POT2 as needed. Refer to Fig-
OFF.
ure 21869. Route the replacement wiring as
2. Chock the wheels and disconnect the battery. Re- shown. Secure, as indicated, with cable ties.
fer to Control of Hazardous Energy.
9. Insert the wires into the connectors as removed in
3. Lockout rragout truck as described in Control of Step 7.
Hazardous Energy.
10. Reassemble the handle to the support. Torque the
4. Remove the console and Multi-Task Control Han- screws {7} removed in Step 5 to 2.82 ± 0.28 Nm
dle cover {1}. {25 ± 2.5 in Ib}.
5. Remove the four screws {3} to remove the lower 11. Remove the wheel chocks and connect the bat-
handle {4}. tery.
6. Remove the cable ties from dust cover {5} as re- 12. Check the operation of the Multi-Task Control Han-
quired. dle. If operating correctly, replace console and
cover
7. Note the connection position of any wires to be dis-
connected. Use the appropriate extraction tool to
remove the wires from the connectors as needed
to remove the handle harness {6}.
8. Route the replacement handle harness through the
handle and dust cover as shown. Secure as indi-
cated with cable ties. Refer to Figure 21869.
9. Insert the wires into the connectors as removed in
Step 7.
10. Assemble and secure the lower handle.
11. Remove the wheel chocks and connect the bat-
tery.
12. Check the operation of the Multi-Task Control Han-
dle. If operating correctly, replace console and
cover.
POT1 or POT2 Replacement

Refer to Figure 21868-01.
1. Lower forks completely and turn the key switch
OFF.
2. Chock the wheels and disconnect the battery. Re-
fer to Control of Hazardous Energy.
3. LockoutfTagout truck as described in Control of
Hazardous Energy.
4. Remove the console and the Multi-Task Control
Handle cover {1}.
5. Remove the four screws {7}.
M4.5-1457-002 Crown 2009 PF1743G-2 Rev. 1/10
01 Rev. 1/10
318
ELECTRICAL
CAOWI' Multi-Task Control Handle
Original Handle Harness Routing Shorter Handle Harness Routing
POT1, POT2, FS, RS Wire Routing
Position pon with terminal side toward upper handle

2 Cable Tie
3 3 mm (0.12 in) Diameter Hole
4 POT1/POT2 Wire Hamess
5 RS - Black Wire (Note: Keep wire between board and
support)
6 FS - Yellow Wire (Note: Keep wire between board and
support)
Figure 21869
Crown 2009 PF1743G-3 Rev. 1/10 M4.5-1457-003

01 Rev. 1110
319
CJ\OWI'
Notes:
320
ELECTRICAL
mow" Battery
Battery Safety Rules

The care and maintenance of the battery is very impor- • Wear protective clothing, such as, rubber apron,
tant to obtain efficient truck operation and maximum gloves, boots and goggles when performing any
battery life. maintenance on batteries. Do not allow electrolyte
to come in contact with eyes, skin, clothing or floor.
it CAUTION If electrolyte comes in contact with eyes, flush im-

mediately and thoroughly with clean water. Obtain
Gases produced by a battery can be explosive. Do not medical attention immediately. Should electrolyte
smoke, use an open flame, create an arc or sparks in be spilled on skin, rinse promptly with clean water
the vicinity of the battery. Ventilate an enclosed area and wash with soap. A baking soda solution (one
well when charging. pound to one gallon of water) will neutralize acid
Batteries contain sulfuric acid which may cause severe spilled on clothing, floor or any other surface. Apply
bums. Avoid contact with eyes, skin or clothing. In case solution until bubbling stops and rinse with clean
of contact, flush immediately and thoroughly with clean water.
water. Obtain medical attention when eyes are af-
fected. A baking soda solution (one pound to one gal- • Keep vent plugs firmly in place at all times except
Ion ofwater) applied to spilled acid until bubbling stops, when adding water or taking hydrometer readings.
neutralizes the acid for safe handling and disposal.
• Do not bring any type of flame, spark, etc., near the
Leakage voltage from battery terminals to battery case battery. Gas formed while the battery is charging,
can cause misleading trouble symptoms with the truck is highly explosive. This gas remains in the cells
electrical system. Since components of the truck elec- long after charging has stopped.
trical system are insulated from truck frame, leakage
voltage will not normally affect truck operation unless a • Do not lay metallic or conductive objects on bat-
short circuit or breakdown of circuit wire insulation to tery. Arcing will result.
truck frame occurs.
• Do not allow dirt, cleaning solution or other foreign
A voltage check from battery connector terminal to bat- material to enter cells. Impurities in electrolyte has
tery case should indicate near zero volts. Typically, a neutralizing effect reducing available charge.
however, the sum of the voltages at both terminals will
equal battery volts. This leakage voltage will discharge • If battery repair is planned, follow the battery man-
the battery. As battery cleanliness deteriorates, the ufacturer's instructions conceming repair practices
usable charge of the battery decreases due to this self and procedures.
discharge.
Although a leakage voltage reading of zero volts may Checking Battery
not be possible, a cleaner battery will have more
usable charge for truck operation and not affect opera- Battery electrolyte level should be checked before
tion of electronic devices on the unit. each charge of the battery. The level should be main-
tained at 13 mm (0.5 in) above plates or just below the
lower lip of the filler hole at all times. If low, add distilled
water or approved local supply (consult battery manu-
facturer) at the end of a charge cycle. Do not overfill.
For maximum battery life, specific gravity readings
should be taken daily on a pilot cell and recorded. 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 before a reliable
reading can be taken. Normal full charged specific
gravity should be between 1.265 and 1.285.
Crown 2001 PF1307!>-1 Rev. 5/09 M4.6-1452-001

02 Rev. 5/09
321
ELECTRICAL
Battery CAOWI'
Battery Care Charging Battery
Your Crown truck is powered by an electrical storage Charging requirements will vary depending on use of
battery. Here are a few suggestions which will help you truck. A battery with a specific gravity of 1.160 or less
give the battery proper care. should be recharged. In some applications more than
one battery is required to provide ample power to the
The battery on your Narrow Aisle Stand-up Rider is
unit during the service period.
located in front of the operator's compartment.
1. Charge the battery only in areas designated for
that use. & CAUTION
2. Make certain the charger being used matches the Never smoke or bring flame near the battery. Gas
voltage and amperage of the truck battery. This formed during charging is highly explosive and can
voltage is listed on the truck data plate. cause serious injury.
3. Before disconnecting or connecting batteries to a Consult the charger manufacturer's manual covering
charger, make sure the charger is OFF. If an at- your charger for hints on operation and maintenance.
tempt is made to do this while the charger is ON, Some of the basic rules are as follows:
serious injury to you, the battery and charger could Placing battery on charge:
result.
4. Before charging, make sure the battery cells con-
• Park truck at charging station with forks lowered
tain the correct amount of water. Charging batter- and key removed.
ies with a low water level might result in damage to • Make certain charger control is in the off position.
the cells. When checking water levels, never use
any type of open flame. Battery fumes are explo- • Connect battery to charger and make certain con-
sive. nectors are mated completely.
5. Before connecting the battery cable to the truck's
receptacle, make sure the key switch is OFF and
• Set timer for specified time. Set for Normal (Daily
all controls are in the OFF position and the brakes Charge, except one night a week when the Equal-
are locked. The battery cable must be fully con- ize [Weekend] Charge should be used.)
nected before the truck is used. If the plug is not • Check ammeter to make certain it shows charge.
making good contact, heat will weld the two parts
of the battery connector together, making it difficult Removing battery from charge:
to remove and necessary to replace.
• Make certain charger is turned off.
6. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal con- • Unplug the connector, using both hands with a
tact is essential not only for operation, but also for straight pulling motion.
proper charging of the battery.
• Hang up the charger cable to prevent damage to
7. The charging requirements will vary depending on
the cable. (Broken connectors can cause poor con-
the use of the truck. The battery should be given an
nections and connector failures).
equalizing charge on a weekly basis. This charge
should normally be an additional three hours at the • Make daily battery checks, add water as needed.
finish rate.
8. Refer to charger manufacturer's instruction for
• Connect battery to truck. Make certain connectors
specific charging procedures. are mated completely.
9. Make certain battery used meets weight and size

requirements of truck (refer to data plate). NEVER
operate truck with an undersized battery.
M4.6-1452-002 Crown 2001 PF13075-2 Rev. 5/09
02 Rev. 5/09
322
ELECTRICAL
CJ\OWrl Battery
Battery Removal & Installation

(S Series Truck Shown)
Battery Removal
& CAUTION
Do not allow any metallic object to come in contact with
the top of the battery cells. This may cause a short cir-
cuit when removing, installing or transporting the bat-
tery. Use an insulator (such as plywood) to cover the
top of the battery before and during removal and instal-
lation.
1. 1. Turn key switch OFF.
2. Disconnect the battery.
Figure 16818-01
4. Position the battery roller stand next to the truck.

Align the stand with the battery. Battery roller stand
should be the same height as the truck's battery
compartment rollers and as long as or longer than
the battery.
Figure 16817-01
3. Lift and remove the battery retainer (one side only).
Figure 16819-01
Crown 2001 PFl3075-3 Rev. 5/09 M4.6-1452-003

02 Rev. 5/09
323
ELECTRICAL
Battery CROWl'
5. Roll battery onto stand. Use approved spreader bar
(1) to lift and move battery to charging area.
Figure 16821-01
3. Position the battery roller stand next to the truck.

Align the stand with the battery compartment. The
battery roller stand should be the same height as
the truck's battery compartment rollers and as long
as or longer than the battery.
Figure 16820-01
Battery Installation
& CAUTION
Do not allow any metallic object to come in contact with
the top of the battery cells. This may cause a short cir-
cuit when removing, installing or transporting the bat-
tery. Use an insulator (such as plywood) to cover the
top of the battery before and during removal and instal-
lation.
1. Be sure the key switch is turned OFF.
2. Remove the battery retainer (one side only).
Figure 16822-01
M4.6-1452-004 Crown 2001 PF13075-4 Rev. 5/09
02 Rev. 5/09
324
ELECTRICAL
mown Battery
4. Using an approved spreader bar (1), move the bat- 5. Remove the roller stand and install the battery re-
tery onto the roller stand and push the battery into tainer.
the battery compartment.
Figure 16824-01
6. Connect the battery.

7. Turn the key switch ON and check truck operation.
& CAUTION
Figure 16823-01 Make certain the same battery or battery of equal
weight is loaded into the truck for truck stability. See
truck's data plate for minimum battery weight.
Battery Cleaning
Always keep vent plugs tightly in place when cleaning
the battery. When properly watered and charged, the
battery will remain clean and dry. All that is necessary
is to brush or blow off any dust or dirt which may accu-
mulate on them. However, if electrolyte is spilled or
overflows from a cell, it should be neutralized with a
solution of baking soda and water (one pound soda to
a gallon of water). To do this, remove the battery from
the truck and clean with the solution of soda and water,
brushing the soda solution beneath the connectors and
removing the grime from the covers. Then rinse the
battery with cool water from a low pressure supply to
remove the soda and loosened dirt. If batteries stay wet
consistently, they may be either overcharge or over-
filled. This condition should be investigated and cor-
rected.
Crown 2001 PF13075-5 Rev. 5109 M4.6-1452-005

02 Rev. 5/09
325
r---------------- - - - - - - - - - ------ -----------------------
ELECTRICAL
Battery l!J\OW"
Troubleshooting
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 the normal char-
ger finish rate also indicate battery condition. New bat-
teries will have cell voltages ranging from 2.55 V to
2.65 V. Older batteries may however range from 2.45 V
to 2.55 V. These readings still indicate a battery in good
condition.
A variation of 0.20 V may be normal if certain cells are
exposed to higher temperatures during discharge. Volt-
age differences that cannot be attributed to battery age
or operating conditions indicate a weak cell(s) and
maintenance is required.
LL CAUTION
Only qualified and experienced personnel should per-
form maintenance and repair on batteries.
M4.6-1452-006 Crown 2001 PF13075-6 Rev. 5109
02 Rev. 5/09
326
ELECTRICAL
CJ\owr. Motors
Motors
Traction Motor
This truck is equipped with a 3-phase AC Traction
Motor (M1). M1 is operated in closed loop control by
ACCESS 3. M1 is monitored by a ball bearing sensor
(ECR1) that communicates both motor speed and
direction to ACCESS 3. Feedback from this encoder is
also used with the truck's OnTracTM Anti-5lip Traction
Control system. ACCESS 3 supplies +12V and BNEG
to ECR1. M1 is located behind the power unit door. M2
Refer to charts for further motor specifications.
Lift Pump Motor· AC Hydraulics

Trucks equipped with AC Hydraulics contain a 3-phase
M1 M4
AC Lift Pump Motor (M2), located behind M1. M2
AC Hydraulics
drives the hydraulic lift pump and is controlled by
ACCESS 2. M2 data is measured by a ball bearing
sensor (ECR6) secured by a bearing retainer at the top
of M2. ACCESS 2 supplies ECR6 with +12V and
BNEG and receives feedback from ECR6. Refer to
Charts for further motor specifications. M3
Lift Pump Motor· DC Hydraulics
24 V Trucks
24 V Trucks with DC Hydraulics contain one DC Lift
Pump Motor (M2), located behind M1.
M2
36 V Trucks
36 V Trucks with DC Hydraulics contain two DC Lift
Pump Motors (M2 and M3), located behind M1 with M2
mounted closest to the compartment opening. M2
drives Pump 1 which provides oil flow for steering, M1 M4
accessory, and hoist functions. M3 is located in the rear DC Hydraulics
of the compartment. It drives Pump 2 which provides
additional oil flow for raise. Figure 21878
M2 is a variable speed motor operated in closed loop

control by ACCESS 2. ECR3, an internal ball bearing
sensor, communicates M2 speed to ACCESS 2.
ACCESS 2 supplies ECR3 with +12V and BNEG and
receives feedback from ECR3. When the P2 tips close,
M3 runs at a fixed speed. P2 is controlled by
ACCESS 2.
Crown 2009 PF17431-1 M4.7-1457-001
327
ELECTRICAL
Motors CJ\OWr\
Chart 1 - AC Motors
Traction Traction AC Lift AC Lift

Motor (M1) (M1) Pump Pump
Function 36 V Trucks 24 V Trucks (M2) EE
(M2)
Part Number 021257 021279 021343 021281

Voltage 36Vac 24 Vac 36Vac 36V
4.8kW 20.54 kW 17.88 kW
Rated Output kW (HP) 3.9kW
(6.43 HP) (27.53 HP) (23.97 HP)
RPM (no load) 1690 2200 2611 2701
Frequency 58.3 Hz 78 Hz 91.7 Hz 94.1 Hz
Direction of Rotation
CCW CCW CCW CCW
(when facing drive end)
Associated
ECR1 ECR1 ECR6 ECR6
Sensors
M4.7-1457-002 Crown 2009 PF17431-2
328
ELECTRICAL
CJ\OWrl Motors
Chart 2- DC Motors
DC Lift Pump DC Lift Pump

Motor Function (M2) (M3) (M2)
36 V Trucks 24 V Trucks
Part Number 021293 021297

7.9kW 4.8kW
Rated Output kW (HP)
(10.59 HP) (6.43 HP)
Direction of Rotation
CCW CCW
(when facing drive end)
Brushes
Number Brush Holders 4 4
Number Brushes 4 4
Brush Size 16x32 mm(0.63x1.24 in) 16x32 mm(O.63x1.24 in)
New Brush Length 33 mm (1.30 in) 33 mm (1.30 in)
Minimum Brush Length (replace) 16 mm (0.62 in) 16 mm (0.62 in)
Spring Tension (New) 1360 gm (48 oz) 1360 gm (48 oz)
Spring Tension (Worn) 907 gm (32 oz) 907 gm (32 oz)
Commutator 37 bars 37 bars
New Diameter (Maximum) 74 mm (2.92 in) 74 mm (2.92 in)
Minimum Diameter (Reslotting) 72 mm (2.85 in) 72 mm (2.85 in)
Minimum Diameter (Replace) 70 mm (2.75 in) 70 mm (2.75 in)
Condition of Performance (No Load)
Volts 12V 12 V
Maximum Amps 30 amps 52 amps
RPM 3700 rpm 4500 rpm
Field Coil Resistance at 24°C (75°F) 0.0064 ohms 0.0016 ohms
Armature Resistance at 24°C (75°F) 0.0044 ohms 0.0044 ohms
Measured Between Bars 1 and 10 1 and 10
Associated Sensors ECR6 N/A
Crown 2009 PF17431-3 M4.7-1457-003
329
ELECTRICAL
Motors CJ\OWI'
Steer Motor
Your truck is also equipped with a steer motor (M4).
The steer motor installed in your truck is dependent
upon the type of steer system used by your truck, Hy-
draulic steering or Electronic Power Steering. Refer to
the Steer Motor section for further information on the
steer motor.
DC Motor and Brush Inspection

Refer to Planned Maintenance section for inspection
intervals.
1. Turn key switch OFF and disconnect the battery.
2. Open or remove the power unit door or panel to
access the appropriate motor. Refer to Electronic
section for motor locations.
3. Remove commutator end head.
4. Clean dirt and carbon dust from winding and brush
box assembly with low pressure air. Use a clean,
dry cloth to clean commutator. Do not use emery
cloth or any other abrasive cloth.
5. Replace the brushes with a length of 16 mm
(0.62 in) or less. Replace longer brushes if they will
reach that length prior to the next inspection.
6. Check the brush springs to ensure all springs
maintain an equal tension against the commutator.
Refer to the charts for minimum "worn" tension.
M4.7-1457-004 Crown 2009 PF17431-4
330
r - - - - - - - - - - - - - - - - - -----------
ELECTRICAL
CJ\owr. Event Code Introduction
Event Code Introduction When a Malfunction Occurs

Proceed to ACCESS 1 and access the Level 2: Field
Lh WARNING
Service Mode.
Never key the truck ON with anyAccess 1 2 3® control NOTE

module connectors disconnected as damage could be Your monitoring system can be accessed at three lev-
done to the Access 1 2 3 modules and control circuits els of authorization:
of the truck. In addition, never disconnect or connect Level 1: Operator Mode
any connectors while the truck is keyed ON as injury to Level 2: Field Service Mode (Full Truck Operation)
yourself or to the truck could occur. Level 3: AnalyzerlTest Mode (No Truck Operation)
Lh CAUTION
This section deals with Level 2 and Level 3. For infor-
mation on Level 1, see the Operator's Manual and
Access 1 2 3 chapter in this manual. For menu infor-
To prevent nuisance codes, as a general rule, if
mation, refer to the Access 1 23 chapter.
Access 1 2 3 module is replaced, Crown recommends
performing all calibrations. Also, if the replacement
Software
module includes updated software, the software in the
remaining modules may have to be updated so all To ensure your truck's Access 1 2 3 software is up-to-
module software is compatible. After replacing an date, use ACCESS 1, enter Level 2: Field Service
Access 1 2 3 module or updating the software, verify Mode and scroll to the Utilities Menu.
the performance and features menu settings are cor-
From there you will be able to view the module and
rect. For performance and feature menu settings and
software part numbers applicable to your truck.
for calibration procedures, refer to Access 1 2 3 chap-
ter in this manual.
No Event Code?
Some Troubleshooting Basics When the truck malfunctions and no event code is en-
tered it usually means the malfunction is not electrical.
Statistically the majority of malfunctions occur in or at
If the truck powers up, but a code is not present, the
output devices, such as relays, contactors and motors.
malfunction is probably mechanical or hydraulic rather
The next components to test are connectors, wiring
than electrical. Information regarding mechanical and
and input devices such as switches, potentiometers or
hydraulic troubleshooting is located in the appropriate
encoders. When measuring the voltage and resistance
section in this manual.
of these components, use a digital volt-ohm multimeter
(DVOM). The last component to suspect is the
To Locate Malfunctioning Components
Access 1 2 3 control module. In all instances, you
should begin your troubleshooting procedure at the Component and wiring location maps are provided at
driven (output) device, proceed to input devices, then, strategic locations on the truck to help you quickly de-
and only then, move on to the Access 1 2 3 control termine the physical location of items in question.
module to which these devices attach. Be sure to re-
All components are clearly marked at the connection
connect all components previously disconnected after
points.
completing the event code steps.
Refer to the Componentry section in this Manual for
further information on individual components.
Crown 2010 PF2513G-1 M4.8-ITD-001
331
ELECTRICAL
Event Code Introduction CJ\OWI'
Test Points
Test points referenced in the event code descriptions
are located on the distribution panel. For an example
refer to Figure 24633.
Distribution panel and test point locations will vary from
what is shown.
TP1 TP2 TP3 TP4 TP5 TP6
TP11 TP10 TP9 TP12 TP8 TP7
Figure 24633
Power Cable Connections
LL CAUTION
Due to capacitance voltage present in some
Access 1 2 3 modules, whenever performing mainte-
nance which may permit contact with the bus bars and
associated power cables, discharge the capacitors.
Refer to the Control of Hazardous Energy section for
procedures to discharge capacitors.
M4.8-ITD-002 Crown 2010 PF2513D-2
332
ELECTRICAL
CJ\owr. Event Codes
Event Codes When a Malfunction Occurs

Proceed to ACCESS 1 and access the Level 2: Field
Lt WARNING
Service Mode as follows.
Never key the truck ON with anyAccess 1 2 3® control NOTE

module connectors disconnected as damage could be Your monitoring system can be accessed at three lev-
done to the Access 1 2 3 modules and control circuits els of authorization:
of the truck. In addition, never disconnect or connect
Level 1: Operator Mode
any connectors while the truck is keyed ON as injury to Level 2: Field Service Mode (Full Truck Operation)
yourself or to the truck could occur. Level 3: AnalyzerlTest Mode (No Truck Operation)
Access 1 2 3® Module Listing: This section deals with Level 2 and Level 3. For infor-
mation on Level 1, see the Operator's Manual. Refer to
ACCESS 1: Display Module (OM) Access 1 2 3 Menus for ACCESS 1 information.
ACCESS 2: Hydraulic Control Module (HCM) To ensure your truck's Access 1 2 3 software is up-to-
ACCESS 3: Traction Control Module (TCM) date, use ACCESS 1 and scroll to the Utilities Menu.
ACCESS 4: Vehicle Control Module (VCM) From here you will be able to view the module and soft-
ware part numbers applicable to your truck.
ACCESS 5: Steer Control Module (SCM)
Lt CAUTION
Afterreplacing an Access 1 2 3 module or updating the
software, it is recommended to verify the performance
and features settings are correct. It is also recom-
mended to recalibrate the truck (refer to "Calibration" in
Access 1 2 3 section of the service manual) after re-
pairs are made to the truck.
Some Troubleshooting Basics

Statistically the majority of malfunctions occur in or at
output devices, such as relay tips, contactors and mo-
tors. The next components to test are connectors, wir-
ing and input devices such as switches, potentiometers
or encoders. When measuring the voltage and resis-
tance of these components, use a digital volt ohm me-
ter (DVOM). The last component to suspect is the
Access 1 2 3 control module. In all instances, you
should begin your troubleshooting procedure at the
driven (output) device, proceed to input devices, then,
and only then, move on to the Access 1 2 3 control
module to which these devices attach. Be sure to re-
connect all components previously disconnected after
completing the event code steps.
Crown 2009 PF17432-1 Rev. 9110 M4.8-1457-001

03 Rev. 9/10
333
ELECTRI€AL
Event Codes CJ\OWI'
Calibration To Locate Malfunctioning Components
When replacing a module or updating Access 1 2 3 Component and wiring location maps are provided at
software, calibration is required. Following is a list of strategic locations to help you quickly determine the
what specific calibration is needed when a module is physical location of items in question.
replaced:
All components are clearly marked at the connection
• Replacement of ACCESS 1 requires calibration of points.
steer sensor feedback (RPS1) on trucks equipped
with electronic power steering (Calibration Menu Test Points
C4.1). Test points referenced in the event code descriptions
are located on the distribution panel.
tilt sensor feedback (POT4) on trucks equipped Power Cable Connections
with the tilt position assist feature (Calibration
Menu C2.6).

& CAUTION
the following: Due to capacitance voltage present in ACCESS 2 and
ACCESS 3, whenever performing maintenance which
- All potentiometers (POT1, POT2 and POT3) in may permit contact with the bus bars and associated
the multi-task control handle (Calibration power cables, discharge the capacitors.
Menus C1.1, C1.2 and C1.3)
Height sensor (ECR2) (Calibration Menu C2.1) area with a level floor.
Load sensor (LS) (Calibration Menu C2.2) 2. Chock truck wheels. Refer to Control of Hazardous
Main lower valve (PVL) (Calibration Menu Energy.
C2.3) 3. Disconnect battery and 10ckouUtagout truck. Refer
- Accessory valve (PVA) (Calibration Menu to Control of Hazardous Energy.
C2.4) 4. Turn and hold the key switch to the start position a
- Accelerometer (Calibration Menu C2.5) minimum of 10 seconds.
- Traction/Steer Wheel Position Sensor (RPS 1) 5. To verify capacitors have discharged, place a digi-
on hydraulic steer truck models (Calibration tal volt-ohm multimeter (DVOM) across the +BV
Menu C2.8) and BNEG terminals of ACCESS 2. The voltage
should be less than 1 V. Repeat the procedure on
• Replacement of ACCESS 5 requires calibration of ACCESS 3.
Electronic Power Steering Motor Encoder (ECR4)
6. Turn key switch to OFF and remove key.
on trucks equipped with electronic power steering
(Calibration Menu C4.1).
Digital Volt'()hm Multlmeter (DVOM)
No Event Code? Use a DVOM when measuring voltage (truck keyed
ON) or resistance (truck keyed OFF). Be sure to recon-
When the truck malfunctions and no event code is en-
nect all components previously disconnected after
tered it usually means the malfunction is not electrical.
completing event code steps.
If the truck powers up, but a code is not present, the
malfunction is probably mechanical or hydraulic rather
than electrical. Information regarding mechanical and
hydraulic troubleshooting is located in the appropriate
section in this Manual.
M4.8-1457-002 Crown 2009 PF17432-2 Rev. 9/10
03 Rev. 9110
334
ELECTRICAL
CJ\OWrl Event Codes
ACCESS 2 ACCESS 2 RR/RD 5700

(HCM) (AC) (HCM) (DC) ACCESS 4 (VCM)
ACCESS 1 (DM)
. ACCESS 5 (SCM)
ACCESS 2 ACCESS 2 RRiRD 5700S

(HCM) (AC) (HCM) (DC) ACCESS 4 (VCM)
ACCESS 3
(TCM)
ACCESS 5 (SCM)
Figure 21866
Crown 2009 PF17432-3 Rev. 5110 M4.8-1457-003

01 Rev. 5/10
335
ELECTRICAL
Event Codes
·ccessd
Comprehel'ls VlJ, System Control
L-,---------------r-J'2
o 00000
Enhanced Display
o 00000
Enhanced Display with CDM
Figure 21865
M4.8-1457-004 Crown 2009 PF174324 Rev. 5110
01 Rev. 5/10
336
ELECTRICAL
CAOWI' Event Code 100
Event Code 100 • If: 120 ohm.

- Then replace ACCESS 1.
Invalid Event Code from ACCESS 3 Module - Not
Used
All functions are disabled. DISTRIBUTION PANEL ACCESS 1
The event code reported is not defined in the vehicle CA204

CM05
1 CAN H TP7 CANH
code. Contact the factory.
2
r-e
1200HM
RESISTOR~
r+---+--t 8
r-++--+--t 9
120 OHM
RESISTOR
3 CANL TP8 CANL
Event Code 102 4

5 CA205
6 1
ACCESS 1 CAN Initialization Issue with ACCESS 2 2
7
ACCESS 2
All functions are disabled. 8
9
NOTE 10
11
Cl
Check for BNEG to ACCESS 1 and ACCESS 2 on the 12 L+---+--l23 ~ ©
CAN bus by verifying indicator lights are ON. Absence CD
of BNEG to modules on the CAN bus will load the bus

Figure 21785
and impede CAN communications.
Step 1: Key truck OFF. Check CAN wires and connec-
tions. CAN_H: Use a DVOM to check wire continuity
from ACCESS 1 CA405-8 to the distribution panel
CA205-1. Then check wire continuity from the distribu-
tion panel CA205-2 to ACCESS 2 CA402-23. CAN_L:
Use a DVOM to check wire continuity ACCESS 1
CA405-9 to the distribution panel CA205-12. Then
check CA205-11 to ACCESS 2 CA402-15. Check for
corrosion on connector pins.
• If: Wiring or connections require repair.
- Then repair or replace as needed.

Step 2: Check the CAN communication lines. With
truck keyed OFF, check the resistance on the distribu-
tion panel between CAN_H (TP7) and CAN_L (TP8);
resistance should be 60 ohm.
• If: 0 ohm.
- Then a short exists between CAN_H and
CAN_L. Check associated wiring connections
and fuses.
• If: More than 60 ohm.

- Then the CAN bus terminating resistors are
open. Disconnect CA204 and CA205 from the
distribution panel. Check the resistance be-
tween TP7 and TP8.

- Then replace the distribution panel.
Crown 2009 PF17432-5 Rev. 5110 M4.8-1457-005

01 Rev. 5/10
337
ELECTRICAL
Event Code 103 CJ\OWI'
Event Code 103
ACCESS 1 CAN Initialization Issue with ACCESS 3 DISTRIBUTION PANEL ACCESS 1
CA204
All functions are disabled. 1 CAN H TP7
CA405
CANH
2
1200HM r--e
RESISTOR~
~--}~ 8
r+-+--~ 9
120 OHM
RESISTOR
NOTE 3 CAN L TP8 CANL
4 Cl
Check for BNEG to ACCESS 1 and ACCESS 3 on the
5 CA205 ~©
ll:l
CAN bus by verifying indicator lights are ON. Absence 1
6
of BNEG to modules on the CAN bus will/oad the bus
7
and impede CAN communications. 3 ACCESS 3
8
Step 1: Key truck OFF. Check CAN wires and connec- 9 CA401
10
tions. CAN_H: Use a DVOM to check wire continuity 10 L-+~~--115
from ACCESS 1 CA405-8 to the distribution panel 11

12 12
CA205-1. The check wire continuity from the distribu-
tion panel CA205-3 to ACCESS 3 CA401-23. CAN_L:
Use a DVOM to check wire continuity from ACCESS 1 Figure 21786
CA405-9 to the distribution panel CA205-12, and
CA205-10 to ACCESS 3 CA401-15. Check for corro-
sion on connector pins.

truck keyed OFF, check the resistance between
CAN_H (TP7) and CAN_L (TP8) on the distribution
panel; resistance should be 60 ohm.
• If: 0 ohm.
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

M4.8-1457-006 Crown 2009 PF17432~ Rev. 5110
01 Rev. 5/10
338
ELECTRICAL
CJ\OWI) Event Code 104
Event Code 104

CA204
All functions are disabled. CA405
1 CAN H TP7 CANH
2
r-e
1200HM
RESISTOR~
~~-; 8
r-+-+-+--i 9
120 OHM
RESISTOR
Cl
~©
4
Check for BNEG to ACCESS 1 and ACCESS 4 on the CA205
5 CD
6
of BNEG to modules on the CAN bus will load the bus
7
and impede CAN communications. 4 ACCESS 4
8
Step 1: Check CAN wires and connections. CAN_H: 9 CA412
9
Use a DVOM to check wire continuity from ACCESS 1 10 L..+-++~--; 1
CA405-8 to the distribution panel CA205-1. Then 11 '-+--+-; 2 Cl
check distribution panel CA205-4 to ACCESS 4 12 12
~©
CD
CA412-2. CAN_L: Use a DVOM to check wire continu-
ity from ACCESS 1 CA405-9 to the distribution panel Figure 21787
CA205-12. Then check from distribution panel
CA205-9 to ACCESS 4 CA412-1. Check for corrosion
on connector pins.

• If: 0 ohm.
and fuses.

- Then the, CAN bus terminating resistors are
tween TP7 and TP8.

• If: 120 ohm.

Crown 2009 PF17432-7 Rev. 5110 M4.8-1457-007

01 Rev. 5/10
339
ELECTRICAL
Event Code 105
CA204
CA405
CANH
2
1200HM r--e
RESISTOR~
~---+--i 8
r-+-+-+-i 9
120 OHM
RESISTOR
C!l
4
Check for BNEG to ACCESS 1 and ACCESS 5 on the
5 CA205 ~©
al
6
of BNEG to modules on the CAN bus will/oad the bus
7
and impede CAN communications. ACCESS 5
8
Step 1: Key truck OFF. Check CAN wires and connec- 9
tions. CAN_H: Use a DVOM to check wire continuity 10
from ACCESS 1 CA405-8 to the distribution panel 11
12 12
CA205-1. Then check distribution panel CA205-6 to
ACCESS 5 CA651-23. CAN_L: Use a DVOM to check
wire continuity from ACCESS 1 CA405-9 to the distri- Figure 21788
bution panel CA205-12. Then check from distribution
panel CA205-7 to ACCESS 5 CA651-15. Check for
corrosion on connector pins. Event Code 111
• If: Wiring or connections require repair. ACCESS 1 Software Incompatible
- Then repair or replace as needed. All functions are disabled.
Step 2: Check the CAN communication lines. With the Step 1: Load ACCESS 1 with compatible software.
CAN_H (TP7) and CAN_L (TP8) on the distribution Event Code 112
• If: 0 ohm. ACCESS 2 Software Incompatible

- Then a short exists between CAN_H and All functions are disabled.
and fuses. Step 1: Load ACCESS 2 with compatible software.

Event Code 113
open. Disconnect CA204 and CA205 from the ACCESS 3 Software Incompatible
tween TP7 and TP8. All functions are disabled.
• If: More than 120 ohm. Step 1: Load ACCESS 3 with compatible software.

Event Code 114
• If: 120 ohm.
- Then replace ACCESS 1. ACCESS 4 Software Incompatible
All functions are disabled.
Step 1: Load ACCESS 4 with compatible software.
M4.8-1457-008 Crown 2009 PF17432-8 Rev. 5110
01 Rev. 5/10
340
ELECTRICAL
CROWl' Event Code 115
Event Code 115 • If: More than 60 ohm.

ACCESS 5 Software Incompatible open. Disconnect CA204 and CA205 from the
All functions are disabled. distribution panel. Check the resistance be-
tween TP7 and TP8.
Step 1: Load ACCESS 5 with compatible software.
Event Code 122 - Then replace the distribution panel.
• If: 120 ohm.

ACCESS 2 CAN Issue
ACCESS 1 CAN bus communication with ACCESS 2
was lost. DISTRIBUTION PANEL ACCESS 1
Step 1: Key truck ON and check the status of CA204
CMOS
ACCESS 2 indicator lights. 1 CAN H TP7 CANH
2
r:-e
1200HM
RESISTOR~
~---4-1 8
~+--+-l 9
120 OHM
RESISTOR
• If: ACCESS 2 indicator lights are ON and event 3 CAN L TP8 CANL
Cl
code continues. 4 ~©
III
5 CA205
- Then proceed to Step 2. 1
6 ACCESS 2
2
• If: ACCESS 2 indicator lights are OFF. 7 CM02
8 1
- Then check and repair power input to 9
ACCESS 2 at CA402-1 and BNEG. 10
11
12
CA205-1. Then check distribution panel CA205-2 to Figure 21789
wire continuity from ACCESS 1 CA405-9 to the distri-
bution panel CA205-12. Then check distribution panel

• If: 0 ohm.
and fuses.
Crown 2009 PF17432-9 Rev. 5110 M4.8-1457-009

01 Rev. 5/10
341
ELECTRICAL
Event Code 123
ACCESS 3 CAN Issue DISTRIBUTION PANEL ACCESS 1
CA204
CA405
CANH
ACCESS 1 CAN bus communication with ACCESS 3 2
1200HM r--e
RESISTOR~
.-+~-< 8
....-+-+-~ 9
120 OHM
RESISTOR
3 CAN L TP8 CANL
was lost. Cl
4 ~©
Step 1: Key truck ON and check the status of 5 CA205
lD
ACCESS 3 indicator lights. 6 1

ACCESS 3
7
• If: ACCESS 3 indicator lights are ON and event
8 3
CA401
1
code continues. 9
10 10
- Then proceed to Step 2. L..+-++~-< 15
11
• If: ACCESS 3 indicator lights are OFF. 12 12
- Then check and repair power input to

ACCESS 3 at CA401-1 and BNEG. Figure 21790

CA205-1. Then check from distribution panel CA205-3
to ACCESS 3 CA401-23. CAN_L: Use a DVOM to
check wire continuity from ACCESS 1 CA405-9 to the
distribution panel CA205-12. Then check CA205-10 to
ACCESS 3 CA401-15. Check for corrosion on connec-
tor pins.

• If: 0 ohm.
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

M4.8-1457-010 Crown 2009 PF17432-10 Rev. 5110
01 Rev. 5/10
342
ELECTRICAL
CJ\owr. Event Code 124
Event Code 124

ACCESS 1
ACCESS 4 CAN Issue DISTRIBUTION PANEL
CA405
CA204 CANH
r+--+--l 8 120 OHM
ACCESS 1 CAN bus communication with ACCESS 4 2

120 OHM r---e
RESISTOR~
r+-+--+--i 9 RESISTOR
CAN L c>
was lost. 3 CAN L TP8 ~©
III
4
Step 1: Key truck ON and check the status of 5 CA205 ACCESS 4
CA410
7
8 4
1
2
code continues. 9
11
• If: ACCESS 4 indicator lights are OFF. 12

ACCESS 4 at CA41 0-1 and CA41 0-2. Figure 21791

bution panel CA205-12. Then check from the distribu-
tion panel CA205-9 to ACCESS 4 CA412-1. Check for

• If: 0 ohm.
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

Crown 2009 PF17432-11 Rev. 5110 M4.8-1457-011

01 Rev. 5/10
343
ELECTRICAL
Event Code 125 • If: 120 ohm.
ACCESS 5 CAN Issue
ACCESS 1 CAN bus communication with ACCESS 5 DISTRIBUTION PANEL ACCESS 1
was lost. CA204

CM05
1 CAN H TP7 CANH
Step 1: Key truck ON and check the status of
2
r-e
1200HM
RESISTOR~
r-+--7-i 8
rl--f--+--l 9
120 OHM
RESISTOR
ACCESS 5 indicator lights. 3 CAN L TP8 CANL
(!)

4 ~©
lD
5 CA205
code continues. 6 1
ACCESS 5 ACCESS 4
7
- Then proceed to Step 2. CA651
8 1
• If: ACCESS 5 indicator lights are OFF. 9 CA410
10 2
- Then check and repair power input to 11
ACCESS 5 at CA651-1 and ACCESS 4 at 12 12
CA41 0-2.
Step 2: Key truck OFF. Check CAN wires and connec- Figure 21792
CA205-1. Then check from distribution panel CA205-6
to ACCESS 5 CA651-23. CAN_L: Use a DVOM to
check wire continuity from ACCESS 1 CA405-9 to the
distribution panel CA205-12. Then check from
CA205-7 to ACCESS 5 CA651-15. Check for corrosion
on connector pins.

• If: 0 ohm.
and fuses.

tween TP7 and TP8.

M4.8-1457-012 Crown 2009 PF17432-12 Rev. 5110
01 Rev. 5/10
344
ELECTRICAL
mowr. Event Code 131
Event Code 131 • If: Settings or software are incorrect.
- Then correct settings or install correct soft-

ACCESS 1 Alarm (ALM1) Driver Shorted ware.
Step 1: Key truck ON. Use a DVOM to check for +BV
between TP4 (positive meter lead) and TP12 (negative
• If: Settings or software are correct.
meter lead) on the distribution panel. - Then replace ACCESS 1.
• If: +BV.
- Then repair or replace wiring from ACCESS 1 Event Code 141
CA405-2 to the distribution panel CA203-7.
ACCESS 1 Zone Select Switch (ZSS-A) Open
• If: 0 V.
Lift is disabled.
- The proceed to Step 2.
Step 1: Key truck ON. Check for BNEG input at
ACCESS 1 CA405-1.
DISTRIBUTION
PANEL
ACCESS 1
CAA05 CA203
21----~7 •
TP4
CA405 HTS1ILMS1IZS5-AlRMT RAS
1
©+
ACCESS 1
•
TP12
0 •
OJ B +BV + BNEG
©tiiC> ALM1
STATUS ALARM © © ©
Figure 21793 Figure 21794
Event Code 134 Event Code 142

ACCESS 1 CAN Issue with ACCESS 4 ACCESS 1 Zone Select Switch (ZSS-A) Issue
All functions are disabled. Lift is disabled.
Follow troubleshooting steps for Event Code 124. Step 1: Check the wiring to ZSS-A for shorts to +BV.
• If: Wiring is OK.
Event Code 138 - Then replace ACCESS 1.
ACCESS 1 Lost CAN Communication

All functions are disabled. ACCESS 1
CAA05 HTS1ILMS1IZSS-AIRMT RAS

Follow troubleshooting steps for Event Code 124.
1 0 •
Event Code 140 +BV + BNEG
© © ©
ACCESS 1 Issue with ACCESS 2 (AC) Figure 21794
Step 1: Verify proper setting for AC hydraulics in Fea-
tures Menu F3.7. Also verify correct ACCESS 2 mod-
ule for AC hydraulics and software in Utilities Menu
U1.3.1 and U1.3.2.
Crown 2009 PF17432-13 Rev. 5110 M4.8-1457-013

01 Rev. 5/10
345
---------------------------------------------------
ELECTRICAL
Event Code 200 CROWl'
Event Code 200 Step 2: Check the CAN communication lines. With
Invalid Event Code from ACCESS 2 Module· Not
Used
All functions are disabled. • If: 0 ohm.
The event code reported is not defined in the vehicle - Then a short exists between CAN_H and
code. Contact factory. CAN_L. Check associated wiring connections
and fuses.
Event Codes 201 • If: More than 60 ohm.

ACCESS 1 CAN Issue with ACCESS 2 open. Disconnect CA204 and CA205 from the
All functions are disabled. distribution panel. Check the resistance be-
tween TP7 and TP8.
NOTE • If: More than 120 ohm.
Check for BNEG to ACCESS 1 and ACCESS 2 on the - Then replace the distribution panel.
CAN bus by verifying indicator lights are ON. Absence
of BNEG to modules on the CAN bus will load the bus • If: 120 ohm.
and impede CAN communications.
Event Code 205 DISTRIBUTION PANEL ACCESS 2
CA204
CA402
1 CAN H TP7
ACCESS 4 CAN Issue with ACCESS 2
2
1200HM
RESISTOR~
r-- .--+--+--115
All functions are disabled. 3 CAN L TP8

4
ACCESS 2 is reporting lost communication with
5 CA205
ACCESS 4.
6 2
7
NOTE 8 4
ACCESS 4
9
Check for BNEG to ACCESS 2 and ACCESS 4 on the CA412
10 9 f-t-+-,
CAN bus by verifying indicator lights are ON. Absence l.......<t-----'~1
of BNEG to modules on the CAN bus will load the bus 11 2 Cl

12 11 ~©
and impede CAN communications. al

Figure 21795
M4.8-1457-014 Crown 2009 PF17432-14 Rev. 5110
01 Rev. 5110
346
ELECTRICAL
CJ\OWrl Event Code 221
Event Code 221 • If: All are correct.
- Then check battery charge level.

AC Hydraulic System Current Sensor
Hydraulic system is disabled.
• If: All are not correct.
Step 1: Key truck ON. Using a DVOM, connect the - Then verify BDI setting in Performance Menu
negative lead to the ACCESS 2 BNEG terminal and the P4 and repair or replace battery or other com-
positive lead to the ACCESS 2 +BV terminal; +BV ponents as needed.
should be present. • If: Battery is properly charged and not undersized
• If: Voltage measured is less than +BV. for duty cycle.
- Then correct the voltage issue (FU9, ED1, cor- - Then check for proper truck configuration in
rectly sized and charged battery). Features Menu F3.
• If: Voltage measured is +BV. • If: Truck is not configured correctly.
- Then use the Analyzer Menu to check the hy- - Then correct truck configuration.
draulic pump motor (M2) actual speed in
A2.2.1 against the M2 Target Speed in A2.2.2.
• If: The motor speed is correct.

ACCESS 2
+
ACCESS 2
Ol
z
m
Gl
36V
' - - - - - - 1 + 11111--------"
Figure 21797
EMERGENCY
DISCONNECT
Event Code 222 CONTACTOR
(ED1)
ACCESS 3
ACCESS 2 Battery Voltage (+BV) Low

+BV
Hydraulic system is disabled. ©
NOTE
Figure 21796
Should Event Code 222 log with Event Code 256, then
refer to Event Code 256 first.
Step 1: Key truck ON. Using a DVOM, connect the
negative lead to the ACCESS 2 BNEG terminal and the
positive lead to the ACCESS 2 +BV terminal; +BV
should be present.
• If: Voltage measured is less than +BV.

- Then check power cable connections, FU9,
ED1, and for correct battery.
Crown 2009 PF17432-15 Rev. 5110 M4.8-1457-015

01 Rev. 5/10
347
ELECTRICAL
ACCESS 2 Battery Voltage (+BV) High ACCESS 2 Internal Temperature Less than _25 0 C
(_13 0 F)
NOTE Step 1: Determine air temperature of environment.
• If: Ambient temperature is below _25 0 C (_13° F)
and the truck has been idle for an extended time.
- Then ACCESS 2 heatsink must be warmed to
operate with full traction capabilities.
should be present. • If: Ambient temperature is well above _25 0 C
• If: Voltage measured is more than +BV. (_13° F) and event code continues.
- Then check for correct battery.
• If: Battery voltage is correct.

Event Code 225
- Then check for proper truck configuration in
Features Menu F3. ACCESS 2 Internal Temperature Less than -40 C
(25° F)
• If: Truck is not configured correctly.
Traction is disabled.
- Then correct truck configuration.
Step 1: Determine air temperature of environment.
• If: Ambient temperature is below -4 0 C (25° F) and

ACCESS 2
the truck has been idle for an extended time.
36V
L.-------:1+ 11111--_ _-' • If: Ambient temperature is well above -4 0 C (25° F)
and event code continues.
Figure 21797 - Then replace ACCESS 2.
M4.8-1457-016 Crown 2009 PF17432-16 Rev. 5110
01 Rev. 5/10
348
ELECTRICAL

ACCESS 2 Internal Temperature Exceeds 85° C ACCESS 2 AC Lift Pump Motor M2 Temperature
(185° F) Sensor (TS2) Above Range 165° C (329° F)
No effect. Hydraulic system is disabled.
Step 1: Check condition and mounting of ACCESS 2
and FAN4 operation.
NOTE
Extreme hydraulic duty cycle or high ambient tempera-
• If: ACCESS 2 mounting is loose or heat sink is
tures could also log Event Code 228.
dirty.
Step 1: Check M2 set ups.
- Then properly secure ACCESS 2. Blow off any
dirt buildup from heat sink. • If: Settings are incorrect.
• If: FAN4 is not operating normally. - Then correct M2 settings.
- Then troubleshoot FAN4 operation issue. • If: Settings are correct.
• If: ACCESS 2 is extremely hot. - Then check TS2 wiring and M2 power cable
connections. Blow off any dirt buildup from M2.
- Then check power cable connections.
• If: Event Code remains.
- Then check battery condition.
ACCESS 2
CA402
ECR6 CA613 ~402
.----------11 +12V
+V/RED 1 3
'ClW >-- GND I - -
~~~ GNDIBLK 2 4
M2 Ul~:l
Z a.
~ CHA I--
AlWHT 3 5
~a)~ >-- CHB I - -
ACCESS 3 B/BLU 4 6
I--
ACCESS 2
T52 CA~
+T·
< ~
BRN 1
BRNIBLK ~
"
7 S
w ~ v ;Q
W
M2 VI V
~
u 'J u
~
{J)
Figure 21798
Figure 21799
Event Code 227

ACCESS 2 Internal Temperature Exceeds 105° C
(221° F)
No effect.
Crown 2009 PF17432·17 Rev. 5110 M4.8-1457-017

01 Rev. 5/10
349
ELECTRICAL
Event Code 229 CJ\OW"
Event Code 229 • If: None of these event codes have been logged.
- Then proceed to Step 2.

ACCESS 2 Lift Pump Motor Temperature Sensor
(TS2) Out of Range Step 2: Key truck OFF and back ON.
Hydraulic system is disabled. • If: Event Code 230 logs.

Step 1: Key truck OFF. Check TS2 wiring for a short to - Then key truck OFF. Check wiring from
truck frame. Use a DVOM to check resistance from ACCESS 2 CA402-5 to ECR6 CA613-3 (Chan-
CA614-1 and CA614-2 to truck frame. Resistance nel A) and CA402-6 to ECR6 CA613-4 (Chan-
should exceed 10K ohm. Then check ECR6 wires, wire nel B) for shorted or broken wiring.
to BNEG at ACCESS 2 CA402-4 and wire from
CA614-1 to CA402-16 for any shorts to truck frame. • If: Wiring is damaged.
• If: Any wires are shorted. - Then repair or replace wiring as needed.
- Then repair or replace as needed. • If: Wiring is good.
• If: No wires are shorted. - Then replace ACCESS 2.
- Then proceed to Step 2. • If: Event codes affect hydraulics operation or

cause shutdowns.
Step 2: With truck keyed OFF. Check TS2 wiring for an
open. Use a DVOM to check continuity of CA614-1 to - Then proceed to Step 3.
CA402-16 and CA614-2 CA402-4.
Step 3: Key truck ON. Check ECR6 for 12 Vdc. Con-
• If: Any wires are broken. nect the positive meter lead to ECR6 CA613-1 and the
negative meter lead to ECR6 CA613-2.
- Then repair or replaced as needed.
• If: 12 V not present.
- Then check wiring and connections.

ECR6 CA613 CA402
+12V f - -
'(!)W
O::zoo
0_...1
+V/RED 1
f--
3
GND r-- • If: Wiring and connections are good and event
GNDlBlK 2 4
M2 000::::>
zitiQ.
f-- CHA r-- code continues.
AlWHT 3 5
~lD~ f-- CHB I - -
BlBlU 4 6 - Then replace M2.
r--
TS2 CA614 ACCESS 2
r:;- "
~
+TO BRN
<{ ~
BRNlBlK ~ /
~ V
ECR6 CA613
+12V-CA402
w JG1 +V1RED 1 3
GND -
E:j
c!:(!)W f--
V
U
~ M2
o~~
zoo~::>
Q.
GNDlBlK 2
f-- CHA -
4
>fu
-.:::.
~lD~
AlWHT 3
f-- CHB -
5
BlBlU 4 6
-
Figure 21799 TS2 CA614 ACCESS 2
r:;-
+TO
<{ ~
BRN
BRNlBlK S- f " S
Event Code 230 W L...- v
~)
IG),
V
V
ACCESS 2 Lift Pump Motor Encoder (ECR6) Count U
U
Issue
Hydraulic system is disabled. Figure 21799
Step 1: Check for Event Codes 266, 267 and 277,

which indicate ECR6 power supply or logic ground is
out of range. If these event codes have logged, resolve
them before proceeding.
M4.8-1457-018 Crown 2009 PF17432-18 Rev. 5110
01 Rev. 5110
350
ELECTRICAL
l!J\OWr. Event Code 231
Event Code 231

ACCESS 2
ACCESS 2 Lift Pump Motor (M2) Stall Detected HCM(AC)
AC Hydraulic System is disabled.

Step 1: Key the truck ON. Use the Analyzer Menu to
check the pump motor (M2) ~ctual speed in A2.2.1
against the M2 Target Speed in A2.2.2.
• If: The motor speed (measured by ECR6) = O. Ver-

ify the motor is rotating.
- If rotating, then use a DVOM to check for 12 V CA402-1
at ECR6. Connect the positive lead to the red +BVKYS
wire at ECR6 and the negative lead to the black G>

wire. Figure 23826
• If: 12 V is present.
- Then continue to Step 2.
• If: 12 V is not present.
- Then check for 12 V at ACCESS 2. Connect

the positive lead to the CA402-3 and the nega-
tive lead to CA402-4.
• If: 12 V is not present.
- Then verify operation of ACCESS 2.

Step 2: Key the truck OFF. Check the continuity of the
Channel A, white wire, from ACCESS 2 CA402 5 to
ECR6 and the continuity of the Channel 8, blue wire,
from ACCESS 2 CA402 6 to ECR6.
• If: The wires or connections need repair.
• If: The wires and connections are good.
- Then replace the lift pump motor (M2).
Crown 2009 PF17432-19 Rev. 5110 M4.8-1457-019

01 Rev. 5/10
351
ELECTRICAL
Event Code 232 mow"
Event Code 232
ACCESS 2 Lift Pump Motor (M2) Rotation More
than 4000 rpm
Step 1: Key truck OFF. Check wiring from ACCESS 2
CA402-5 to ECR6 CA613-3 (Channel A) and CA402-6
to ECR6 CA613-4 (Channel B) for shorted or broken
wiring.
• If: Wiring is damaged.
- Then repair or replace wiring as needed.
• If: Wiring is good.

Step 2: Key truck ON. Check ECR6 for 12 V. Connect
the positive meter lead to ECR6 CA613-1 and the neg-
ative meter lead to ECR6 CA613-2.
• If: 12 V and event code continues.
- Then check tach rpm at A2.2.1.
• If: rpm is greater than 4000 rpm.
- Then replace the A2 module.
• If: The speed is normal (0 - 3500 rpm).
- Then monitor the event code.
• If: The code continues.
- Then replace M2.
ECR6 CA613 ~402

+12V
+V/RED 1 3
a::(!)W I-- GND I - -
o~~ GNDIBLK 2 4
M2 (/)~=>
Z Q..
I-- CHA I - -
AlWHT 3 5
~a1~ BIBLU 4
I-- CH B I--
6
I--
ACCESS 2
TS2 CA~
+TO
< ~
BRN
BRNIBLK ~
1
/
A
S
w ~ v G).
W
V
M2 V\ v
U oJ U
U
Figure 21799
Crown 2009 PF17432-20 Rev. 5110

M4.8-1457-020
01 Rev. 5/10
352
ELECTRICAL
CJ\OWf\ Event Code 233
Event Code 233

ACCESS 2 Battery Voltage Below Range
ACCESS 2
NOTE
+
Should Event Code 256 for Event Code 222 log with
Event Code 233, then refer to Event Code 256 first. CD
z
m
G>
should be present.
• If: Voltage measured is less than +BV.

EMERGENCY
- Then check the power cable connections, FU8, DISCONNECT
CONTACTOR
ED1, and for correct battery. (ED1)
ACCESS 3
• If: All are correct.
o
+BV
- Then check battery charge level and individual ©
cell condition. L..::::::....L_----L--+-_-=---.J

Figure 21796
- Then verify BDI setting in Performance Menu
P4 and repair or replace battery or other com-
ponents as needed.
• If: Battery is properly charged and not undersized

for dUty cycle.
- Then check for proper truck model number in
Features Menu F3.1.

Step 2: Key truck OFF, then back ON. Monitor truck.
• If: Problem continues.
Crown 2009 PF17432-21 Rev. 5110 M4.8-1457-021

01 Rev. 5/10
353
ELECTRICAL
Event Code 234
ACCESS 2 Battery Voltage (+BV) Very Low cr
>-0
crl-
Hydraulic system is disabled. wU
~~
ACCESS 2 <z
100
NOTE U
+
Extreme duty cycle combined with incorrect or mal-
functioning battery could also log Event Code 234. Dl
Z
Should Event Code 222 or Event Code 356 log with m
G>
Event Code 234, then refer to Event Code 356 first.
should be present.
EMERGENCY
DISCONNECT
• If: Voltage is less than +BV. CONTACTOR
(ED1)
ACCESS 3
- Then check for correct battery, power cable
connections, FU9 and ED1.
o
+BV
• If: Power circuit checks are OK. ©

- Then check battery charge level.
• If: Battery is properly charged. Figure 21796

Features Menu F3.
M4.8-1457-022 Crown 2009 PF17432·22 Rev. 5110
01 Rev. 5/10
354
ELECTRICAL
CAown Event Code 235

ACCESS 2 Battery Voltage Above Range ACCESS 2 Battery Voltage (+BV) Very High
All functions are disabled. Hydraulic system is disabled.
NOTE NOTE
Should Event Code 256 or Event Code 222 log with Should Event Code 222 or Event Code 356 log with
Event Code 235, refer to Event Code 256 first. Event Code 236, then refer to Event Code 356 first.
Step 1: Key truck ON. Using a DVOM, connect the Follow troubleshooting steps for Event Code 223.
should be present. Event Code 237
• If: Voltage measured is greater than +BV. ACCESS 2 Battery Voltage (+BV) Fluctuating
- Then check for the correct battery or a battery Hydraulic system is disabled.
overcharge condition.
Battery voltage is dropping excessively under load.
• If: Voltage measured is correct.
- Then check the Features Menu F3.1 to verify negative lead to the ACCESS 2 BNEG terminal and the
prop~r truck model configuration. positive lead to the ACCESS 2 +BV terminal; +BV
should be present.
• If: Voltage is less than +BV.
- Then check condition of power cables, ED and
connections.
0:: • If: Connections require repair.

(Q)~ >-0
0::1-
W<.> - Then repair or replace as needed.
~~
~z
ACCESS 2 1O0
<.> • If: Con'nections are OK.
+
- Then check condition of battery or install a
1O known good battery and monitor Event Code
Z
m 237.
(i)
ACCESS 2
EMERGENCY
DISCONNECT
CONTACTOR 36V
(ED1) L.-----;-l+ II1I f - - - - - - - '
ACCESS 3
o
+BV Figure 21797
(Q)
Figure 21796
Crown 2009 PF17432-23 Rev, 5110 M4.8-1457-023

01 Rev. 5/10
355
ELECTRICAL
Event Code 238

ACCESS 2 Battery Voltage (+BV) Under Voltage ACCESS 2 Battery Voltage {+BV} Over Voltage
Hydraulic system is disabled. Steering, traction and hydraulics are disabled.
Step 1: Check battery status. Follow troubleshooting steps for Event Code 238.
• If: Correct battery is installed and it is properly

charged. Event Code 240
- Then check for proper truck configuration in Through
Features Menu F3.
Event Code 244
• If: Configuration is correct.
ACCESS 2 General Purpose Coli Driver Over Cur-
- Then proceed to Step 2. rent
• If: Battery does not have the correct voltage or is (Note: This event code is currently not used.)
not property charged or if battery is not configured
correctly.
Event Code 245
- Then resolve the battery issue.
Through
positive lead to ACCESS 2 CA402-1 and negative lead Event Code 249
to BNEG; +BV should be present.
ACCESS 2 General Purpose Coli Driver Open Cir-
• If: Voltage is above 0 V, but much less than +BV. cuit
- Then proceed to Step 3. (Note: This event code is currently not used.)
• If: +BV.
- Then check the wiring from CA201-7 to Event Code 250
CA402-1 and repair or replace wiring as Through
needed.
Event Code 254
Step 3: Connect the positive meter lead to distribution
panel CA201-7 and the negative meter lead to ACCESS 2 General Purpose Coli Driver Shorted
ACCESS 2 BNEG.
(Note: This event code is currently not used.)
• If: Voltage is above 0 V, but much less than +BV.
- Then check the condition of the distribution

panel and replace as needed.
ACCESS 2
DISTRIBUTION
PANEL
CA402 CA201
1 f--+--+--l 7
Figure 21800
M4.8-1457-024 Crown 2009 PF17432-24 Rev. 5110
01 Rev. 5/10
356
ELECTRICAL
CAOWf\ Event Code 255

ACCESS 2 PWM Driver Over Voltage ACCESS 2 Detected Open ED Circuit
All functions are disabled. All functions are disabled.
Step 1: Key truck ON. Using a DVOM, connect the Follow troubleshooting steps for Event Code 356.
positive meter lead to distribution panel CA201-7 and
the negative meter lead to TP1; +BV should be pres-
ent. Event Code 257
• If: 0 V. ACCESS 2 Detected ED Contactor Tips Shorted
- Then check FU1 for an open. All functions are disabled.
• If: +BV. Follow troubleshooting steps for Event Code 356.

Step 2: Connect the positive meter lead to ACCESS 2
CA402-1 and the negative meter lead to TP1; +BV
should be present.
• If: 0 V.
- Then repair or replace wire between CA402-1
and CA201-7.
• If: +BV.
©~
DISTRIBUTION
PANEL
CA201
ACCESS 2
7
©+ TP1
III
CA402 •
©~G) 1
ACCESS 4
CA412
BOI +BV CA412 BOI
3
4 BNEG
FU1
15A
36V
+ IIII
Figure 21801
Crown 2009 PF17432·25 Rev. 5110 M4.8-1457-025

01 Rev. 5/10
357
ELECTRICAL
Event Code 258
DISTRIBUTION
ACCESS 2 Pre-Charge Power Limit Out of Range PANEL
ACCESS 2 r-----i 7
NOTE TP1
The power limit ofthe pre-charge resistor internal to A2 CA402 •

has been exceeded. ©rp 1
Step 1: Check battery status.

Figure 23827
- Then check for proper truck model number in
Features Menu F3.1. ACCESS 2 Pre-Charge Time Limit Exceeded
• If: Configuration is correct. All functions are disabled.
- Then proceed to Step 2. Follow troubleshooting steps for Event Code 258.
• If: Battery does not have the correct voltage or is

not properly charged or if battery is not configured Event Code 260
~re~~ .
ACCESS 2 Pre-Charge Electrical Error
- Then resolve the battery issue.
Step 2: Key the truck ON and cycle the operator pres-
ence pedal. Using a DVOM, connect the negative lead
NOTE
to the ACCESS 2 B- terminal and the positive lead to
the ACCESS 2 +BV terminal; +BV should be present. Resistive load is present on the ED bus during pre-
charge. This condition is most commonly a shorted
• If: Voltage measured is +BV. driver condition.
- Then proceed to Step 3. Step 1: Check battery status.
• If: Voltage measured is above OV, but much less • If: Correct battery is installed and it is properly
than +BV. charged.
- Then check the power cables to ACCESS 2. - Then check for proper truck model number in
Do not over torque power cables. Features Menu F3.1.
Step 3: With truck still keyed ON and using a DVOM,
connect the positive lead to CA402-1 on ACCESS 2
and the negative lead to B- on ACCESS 2. Check the - Then proceed to Step 2.
positive wiring to the distribution panel.
• If: Above 0 V, but much less than +BV. not properly charged or if battery is not configured
correctly.
- Then connect the positive lead to CA201-7 on
the distribution panel and the negative lead to - Then resolve the battery issue.
B- on ACCESS 2.
Step 2: Check other events logged with Event Code
• If: +BV. 260.
Then check the wiring and connections be- • If: No other events logged.
tween CA201-7 and CA402-1. Repair or re-
place as needed.
M4.8-1457-026 Crown 2009 PF17432-26 Rev. 5110
01 Rev. 5/10
358
ELECTRICAL
cnowr. Event Code 261
Event Code 261 Step 2: Disconnect the wire from CA402-3. Connect
the positive meter lead to ACCESS 2 CA402-3 and the
negative meter lead to distribution panel TP1.
ACCESS 2 Issue
All functions are disabled. • If: 12 V.
Step 1: Calibrate ACCESS 2, if possible, and verify - Then replace ECR6.

truck operation.
• If: Not approximately 12 Vand Event Code contin-
• If: Event code continues. ues.
- Then replace ACCESS 2. - Then replace ACCESS 2.
Event Code 264 DISTRIBUTION

PANEL
Event Code 265
TP1
ACCESS 2 Internal 5 V Supply Out of Range •
All functions are disabled. ECR6 CA613 ~402
+12V
+V/RED
...!.- 3
Event Code 264: ACCESS 2 Internal 5 V Supply Out of 'C!lW
O::z(/) GND -
0_-, GNDlBlK 2 4
Range (High) M2 z(/)~::J
Q.
- CHA -
5
~lD~
AlWHT
~ CHB -6
Event Code 265: ACCESS 2 Internal 5 V Supply Out of BlBlU 4
-
Range (Low) TS2 CA~
ACCESS 2
~
+ BRN 1 "
Step 1: Key truck OFF and back ON. « ~
BRN/BlK S- f
w ~ V
iGl
• If: Event code continues. w
M2 ) V
~
- Then replace ACCESS 2. U 'J U
~
Figure 21803
Event Code 266
ACCESS 2 12 V Power Supply for ECR6 Out of
Event Code 269
Range
ACCESS 2 Internal 15 V Power Supply Out of
All functions are disabled. Range
Event Code 266: ACCESS 2 12 V Power Supply for All functions are disabled.
ECR6 Out of Range (High)
Event Code 268: ACCESS 2 Intemal15 V Power Sup-
Event Code 267: ACCESS 2 12 V Power Supply for ply Out of Range (High)
ECR6 Out of Range (Low)
Event Code 269: ACCESS 2 Internal 15 V Power Sup-
Step 1: Key truck ON. Using a DVOM, connect the ply Out of Range (Low)
positive meter lead to ACCESS 2 CA402-3 and the
negative lead to distribution panel TP1; 12 V should be Step 1: Internal ACCESS 2 issue. Key truck OFF then
present. back ON.
• If: 0 V. • If: Event code continues.
• If: Approximately 12 Vand Event Code continues.
Crown 2009 PF17432-27 Rev. 5110 M4.8-1457-027

01 Rev. 5/10
359
ELECTRICAL
Event Code 270 Event Code 271 CJ\OWI'
ACCESS 2 Internal 5 V Power Supply Out of Range ACCESS 2 Internal 2.5 V Reference Voltage Out of
Range
ply Out of Range (High) Event Code 274: ACCESS 2 Internal 2.5 V Reference
Voltage Out of Range (High)
ply Out of Range (Low) Event Code 275: ACCESS 2 Internal 2.5 V Reference
Voltage Out of Range (Low)
Step 1: Internal ACCESS 2 issue. Key truck OFF then
back ON. Step 1: Internal ACCESS 2 issue. Key truck OFF then
back ON.
• If: Event code continues.
Event Code 272

Event Code 277
ACCESS 2 Internal 227 mv Reference Voltage Out
of Range ACCESS 2 Internal Analog Ground Voltage Out of
Range
Event Code 272: ACCESS 2 Internal 227 mv Refer-
ence Voltage Out of Range (High) Event Code 276: ACCESS 2 Internal Analog Ground
ence Voltage Out of Range (Low) Event Code 277: ACCESS 2 Internal Analog Ground
back ON. Step 1: Internal ACCESS 2 issue. Key truck OFF then
back ON.
M4.8-1457-028 Crown 2009 PF17432-28 Rev. 5110
01 Rev. 5/10
360
ELECTRICAL
Event Code 278

Event Code 282
ACCESS 2 Over Current Condition
All hydraulic functions are disabled. ACCESS 2 Short
Step 1: Disconnect M2 cables from ACCESS 2 and All hydraulic functions are disabled.
key truck ON.
Event Code 281: ACCESS 2 Short Between +BV and
• If: Event code continues. Terminal U
- Then replace ACCESS 2. Event Code 282: ACCESS 2 Short Between BNEG
and Terminal U
• If: Event code clears.
Step 1: Check condition of M2 cables.
• If: Cables are shorted.
Step 2: Check M2 and cabling for phase to phase and
phase to truck frame shorts. - Then repair or replace cables.
• If: Short exists between U V or W cables or truck

I
• If: Cables are good.
frame. - Then proceed to Step 2.
- Then disconnect cabling and check for M2 Step 2: Disconnect M2 cabling from ACCESS 2 and
winding shorts to truck frame. key truck ON.
• If: Short exists in M2. • If: Event code continues.

- Then replace M2. - Then replace ACCESS 2.
• If: Event Code clears.
©) ~ - Then replace M2.
ACCESS 2
ACCESS 2
Figure 21804
Event Code 279

Figure 21804
Event Code 280
ACCESS 2 Internal Short
All hydraulic functions are disabled.
Step 1: Internal ACCESS 2 issue. Key truck OFF and
back ON.

Crown 2009 PF17432-29 Rev. 5110 M4.8-1457-029

01 Rev. 5/10
361
ELECTRICAL
Event Code 284 Through
Event Code 292
ACCESS 2 Short
All hydraulic functions are disabled. ACCESS 2 Lift Pump Motor (M2) Short
Event Code 283: ACCESS 2 Short Between +BV and All hydraulic functions are disabled.
Terminal V
Event Code 290: Short V to W
Event Code 284: ACCESS 2 Short Between BNEG
Event Code 291: Short VL to WH
and Terminal V
Event Code 292: Short VH to WL
Event Code 285

Through
ACCESS 2 Short Event Code 295
ACCESS 2 Lift Pump Motor (M2) Short
TerminalW All hydraulic functions are disabled.
Event Code 286: ACCESS 2 Short Between BNEG Event Code 293: Short W to U
and Terminal W
Event Code 294: Short WL to UH
Event Code 295: Short WH to UL
Event Code 287
Through
Event Code 289
ACCESS 2 Short from Terminal U to V
Event Code 287: Short U to V
Event Code 288: Short UL to VH
Event Code 289: Short UH to VL
M4.8-1457-030 Crown 2009 PF17432-30 Rev. 5110

01 Rev. 5/10
362
ELECTRICAL
Event Code 300 - Then the CAN bus terminating resistors are
open. Proceed to Step 3.
Invalid Event Code from ACCESS 3 Module· Not Step 3: Disconnect CA204 and CA205 from the distri-
Used bution panel. Check the resistance between TP7 and
TP8.
The event code reported is not defined in the vehicle • If: More than 120 ohm.
code. Contact factory. - Then replace the distribution panel.
Event Code 301

DISTRIBUTION PANEL ACCESS 3
ACCESS 1 CAN Issue with ACCESS 3 CA204

CA401
1 CAN H TP7
2
1200HM
RESISTOR~
r--e .--+-+----i15
ACCESS 3 is reporting lost communication with 3 CAN L TP8
ACCESS 1. 4
5
Follow troubleshooting steps for Event Code 103. 6
7
ACCESS 4
8
Event Code 304 9
9 f--+--+---, CA412
10
10 '---<(---;~ 1
ACCESS 4 CAN Issue with ACCESS 3 11
l----E--~ 2 t'>
12 ~©
lD
ACCESS 3 is reporting lost communication with

Figure 21805
ACCESS 4.

• If: 0 ohm.
CAN_L. Check associated wiring, connections
and fuses.
Crown 2009 PF17432-31 Rev. 5110 M4.8-1457-031

01 Rev. 5/10
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ELECTRICAL
Event Code 305 cnOWI'
Event Code 305
ACCESS 5 CAN Error with ACCESS 3 DISTRIBUTION PANEL ACCESS 3
CA204
1 CAN H TP7
ACCESS 3 is reporting lost communication with 2
r--e
1200HM
RESISTOR~
r+~--l15
r--l-+-+-l 23
ACCESS 5. 3 CAN L TP8
4
5 CA205
NOTE
6 3
Check for BNEG to ACCESS 3 and ACCESS 5 on the 7
ACCESS 5
of BNEG to modules on the CAN bus will/oad the bus 9
and impede CAN communication. 10
11 (!)
Step 1: Key truck OFF. Check CAN wires and connec- 12 10 L+~--l23 ~©
tions. CAN_H: Use a DVOM to check wire continuity In

CA205-3. Then check distribution panel CA205-6 to Figure 23828
wire continuity from ACCESS 3 CA401-15 to the distri- Event Code 306
bution panel CA205-10. Then check from distribution
panel CA205-7 to ACCESS 5 CA651-15. Check for
ACCESS 5 Communication Fault with ACCESS 3 at
Startup
• If: Wiring or connections require repair. Traction is disabled.
NOTE
Step 2: Check the CAN communication lines. With the
truck keyed OFF, check the resistance between Check for BNEG to ACCESS 3 and ACCESS 5 on the
CAN_H (TP7) and CAN_L (TP8) on the distribution CAN bus by verifying indicator lights are ON. Absence
panel; resistance should be 60 ohm. of BNEG to modules on the CAN bus will/oad the bus
and impede CAN communication.
• If: 0 ohm.
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

M4.8-1457-032 Crown 2009 PF17432-32 Rev. 5110
01 Rev. 5/10
364
ELECTRICAL
Event Code 322
Event Code 322

ACCESS 3 Battery Voltage (+BV) Low 0::
>-0
0::1-
Traction is disabled. wU
~~
ACCESS 2 <z
alo
NOTE U
+
refer to Event Code 356 first. til
Z
m
G)
should be present.
• If: Voltage is less than +BV.

EMERGENCY
- Then check power cable connections, FU10, DISCONNECT
CONTACTOR
ED1, and for correct battery. (ED1)
ACCESS 3
• If: All are correct.
+BV
- Then check battery charge level and individual ©
cell condition. ~:......L._--'--..::r---=--"

Figure 21796
- Then verify BDI setting in Performance Menu
P4 and repair or replace battery or other com-
ponents as needed.
• If: Battery is properly charged and not undersized

for duty cycle.
Features Menu F3.
Crown 2009 PF17432-33 Rev. 5/10 M4.8-1457-033

01 Rev. 5/10
365
ELECTRICAL
Event Code 323 l!J\OWI'
ACCESS 3 Battery Voltage (+BV) High ACCESS 3 Internal Temperature Less than -40 C
(25 0 F)
Full traction is disabled.
NOTE Step 1: Determine air temperature of environment.
• If: Ambient temperature is below -4 0 C (_25 0 F) and
the truck has been idle for an extended time.
Step 1: Key truck ON. Using a DVOM. connect the
should be present. • If: Ambient temperature is well above -4 0 C
• If: Voltage is more than +BV. (_25 0 F) and event code continues.
- Then check for correct battery.
• If: Battery voltage is correct.

Event Code 325
Features Menu F3. ACCESS 3 Internal Temperature Less than _25 0 C
(13 0 F)
Step 1: Determine air temperature of environment.
ACCESS 3
• If: Ambient temperature is below _25 0 C (13 0 F)
and the truck has been idle for an extended time.
36V
• If: Ambient temperature is well above _25 0 C
'--------:-l+ Ii II f - - - - - - - ' (13 0 F) and event code continues.
Figure 21807
M4.8-1457-034 Crown 2009 PF17432-34 Rev. 5110
01 Rev. 5/10
366
ELECTRICAL

ACCESS 3 Internal Temperature Exceeds 85° C ACCESS 3 Traction Motor (M1) Temperature Sen-
(185° F) sor (TS1) Above Range 165° C (329° F)
No effect. Traction is disabled.
Step 1: Check mounting of ACCESS 3 and FAN3 op-
eration. NOTE
Extreme duty cycle or high ambient temperatures
• If: ACCESS 2 mounting is loose or heat sink is
could also log Event Code 328.
dirty.
Step 1: Verify M1 performance settings.
- Then properly secure ACCESS 2. Blow off any
dirt buildup from heat sink. • If: Settings are incorrect.
• If: FAN3 is not operating normally. - Then correct M1 settings.
- Then troubleshoot FAN3 operation issue. • If: Settings are correct.
• If: ACCESS 3 is extremely hot. - Then check TS 1 wiring and M1 power cable
connections. Blow off any dirt buildup from M1.
- Then check power cable connections.
• If: Condition remains.
- Then check battery condition.
ACCESS 2
CA402
DISTRIBUTION
_------------l1 PANEL
TP1
ACCESS 3
•
ECR1 CA630 £A401
+12V
+V/RED 1 3
li:C!lW
oz(/) - GND -
4
GNDlBlK
~
_...J
M1 (/)0:::::> CHA -
~L:io.. AlWHT 3 5
(/)lll~
BlBlU 4
- CHB -
6
f--
ACCESS 3
Figure 21798
TS1 CA~
+To
c( ~
BRN
BRNlBlK ~
1
7" S
w ~ v
Event Code 327 Ii.>.
ACCESS 3 Internal Temperature Exceeds 105° C

lE:v) v
U
v
U
(221° F)
Figure 21808
No effect.
Step 1: Check mounting of ACCESS 3 and FAN3 op-
eration.
Crown 2009 PF17432-35 Rev. 5110 M4.8-1457-035

01 Rev. 5/10
367
ELECTRICAL
Event Code 329
ACCESS 3 Traction Motor Temperature Sensor
(TS1) Out of Range
Step 1: Key truck OFF. Check TS1 wiring for a short to
truck frame. Use a DVOM to check resistance from
Check CA631-1 and CA631-2 to truck frame. Resis-
tance should exceed 10K ohm. Then check ECR1
wires, wire to BNEG at ACCESS 3 CA401-4 and wire
to CA401-16 for a short to truck frame.
• If: Any wires are shorted.
• If: No wires are shorted.

Step 2: With truck keyed OFF. Check TS1 wiring for an
open. Use a DVOM to check continuity from CA631-1
to CA401-4 and CA631-2 to CA401-16.
• If: Any wires are broken.
DISTRIBUTION
PANEL
TP1
•
ECR1 CA630 ~401
+12 V
+VIRED 1 3
'c>w
ll:zC/l I- GND -
O_..J GND/BLK 2 4
M1 zC/l~:)
n. I- CHA -
AlWHT 3 5
lJllD~ B/BLU 4
I- CHB -
6
-
ACCESS 3
TS1 CA~
~
+T" BRN 1
c( ~
BRNlBLK S- f"
w ~ V
.QI
W
M1 v\ v v
U 'J U
U
Figure 21808
M4.8-1457-036 Crown 2009 PF17432-36 Rev. 5110
01 Rev. 5/10
368
ELECTRICAL
Event Code 330

DISTRIBUTION
ACCESS 3 Traction Motor Encoder (ECR1) Count PANEL
Issue
Traction is disabled. TP1
Step 1: Check for Event Codes 366, 367 and 377,

•
which indicate ECR1 power supply or logic ground is ECR1 CA630 £..A401
+12V
out of range. If these event codes have logged, resolve +VIRED 1 3
'ClW
O::z(/) - GND -
O_...J GNDIBLK 2 4
them before proceeding. M1 (/)0:::::> - CHA -5
~~a. AfNHT 3
(/)lD~ - CH B -
• If: None of these event codes have been logged. BIBLU 4
-
6
TS1 CA631 ACCESS 3

- Then proceed to Step 2. 1"1
~
+To BRN 1\
« ::.:: /
Step 2: Key truck OFF and back ON. BRNlBLK ~
w L..-
v
~
W
• If: Event Code 330 logs. v ><
~
M1 VI
U 'J U
- Then key truck OFF. Check wiring from
-0
ACCESS 3 CA401-5 to ECR1 CA630-3 (Chan-
Figure 21808
nel A) and ACCESS 3 CA401-6 to CA630-4
(Channel B).
Event Code 331
• If: Wiring is damaged.
- Then repair or replace as needed. ACCESS 3 Stall Detected

Step 1: Verify that abnormal operation did not create
event (e.g. debris in tire, etc.).
• If: Event codes affect traction operation or shut- Step 2: Key the truck ON. Use the Analyzer Menu to
downs continue. check the M1 Traction Speed against the M1 target
- Then proceed to Step 3. speed in A2.3.1.
Step 3: Key truck ON. Check ECR1 for 12 Vdc. Con- • If: The speed is approximately correct.
nect the positive meter lead to ECR1 CA630-1 and the
negative meter lead to CA630-2.

• If: The speed is not correct.
- Then replace M1.

Step 3: Verify that the traction motor (M1) and drive are
• If: Wiring and connections are good and Event in alignment and the bearing cup holder is tight. Oper-
Code continues. ate the truck and monitor drive for excessive lateral
- Then replace M1. movement.
• If: Operational checks are OK and the event con-

tinues.
Crown 2009 PF17432-37 Rev. 5110 M4.8-1457-037

01 Rev. 5/10
369
ELECTRICAL
ACCESS 3 Traction Motor (M1) Rotation More than ACCESS 3 Battery Voltage Below Range
4000 rpm
Step 1: Key truck OFF. Check wiring from ACCESS 3 NOTE
CA401-5 to ECR1 CA630-3 (Channel A) and Should Event Code 356 or Event Code 222 log with
ACCESS 3 CA401-5 and CA401-6 to ECR1 CA630-4 Event Code 333, then refer to the ED system event
(Channel B) for shorted or broken wiring. code first.
• If: Wiring is damaged. Step 1: Follow troubleshooting steps for Event Code
322.

• If: All checks OK and the truck model is configured
correctly in F3.1.
- Then monitor operation.
Step 2: Key truck ON. Check ECR1 for 12 V. Connect
the positive meter lead to ECR1 CA630-1 and the neg- • If: Event continues.
ative meter lead to ECR1 CA630-2. - Then replace ACCESS 3.
- Then check ECR1 wiring and connections.
• If: 12 V and Event Code continues.
- Then replace M1.
DISTRIBUTION
PANEL
TP1
•
ECR1 CA630 ~401
+12V
+VIRED 1 3
ci::(!)W - GND I--
o~~ GND/BLK 2 4
M1 cna:::::> - CHA I--
zU)o.. AlWHT 3 5
mlD~ B/BLU 4
- CHB I--
6
I--
TS1 CA631 ACCESS 3

r:;-
+To
< ~
BRN
BRNlBLK S- v f
A
S
w ~
f:)
Co).
V
V
U
-.Y. U
Figure 21808
M4.8-1457-038 Crown 2009 PF17432-38 Rev. 5110
01 Rev. 5/10
370
ELECTRICAL
CJ\OW" Event Code 334

ACCESS 3 Battery Voltage (+BV) Very Low ACCESS 3 Battery Voltage Above Range
Traction is disabled. All functions are enabled.
NOTE NOTE
Extreme duty cycle combined with incorrect or mal- Should Event Code 356 or Event Code 222 log with
functioning battery could also log Event Code 334. Event Code 335, then refer to the ED system event
Should Event Code 222 or Event Code 356 log with code first.
Step 1: Key truck ON. Using a DVOM, connect the negative lead to ACCESS 3 BNEG terminal and the
negative lead to ACCESS 3 BNEG terminal and the positive lead to ACCESS 3 CA401-1. +BV should be
positive lead to ACCESS 3 +BV terminal; +BV should present and the voltage should not exceed 2.25 V per
be present. cell.
• If: Voltage is less than +BV. • If: Voltage is greater than +BV.
- Then check for correct battery, power cable - Then check for correct battery or overcharge
connections, FU10 and ED1. condition.
• If: Power circuit checks are OK. • If: Battery voltage is correct (36 - 42 V).
- Then check battery charge level. - Then check for proper truck model in Features
Menu F3.1.
• If: Battery is properly charged.

• If: Truck is not configured properly.
Features Menu F3. - Then correct truck configuration.
• If: Truck is not configured correctly. • If: The truck is configured properly and event con-
tinues.
ACCESS 4
CA412
,--------------i 3
o
©~
©+
ACCESS 3
DISTRIBUTION
PANEL
ACCESS 3 CA201
Ol CArt
©~G) }]
FU10
SOOA
Figure 21809
ED1
36V
FU1 L..- ~+ II II f - - - - - - - - - '
15A
Figure 21806
Crown 2009 PF17432-39 Rev. 5110 M4.8-1457-039

01 Rev. 5/10
371
ELECTRICAL
ACCESS 3 Battery Voltage (+BV) Very High ACCESS 3 Battery Voltage (+BV) Under Voltage
Traction is disabled. All functions are disabled.
NOTE
Should Event Code 222 or Event Code 356 log with
charged.
Features Menu F3.
Event Code 337 • If: Configuration is correct.

ACCESS 3 Battery Voltage (+BV) Fluctuating
Full traction is disabled. not properly charged or if battery is not configured
Battery voltage is dropping excessively under load. correctly.
Step 1: Key truck ON. Using a DVOM, connect the - Then resolve the battery issue.
negative lead to the ACCESS 3 BNEG terminal and the Step 2: Key truck ON. Using a DVOM, connect the
positive lead to the ACCESS 3 +BV terminal; +BV positive lead to ACCESS 3 CA401-1 and the negative
should be present. lead to BNEG; +BV should be present.
• If: Voltage is less than +BV. • If: Voltage is above 0 V, but much less than +BV.
- Then check condition of power cables and con- - Then proceed to Step 3.
nections.
• If: +BV.
• If: Connections require repair.
- Then check the wiring from CA201-8 to
- Then repair or replace as needed. CA401-1 and repair or replace wiring as
needed.
• If: Connections are OK.
Step 3: Connect the positive meter lead to the distribu-
- Then check condition of battery or install a tion panel CA201-8 and the negative meter lead to
known good battery and monitor Event Code
ACCESS 3 BNEG
337.
• If: Voltage is above 0 V, but much less than +BV.

ACCESS 3
panel and replace as needed.
36V
L-------:-l+ IIIi 1--------' ACCESS 3
DISTRIBUTION
PANEL
Figure 21807
CA401 CA201
1 I--+-+---l 8
Figure 21809
M4.8-1457-040 Crown 2009 PF1743240 Rev. 5/10
01 Rev. 5/10
372
ELECTRICAL
CJ\own Event Code 339
Event Code 339 Step 3: Key truck OFF. Disconnect the negative wire
from ACCESS 3 CA401-18. Key truck ON and observe
code.
ACCESS 3 Battery Voltage (+BV) Over Voltage
Steering, traction and hydraulics are disabled. • If: Event Code changes to open (Event Code 346).
Follow troubleshooting steps for Event Code 338. - Then negative wire is shorted. Repair or re-
place as needed.
Event Code 340 • If: Event Code remains.

ACCESS 3 Emergency Disconnect Contactor (ED1)
Coil Driver Over Current
Steering, traction and hydraulics are disabled. DISTRIBUTION
PANEL ACCESS 3
Follow troubleshooting steps for Event Codes 222, CA203 ~401
256, and 356. 10 f------,El.---~---1~
TP1
•
TP4
•
ALM2
TRAVEL ALARM
+I(5\BV
~
n 1(5\+
~
BNEG
©
Event Code 341
Figure 21810
ACCESS 3 Travel Alarm (ALM2) Coil Driver Over
Current Event Code 342
ALM2 is disabled. Event Code 343
Step 1: Key truck OFF. Disconnect the negative wire
from ALM2. Key truck ON. ACCESS 3 General Purpose Coil Driver Over Cur-
rent
• If: Event Code changes to open (Event Code 346).
Note: This event code is currently not used.
- Then ALM2 or positive circuit is shorted. Pro-
ceed to Step 2.

- Then a short is internal to ACCESS 3 or the
wiring from ACCESS 3 to ALM2.
Step 2: Key truck OFF. Use a DVOM to check resis-
tance across ALM2 from the positive terminal to the
negative terminal. Resistance should be approximately
20 ohm.
• If: ALM2 coil is shorted.

- Then replace ALM2.
• If: ALM2 is approximately 20 ohm.
- Then check wiring from ALM2 to positive at dis-

tribution panel CA203-10.
• If: The wiring is shorted.
Crown 2009 PF1743241 Rev. 5110 M4.8-1457-041

01 Rev. 5/10
373
ELECTRICAL
Event Code 344
DISTRIBUTION
ACCESS 3 Fan (FAN3 and FAN4) Coli Driver Over PANEL
Current
ACCESS 3
FAN3 and FAN4 are disabled. TP4

•
from FAN3 and FAN4. Key truck ON.
- Then FAN3, FAN4 or positive circuit is shorted. Figure 21811

Proceed to Step 2.
• If: Event Code remains. Event Code 345

- Then a short is internal to ACCESS 3 or the ACCESS 3 Emergency Disconnect Contactor (ED1)
wiring from ACCESS 3 to FAN3 and FAN4. Coli Driver Open Circuit
Traction and hydraulics are disabled.
tance across each fan from the positive terminal to the
negative terminal. Resistance should be approximately Follow troubleshooting steps for Event Code 356.
20 ohm for each.
• If: FAN3 or FAN4 coil is shorted.
- Then replace shorted fan.
• If: Both fans are approximately 40 ohm.
- Then check wiring from FAN3 and FAN4 to

positive at distribution panel CA201-12.

code.

- Then negative wiring is shorted. Repair or re-
place as needed.

M4.8-1457-042 Crown 2009 PF1743242 Rev. 5110
01 Rev. 5/10
374
ELECTRICAL
mow" Event Code 346

Event Code 348
ACCESS 3 Travel Alarm (ALM2) Coli Driver Open
Circuit
ACCESS 3 General Purpose Coli Driver Open Cir-
ALM2 is disabled. cuit
Step 1: Key truck OFF. Disconnect the wires from Note: This event code is currently not used.
ALM2 and check ALM2 resistance.
• If: Less than approximately 20 ohm . Event Code 349

- Then replace ALM2.
ACCESS 3 Fan (FAN3 and FAN4) Coil Driver Open
• If: Approximately 20 ohm. Circuit
- Then proceed to Step 2. FAN3 and FAN4 are disabled.
Step 2: Key truck ON. Use a DVOM to check voltage Step 1: Key truck OFF. Disconnect the wires from
while engaging travel. Connect the positive meter lead FAN3 and FAN4 and check each fan resistance.
to distribution panel CA204-10 and the negative meter
lead to CA401-18.
• If: Less than approximately 20 ohm.
- Then replace FAN3 and FAN4.

• If: 0 V.
- Then disconnect the wire from ACCESS 3
• If: Approximately 20 ohm.
CA401-18. Connect the positive meter lead to - Then check for +BV between the wires and
ACCESS 3 CA401-18 and the negative meter FAN3 and FAN4.
lead to TP4 on the distribution panel while en-
gaging travel. • If: 0 V.
• If: 0 V. - Then disconnect the wire from ACCESS 3

CA401-8 and check for +BV between CA401-8
- Then replace ACCESS 3. and TP4 on the distribution panel.
• If: +BV. • If: 0 V.

- Then proceed to Step 3. - Then replace ACCESS 3.
Step 3: With truck keyed ON. Connect the positive me-
• If: +BV.
ter lead to TP1 on the distribution panel and the nega-
tive meter lead to the negative wire from CA203-10. - Then check the distribution panel and associ-
Measure voltage while engaging travel. ated positive wiring.
• If: 0 V.
- Then check the distribution panel and associ- DISTRIBUTION
PANEL
ated positive wiring. Repair or replace as
needed. ACCESS 3
TP4
•
DISTRIBUTION
PANEL ACCESS 3
CA203
101-------, r--+-1
+ BNEG Figure 21811
TP1 TP4 ALM2
L.- • • --' TRAVEL ALARM © ©
Figure 21810
Crown 2009 PF17432-43 Rev. 5110 M4.8-1457-043

01 Rev. 5/10
375
- - - - - - - - - - - --- --- ---------------------------------
ELECTRICAL
ACCESS 3 Emergency Disconnect Contactor (ED1) ACCESS 3 PWM Driver Over Voltage
Coil Driver Shorted
Traction and hydraulics are disabled.
Follow troubleshooting steps for Event Codes 222, 256 positive lead to CA201-8 and the negative lead to dis-
and 356. tribution panel TP1. Check for +BV.
• If: OV.
Event Code 351 - Then check FU1 for an open.
ACCESS 3 Travel Alarm (ALM2) Coil Driver Shorted • If: +BV.

ALM2 is disabled. - Then proceed to Step 2.
Follow troubleshooting steps for Event Code 341. Step 2: Connect the positive meter lead to ACCESS 3
CA401-1 and the negative meter lead to TP1.
Event Code 352 • If: 0 V.

Event Code 353 - Then repair or replace wire between CA401-1
and CA201-8.
ACCESS 3 General Purpose Coil Driver Shorted
Note: This event code is currently not used.
DISTRIBUTION
PANEL
CA201
Event Code 354 ACCESS 3
8
ACCESS 3 Fan (FAN3 and FAN4) Coil Driver TP1
Shorted CA401 •
1 f-+--+-'
FAN3 and FAN4 are disabled. ACCESS 4
CA412
BDI +BV 3 CA412 BDI
Follow troubleshooting steps for Event Code 344. 4 BNEG
KYS
FU1 START
....
15::J)-A++a.. voACC
'lGN
o~ ~v
L---'===~ ~+ IIII
Figure 21813
M4.8-1457-044 Crown 2009 PF17432-44 Rev. 5110
01 Rev. 5/10
376
ELECTRICAL
£!J\OWr. Event Code 356
Event Code 356

ACCESS 4
ACCESS 3 Detected Open Emergency Disconnect
CA412
Contactor (ED1) Circuit r------------j 3

CA411
Step 1: Check FU1 and FU10. }---------j 1
• If: Fuses are not functioning correctly. ACCESS 3

FU10
Step 2: Key truck ON and check for +BV between ED1 500 A
coil +BV and BNEG terminals.
ED1
• If: +BV. FU1

36V
' - - - - - - - - - : - 1 + 1/ 111-----------'
15A
- Then ED1 coil supply is correct, proceed to
Step 3. Figure 21806
• If: Approximately 80% +BY.
- Then ACCESS 3 driver is open, replace

ACCESS 3.
• If: 3 V.
- Then ACCESS 3 ED1 driver is correct, replace
ED1.
Step 3: Key truck OFF. Disconnect the wire from ED1
BNEG coil terminal. Check the resistance of ED1 coil.
• If: 20 ohm.
- Then reconnect the wire and proceed to Step
4.
• If: Resistance is not 20 ohm.
- Then replace ED1.

Step 4: Enter Service Mode 3. Select ED1 Test Output
Menu to activate ED1 switches. Check for +BV with no
active switches between ED1 BNEG coil connection
and BNEG.
• If: 0 V.
- Then disconnect the wire from ACCESS 3
CA401-2 and check for +BV.
• If: +BV.
- Then ACCESS 3 is shorted, replace
ACCESS 3.
• If: Not +BV.

- Then ACCESS 4 switch is open, replace
ACCESS 4.
Crown 2009 PF17432-45 Rev. 5110 M4.8-1457-045

01 Rev. 5/10
377
--- -------------------------------------------,
ELECTRICAL
Event Code 357 CRown
Event Code 357 • If: Battery does not have the correct voltage or is
not properly charged.
ACCESS 3 Detected Emergency Disconnect Con- - Then resolve the battery issue.
tactor (ED1) Tips Shorted
Step 2: Check the voltage on both sides of FU10.
• If: Voltage drop across FU1 0 is more than 0.5 V.
Step 1: Check ED1 contactor tips for a short.
- Then replace FU10.
• If: Contacts are shorted.
Step 3: Key truck ON and cycle pedal. Check for +BV
- Then repair or replace as needed. at ACCESS 3 +BV and BNEG terminals.
• If: ED1 is OK. • If: +BY.
- Then key truck OFF and check ED1 power cir- - Then proceed to Step 3.
cuit connections.
• If: Voltage is above 0 V, but much less than +BY.
• If: Cable connections are OK.
- Then check cables to ACCESS 3.
- Then follow troubleshooting steps for Event
Code 356. Step 4: Check for +BV between CA401-1 and BNEG
on ACCESS 3.
• If: Voltage ls above 0 V, but much less than +BV.

0::
>-0
0::1-
- Then check for +BV between CA201-8 on the
UJtl distribution panel and BNEG on ACCESS 3.
I=~
c(z
000
tl • If: +BV.
- Then check the wiring between CA201-8 and

CA401-1.
Step 5: Replace ACCESS 3.
EMERGENCY
DISCONNECT ACCESS 3
FU10 DISTRIBUTION
CONTACTOR
(ED1)
500 A PANEL
o CA201
f---+-+-----j 8
Figure 21802
36V
+ II1I
Event Code 359
Figure 21814
ACCESS 3 Pre-eharge Time Limit Exceeded

This event code indicates FU1 0 is possibly open.
• If: Battery has the correct voltage and is charged.
Crown 2009 PF17432-46 Rev. 5110

M4.8-1457-046
01 Rev. 5/10
378
ELECTRICAL

ACCESS 3 Pre-eharge Time Limit Exceeded ACCESS 3 Issue
Step 1: Calibrate ACCESS 3 if possible and operate
NOTE the truck.
Resistive load is present on the ED bus during pre-
charge. This condition is generally a shorted driver
condition. - Then replace ACCESS 3.
• If: Correct battery is installed and it is properly Event Code 364

Features Menu F3. ACCESS 3 Internal 5 V Supply Out of Range
Event Code 364: ACCESS 3 InternalS V Supply Out of
- Then proceed to Step 2. Range (High)
Step 2: Key the truck ON. Using a DVOM, connect the Event Code 365: ACCESS 3 InternalS V Supply Out of
positive lead to ACCESS 3 CA401-1 and the negative Range (Low)
lead to BNEG; +BV should be present.
• If: If voltage measured is +BV. back ON.
- Then proceed to Step 3: • If: Event code continues.
• If: voltage measured is above 0 V, but much less - Then replace ACCESS 3.
than +BV.
panel. Repair or replace the distribution panel
or wiring as needed.
Step 3: Key the truck OFF. Check the wiring from
ACCESS 3 CA401-1 to CA201-8 on the distribution
panel. Repair or replace as needed.
Step 4: Check other events logged with Event Code
360.
FU10 DISTRIBUTION
SOOA PANEL
CA201
f--+-+---J 8
36V
+ llil
Figure 21814
•
Crown 2009 PF17432-47 Rev. 5110 M4.8-1457-047
01 Rev. 5/10
379
ELECTRICAL
Event Code 366 Event Code .367 CJ\OWI'
ACCESS 3 12 V Power Supply for ECR1 Out of ACCESS 3 Internal 15 V Power Supply Out of
Range Range
Event Code 366: ACCESS 3 12 V Power Supply for Event Code 368: ACCESS 3 Internal 15 V Power Sup-
ECR1 Out of Range (High) ply Out of Range (High)
Event Code 367: ACCESS 3 12 V Power Supply for Event Code 369: ACCESS 3 Internal 15 V Power Sup-
ECR1 Out of Range (Low) ply Out of Range (Low)
Step 1: Using a DVOM, connect the positive meter Step 1: Internal ACCESS 3 issue. Key truck OFF then
lead to ACCESS 3 CA401-3 and the negative meter back ON.
lead to TP1 (BNEG) on the distribution panel.
• If: 0 V.
• If: Approximately 12 V and event code continues. Event Code 370

- Then proceed to Step 2. Event Code 371
Step 2: Disconnect the wire from CA401-3. Connect
the positive meter lead to ACCESS 3 CA401-3 and the ACCESS 3 Internal 5 V Power Supply Out of Range
negative meter lead to distribution panel TP1 (BNEG). All functions are disabled.
• If: 12 V. Event Code 370: ACCESS 3 Internal 5 V Power Sup-

ply Out of Range (High)
- Then replace ECR1.
• If: Not approximately 12 V and event code contin- ply Out of Range (Low)
ues.
- Then replace ACCESS 3. back ON.

DISTRIBUTION _ Then replace ACCESS 3.
PANEL
TP1
•
ECR1 CA630 r£-A401
+12V
+VIRED 1 3
a:C>W I-- GND I--
oz<ll
_....I GNDIBLK 2 4
M1 <IlD::=> I-- CHA I - -
zitio.. NWHT 3 5
~lD~ BIBLU 4
I-- CH B I - -
6
I--
ACCESS 3
TS1 CA~
+r. BRN 1
~
1\
« ~
BRN/BLK ~ /
e: v
)
w
v
U
~ v
=
v
U
Figure 21808
M4.8-1457-048 Crown 2009 PF17432-48 Rev. 5110
01 Rev. 5110
380
ELECTRICAL
mow" Event Code 372 Event Code 373
Event Code 372 Step 1: Internal ACCESS 3 issue. Key truck OFF then
back ON.
Event Code 373
ACCESS 3 Internal 227 mv Reference Voltage Out - Then replace ACCESS 3.
of Range
Event Code 378
ence Voltage Out of Range (High) ACCESS 3 Over Current Condition
Event Code 373: ACCESS 3 Internal 227 mv Refer- Traction is disabled.
ence Voltage Out of Range (Low)
Step 1: Key truck OFF. Disconnect M1 cables from
Step 1: Internal ACCESS 3 issue. Key truck OFF then ACCESS 3 and key truck ON.
back ON.
Event Code 374 - Then proceed to Step 2.
Event Code 375 Step 2: Check M1 and cabling for phase to phase and
phase to truck frame shorts.
ACCESS 3 Internal 2.5 V Reference Voltage Out of • If: Short exists between U V or W cables or truck
I
Range
frame.
- Then disconnect cabling and check for M1
Event Code 374: ACCESS 3 Internal 2.5 V Reference Winding shorts to truck frame.
• If: Short exists in M1.
Event Code 375: ACCESS 3 Internal 2.5 V Reference
Voltage Out of Range (Low) - Then replace M 1.

back ON.

ACCESS 3
Event Code 376

Event Code 377
Figure 21815
ACCESS 3 Internal Analog Ground Voltage Out of
Range
Event Code 376: ACCESS 3 Internal Analog Ground
Event Code 377: ACCESS 3 Internal Analog Ground
Crown 2009 PF17432-49 Rev. 5110 M4.8-1457-049

01 Rev. 5/10
381
ELECTRICAL
Event Code 379
Event Code 380
ACCESS 3 Internal Short
ACCESS 3
back ON.

Figure 21815
Event Code 383

Event Code 381
Event Code 384
Event Code 382
ACCESS 3 Short
ACCESS 3 Short
Event Code 381: ACCESS 3 Short Between +BV and Terminal V
Terminal U
Event Code 384: ACCESS 3 Short Between BNEG
Event Code 382: ACCESS 3 Short Between BNEG and Terminal V
and Terminal U
Follow troubleshooting steps for event code 382.
Step 1: Check condition of M1 cables.
• If: Cables are shorted. Event Code 385

- Then repair or replace cables. Event Code 386
• If: Cables are OK.
ACCESS 3 Short
Step 2: Disconnect M1 cabling from ACCESS 3 and
key truck ON.
Terminal W
• If: Event code continues. Event Code 386: ACCESS 3 Short Between BNEG
- Then replace ACCESS 3. and Terminal W
- Then replace M1.
Crown 2009 PF17432-60 Rev. 5110

M4.8-1457-050
01 Rev. 5110
382
ELECTRICAL
CJ\OWI' Event Code 387 Through Event Code 389
Event Code 387 Step 1: Operate tilt while monitoring POT412 V supply
voltage in Analyzer Menu A2.3.6.2.
Through
• If: 12 V.
Event Code 389
ACCESS 3 Short from Terminal U to V
• If: Approximately 12 V and event code continues.
Event Code 387: Short U to V
Step 2: Disconnect ECR1 and operate tilt while moni-
Event Code 388: Short UL to VH toring POT4 12 V supply voltage in Analyzer Menu
Event Code 389: Short UH to VL A2.3.6.1.
Follow troubleshooting steps for event code 382. • If: Approximately 12 V and event code continues.

Event Code 390 Step 3: Operate tilt while monitoring POT4 wiper input
Through voltage in Analyzer Menu A2.3.6.1.
Event Code 392 • If: Wiper input voltage is not consistent with tilt
movement.
ACCESS 3 Traction Motor (Mi) Short - Then proceed to Step 4.
Traction is disabled. Step 4: Use a DVOM to check wiper input voltage at
Event Code 390: Short V to W T8406-12. Connect the positive meter lead to
T8406-12 and the negative meter lead to T8406-9.
Event Code 391: Short VL to WH
Event Code 392: Short VH to WL
• If: Wiper input voltage is not consistent with tilt
movement.
- Then replace POT4.
Event Code 393

~6
Through -~ 9 ~ ~ ACCESS 3
Event Code 395 POT4

CSl:CSl CM01
-
12 1]
~-CSl13
ACCESS 3 Traction Motor (Mi) Short -
ECR1 CA630
Traction is disabled. +V/RED 1
+12V -
'(!)w
O::zcn
0_....1 GND/BLK 2
- GND -43
Event Code 393: Short W to U M1 zcn~::>
ll.
- CHA -5
AlWHT 3
Event Code 394: Short WL to UH ~lll~ BIBLU 4
- CHB f--
6
f--
Event Code 395: Short WH to UL TS1 CA~

+T'
« -l£
BRN
BRNIBLK ~
1
/" till
w ~ V
.Gl
W
M1 V\ V lJ)
Event Code 398 U 'J U
~
'='
ACCESS 3 Tilt Sensor (POT4) Out of Range Figure 21816
All functions are enabled.

POT4 wiper input is outside the calibrated range.
Crown 2009 PF17432-51 Rev. 5110 M4.8-1457-051

01 Rev. 5/10
383
~- ----------------------------
ELECTRICAL
Event Code 400
ACCESS 4 Invalid Event ACCESS 4

The event code reported is not defined in the vehicle
code.
CA412
33
Event Code 401 34H~---""':=~
35 ~-~---':"'::':::.j.d
ACCESS 4 Steer Feedback RPS1 (High)
+BV BNEG
(Hydraulic steer units)
Full speed traction is disabled.
NOTE Figure 23829

RPS1 input at CA412-34 is always high.
Step 1: With the truck keyed ON. View the signal volt-
age from the steer feedback sensor (RPS1) in Analyzer
Menu A2.4.21.1. The appropriate range is 0.7 - 4.5 V.
• If: Always high.
Then using a DVOM, connect the positive lead

to ACCESS 4 CA412-34 and the negative lead
to ACCESS 4 CA412-33 to check the voltage.
• If: Always high.
- Then check RPS1 and associated wiring.
- Then replace RPS1 and calibrate using Cali-

bration Menu C2.8.
• If: Event continues.

M4.8-1457-052 Crown 2009 PF17432-62 Rev. 5/10
01 Rev. 5/10
384
ELECTRICAL

ACCESS 4 Steer Feedback RPS1 5 V Power Supply ACCESS 4 FRAM Issue
(low) Traction is disabled.
(Hydraulic steer units) ACCESS 4 is unable to write memory location.
Step 1: Key truck OFF then back ON.
NOTE • If: Event code continues.
RPS1 input at CA412-34 is always low. - Then replace ACCESS 4.

Step 1: With the truck keyed ON. View the signal volt-
age from the steer feedback sensor (RPS1) in Analyzer Event Code 404
Menu A2.4.21.1. The appropriate range is 0.7 - 4.5 V.
• If: Always low. ACCESS 4 FRAM Event History Issue
- Then using a DVOM, connect the positive lead All functions are enabled.
to ACCESS 4 CA412-34 and the negative lead Event history has been lost.
to ACCESS 4 CA412-33 to check the voltage.
• If: Always low.
- Then check RPS1 and associated wiring.
- Then replace RPS1 and calibrate using Cali- Event Code 405
bration Menu C2.8.
ACCESS 4 Hour Meter Memory Corrupt
• If: Problem continues.
All functions are enabled.
Event history has been lost.
ACCESS 4
CA412
Event Code 406
33
34~----~::..jCI
ACCESS 4 Invalid Calibration Value
35 f-------*--....:....:..:'-4CI
+BV BNEG
ACCESS 4 has lost calibration. Recalibrate the truck in
the Calibration Menu.
Figure 23829 • If: Event code continues.
Crown 2009 PF17432·53 Rev. 5110 M4.8-1457-053

01 Rev. 5/10
385
ELECTRICAL
Event Code 407 l!J\own
Event Code 407
ACCESS 4 Low Input Voltage
ACCESS 4 observes incorrect battery voltage (low).
Step 1: Check for proper battery voltage and condition
of battery.
• If: Voltage is incorrect or battery is in need of repair.
- Then correct, repair or replace the battery.
• If: Battery is OK and event code continues.
ACCESS 4
36V
L-_~+11111-------'
Figure 21817
Event Code 408

ACCESS 4 High Input Voltage
ACCESS 4 observes incorrect battery voltage (high).
Step 1: Check for proper battery voltage and condition
of battery.
• If: Voltage is incorrect or battery is in need of repair.
- Then correct, repair or replace the battery.
• If: Battery is OK and event code continues.
ACCESS 4
36V
L-------;1+ 11111--_----'
Figure 21817
M4.8-1457-054 Crown 2009 PF17432-64 Rev. 5110
01 Rev. 5/10
386
ELECTRICAL
Event Code 409

ACCESS 1
ACCESS 4 CAN Communication Issue with DISTRIBUTION PANEL
CM05
ACCESS 1 CA204
~~~ 8
CANH
120 OHM
1 CAN H TP7
2
1200HM r-e
RESISTOR~
"'++-+--j 9 RESISTOR
CAN L c>
ACCESS 4 CAN bus communication with ACCESS 1 3 CAN L TP8 ~©

CD
was lost. 4
5 CA205 ACCESS 4
Step 1: Key truck ON and check the status of 6 1
CM10
8 4
2
9
code continues. 10
12
• If: ACCESS 4 indicator lights are OFF.
- Then check and repair power input to Figure 21791

ACCESS 4 at CA41 0-1 and CA41 0-2.
tions. CAN_H: Using a DVOM, check wire continuity
ACCESS 4 CA412-2. CAN_L: Using a DVOM, check
CA205-9 to ACCESS 4 CA412-1.

Step 3: Check the CAN communication lines. Key
truck OFF and check the resistance between CAN_H
(TP7) and CAN_L (TP8) on the distribution panel; re-
sistance should be 60 ohm.
• If: 0 ohm.
- Then a short exists between CAN Hand
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

Crown 2009 PF17432-55 Rev. 5110 M4.8-1457-055

01 Rev. 5/10
387
ELECTRICAL
Event Code 410
ACCESS 4 CAN Communication Issue with DISTRIBUTION PANEL ACCESS 2
ACCESS 2 CA204
CA402
1 CAN H TP7
2
r--e
1200HM
RESISTOR~
.----+--+----i 15
ACCESS 4 CAN bus communication with ACCESS 2 3 CAN L TP8
was lost. 4
5
Step 1: Key truck ON and check the status of
6
ACCESS 4 indicator lights. 7
ACCESS 4
• If: ACCESS 4 indicator lights are ON and event 8
9
code continues.
10
12 11 ~==::r-~7---1
• If: ACCESS 4 indicator lights are OFF.
- Then check and repair power input to Figure 21795

tions. CAN_H: Using a DVOM, check wire continuity
ACCESS 2 CA402-23. CAN_L: Using a DVOM check
bution panel CA205-9. Then check CA205-11 to
ACCESS 2 CA402-15.

(TP7) and CAN_L (TP8) on the distribution panel; re-
sistance should be 60 ohm.
• If: 0 ohm.
CAN_L. Check associated wiring, connections
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

M4.8-1457-056 Crown 2009 PF17432.Q6 Rev. 5110
01 Rev. 5110
388
ELECTRICAL
Event Code 411

ACCESS 4
ACCESS 4 Proportional Lower Valve (PVL) Driver
Over Current TILT ~;11
SIDESHIFT
Raise and lower are disabled. }--:--=....::o-~ 29
'R}-----=~----=-REAo:-:.Co-H.:....j 28
PVL driver output is shorted to +BV.
Step 1: Key truck OFF. Disconnect green/white wire
from PVL. Key truck ON and observe code.
• If: Event Code changes, to open (Event Code 435).
- Then PVL or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to PVL.
Proceed to Step 3.
tance across PVL from the positive terminal to the neg-
ative terminal. Resistance should be approximately 30
ohm.
• If: PVL coil is shorted.

36V
- Then replace PVL. L.-_~+11111-----'
• If: PVL is approximately 30 ohm. Figure 21818
- Then check red/white wiring from PVL to posi-

tive at CA41 0-4 for a short.

code.
- Then green/white wire is shorted, repair or re-

place as needed.

- Then inspect CA411 connector for damage.
• If: Connector is not damaged or shorted.
Crown 2009 PF17432-57 Rev. 5110 M4.8-1457-057

01 Rev. 5/10
389
ELECTRICAL
Event Code 415 CJ\own
Event Code 415
ACCESS 4
ACCESS 4 Proportional Accessory Valve (PVA)
Driver Over Current .~_ _---oT.:.=ILoT-I ~:411
}....:S:..:..:ID:..::(Ej..:.SH.:o1FT-I 29
Accessory hydraulics are disabled.
REACH 28
PVA driver output is shorted to +BV.
:Y\---.lU..et:IS1.Si\ 24
:Vl-"""":::::::--..lJJ.!!liUI 25
from PVA. Key truck ON and observe code.
26
- Then PVA or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to PVA.
Proceed to Step 3.
tance across PVA from the positive terminal to the neg-
ohm.
• If: PVA coil is shorted.
- Then replace PVA.
• If: PVA is approximately 30 ohm. Figure 21818
- Then check red/white wiring from PVA to posi-


code.

place as needed.

Crown 2009 PF17432-68 Rev. 5/10

M4.8-1457-058
01 Rev. 5110
390
ELECTRICAL
Event Code 418

ACCESS 4
ACCESS 4 Bypass Solenoid (SVBY) Driver Over
Current TILT ~~11
SIDESHIFT
l---o-~29
Raise is disabled. REACH
RJ------'---o-o-i 28
SVBY driver output is shorted to +BV.
NOTE
This coil is not driven on the 36 Vdc hydraulic models.
from SVBY. Key truck ON and observe code.
- Then SVBY or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SVBY.
Proceed to Step 3.
tance across SVBY from the positive terminal to the
negative terminal. Resistance should be approximately 36V
'----:-i+ IIII f------'
30 ohm.
• If: SVBY coil is shorted. Figure 21818
- Then replace SVBY.
• If: SVBY is approximately 30 ohm.
- Then check red/white wiring from SVBY to pos-

itive at CA41 0-4 for a short.

code.
• If: Event Code changes, to open (Event Code 801 ).

place as needed.

Crown 2009 PF17432-59 Rev. 5110 M4.8-1457-059

01 Rev. 5/10
391
ELECTRIGAL
Event Code 419
ACCESS 4
ACCESS 4 Raise Solenoid (SCV) Driver Over Cur-
TILT CA411
rent .i-=-----o--o~ 30
SIDESHIFT
Full speed raise is disabled. ....,,=-~-4svs 29
R}------:~----=-RoEA....:;Co-H~ 28
SCV driver output is shorted to +BV.
Note: This coil is not driven on the 36 Vdc hydraulic
models.
from SCV. Key truck ON and observe code.
- Then SCV or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SCV.
Proceed to Step 3.
tance across SCV from the positive terminal to the neg-
ohm.
• If: SCV coil is shorted.

Figure 21818
- Then replace SCV.
• If: SCV is approximately 30 ohm.
- Then check red/white wiring from SCV to posi-


code.

place as needed.

Crown 2009 PF17432~ Rev. 5110

M4.8-1457-060
01 Rev. 5/10
392
ELECTRICAL
Event Code 420

ACCESS 4
ACCESS 4 Lower Solenoid (SVL) Driver Over Cur-
rent TILT ~;11
SIDESHIFT
Raise and lower are disabled. )----O--o---i 29
REACH 28
SVL driver output is shorted to +BV.
.Y}----"l..I..I:.L:llo""l24
}---=------'-""""''-Y 25
from SVL. Key truck ON and observe code.
)---"""-'.<.Ioo!..>j26
• If: Event Code changes, to open (Event Code 803). 27
- Then SVL or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SVL.
Proceed to Step 3.
tance across SVL from the positive terminal to the neg-
ohm.
• If: SVL coil is shorted.
- Then replace SVL.
• If: SVL is approximately 30 ohm. Figure 21818
- Then check red/white wiring from SVL to posi-


code.

place as needed.

- Ther:'l replace ACCESS 4.
Crown 2009 PF17432-el Rev. 5/10 M4.8-1457-061

01 Rev. 5/10
393
ELECTRICAL
Event Code 421
ACCESS 4
ACCESS 4 Accessory Solenoid (SVA) Driver Over
TILT CA411
Current
SIDESHIFT 30
Accessory hydraulics are disabled. }----O-~29
REACH
Rf------'--{}--<D---128
SVA driver output is shorted to +BV.
from SVA. Key truck ON and observe code.
- Then SVA or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SVA.
Proceed to Step 3.
tance across SVA from the positive terminal to the neg-
ohm.
• If: SVA coil is shorted.
- Then replace SVA.
• If: SVA is approximately 30 ohm. Figure 21818
- Then check red/white wiring from SVA to posi-


code.
• If: Event Code changes. to open (Event Code 804).

place as needed.

M4.8-1457-062 Crown 2009 PF17432.a2 Rev. 5110
01 Rev. 5/10
394
ELECTRICAL
-
Event Code 422
ACCESS 4
ACCESS 4 Reach Solenoid (SVR) Driver Over Cur- CA411
rent TILT
~-----o--=O---l30
\S~ID:..:EoS~Ho-IFT.:..j
Reach is disabled. r- 29
REACH 28
SVR driver output is shorted to +BV.
from SVR. Key truck ON and observe code.
- Then SVR or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SVR.
Proceed to Step 3.
tance across SVR from the positive terminal to the neg-
ohm.
• If: SVR coil is shorted.

- Then replace SVR.
• If: SVR is approximately 30 ohm. Figure 21818
- Then check red/white wiring from SVR to posi-


code.

place as needed.

Crown 2009 PF17432~3 Rev. 5110 M4.8-1457-063

01 Rev. 5/10
395
ELECTRICAL
Event Code 423
ACCESS"
ACCESS 4 Sideshift Solenoid (SVS) Driver Over
TILT CA411
Current
SIDESHIFT 30
Sideshift is disabled. l----O-~29
REACH
R}----'----o-o---j 28
SVS driver output is shorted to +BV.
Step 1: Key truck OFF. Disconnect green/white wire 24
from SVS. Key truck ON and observe code. VJ---='------''''''''''''''-'-i 25
l--"""'"""-".l.IoaJ...>l26
• If: Event Code changes. to open (Event Code 806). 27
- Then SVS or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SVS.
Proceed to Step 3.
tance across SVS from the positive terminal to the neg-
ohm.
• If: SVS coil is shorted.

- Then replace SVS.
• If: SVS is approximately 30 ohm. Figure 21818
- Then check red/white wiring from SVS to posi-


code.
• If: Event Code changes. to open (Event Code 806).

place as needed.

M4.8-1457-064 Crown 2009 PF17432-64 Rev. 5110
01 Rev. 5/10
396
ELECTRICAL
Event Code 424

ACCESS 4
ACCESS 4 Tilt Solenoid (SVT) Driver Over Current
TILT ~;11
Tilt is disabled. SIDESHIFT
"'-"=-----'--{:SVS 29
SVT driver output is shorted to +BV. REACH 28

Yl---....!2.l.r:t::!S!2j 24
from SVT. Key truck ON and observe code.
25
• If: Event Code changes, to open (Event Code 807). f---"""""-!.~26
}-~0l00!J,,~=lI.j27
- Then SVT or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to SVT.
Proceed to Step 3.
tance across SVT from the positive terminal to the neg-
ohm.
• If: SVT coil is shorted.

- Then replace SVT.
• If: SVT is approximately 30 ohm.

Figure 21818
- Then check red/white wiring from SVT to posi-
tive at CA41 04 for a short.

code.

place as needed.

Crown 2009 PF17432-65 Rev. 5110 M4.8-1457-065

01 Rev. 5/10
397
ELECTRICAL
Event Code 425
ACCESS 4
ACCESS 4 Fan (FAN1) Driver Over Current
CA410
FAN1 is disabled. 4
FAN1 driver output is shorted to +BV.

from FAN1. Key truck ON and observe code.
- Then FAN1 or positive circuit is shorted. Pro-

ceed to Step 2.

Figure 21819
green/white wiring from ACCESS 4 to FAN1.
Proceed to Step 3.
tance across FAN1 from the positive terminal to the
negative terminal. Resistance should be approximately
30 ohm.
• If: FAN1 coil is shorted.
- Then replace FAN1.
• If: FAN1 is approximately 30 ohm.
- Then check red/white wiring from FAN1 to pos-

itive at CA41 0-4 for a short.

code.

place as needed.

M4.8-1457-066 Crown 2009 PF17432~ Rev. 5110
01 Rev. 5110
398
ELECTRICAL
Event Code 426

ACCESS 4
ACCESS 4 Hom (HN) Driver Over Current
HN is disabled.
HN driver output is shorted to +BV.
from HN. Key truck ON and observe code.
- Then HN or positive circuit is shorted. Proceed Figure 21820

to Step 2.

green/white wiring from ACCESS 4 to HN. Pro-
ceed to Step 3.
tance across HN from the positive terminal to the neg-
ohm.
• If: HN coil is shorted.

- Then replace HN.
• If: HN is approximately 30 ohm.
- Then check red/white wiring from HN to posi-


code.

place as needed.

- Then inspect CA41 0 connector for damage.
Crown 2009 PF17432-67 Rev. 5110 M4.8-1457-067

01 Rev. 5/10
399
ELECTRICAL
Event Code 427 CJ\OWI)
Event Code 427
ACCESS 4
CA411
Coil Driver Over Current TILT 30
SIDESHIFT 29
ED1 is disabled.
REACH 28
ED1 driver output is shorted to BNEG.
from ED1. Key truck ON and observe code.
- Then ED1 or positive circuit is shorted. Pro-

ceed to Step 2.

green/white wiring from ACCESS 4 to ED1.
Proceed to Step 3.
tance across ED1 from the positive terminal to the neg-
ohm.
• If: ED1 coil is shorted.

- Then replace ED1.
• If: ED1 is approximately 30 ohm. Figure 21818
- Then check red/white wiring from ED1 to posi-


code.

place as needed.

M4.8-1457-068 Crown 2009 PF17432-68 Rev. 5110
01 Rev. 5/10
400
ELECTRICAL
Event Code 428 • If: +BV is present at PVL on one side only.
- Then PVL coil is open, replace PVL.

ACCESS 4 Proportional Lower Valve (PVL) Driver
Shorted • If: +BV is present at both sides of PVL.
Raise and lower are disabled. - Then check the voltage at CA411-13 for +BV.
PVL driver is shorted internally to ACCESS 4; PVL is • If: +BV.
driven when it should be OFF.
- Then key truck OFF and back ON. Check the
Follow troubleshooting steps for Event Code 411 .
voltage again at CA411-13 while testing the
output in Analyzer Menu A4.4.1. Voltage
Event Code 432 should drop to 18-20 Vdc.
• If: Voltage stays at +BV.

Driver Shorted - Then replace ACCESS 4.
Raise and lower are disabled.

PYA driver is shorted internally to ACCESS 4; PYA is ACCESS 4
CA411
driven when it should be OFF. TILT 30
Follow troubleshooting steps for Event Code 415. SIDESHIFT 29

REACH 28
Event Code 435

ACCESS 4 Proportional Lower Valve (PVL) Open
Circuit
An open circuit exists in either the PVL coil or the pos-
itive or negative wiring to the solenoid.
ACCESS 4 supplies a constant positive to the coil and
switches negative in proportion to the command. Test
by tracing the positive through the coil and back to the
coil driver output.
Step 1: Connect the negative lead to known battery
negative. Probe for +BV on PVL. With truck keyed ON,
+BV should be present at both sides of the coil.
• If: +BV is not present at PVL.
- Then check the positive wiring back to

ACCESS 4 CA41 0-4.
• If: +BV is not present at CA41 0-4. Figure 21818
• If: +BV is present at CA41 0-4.
- Then repair or replace wiring from CA41 0-4 to

PVL.
Crown 2009 PF17432~9 Rev. 5110 M4.8-1457-069

01 Rev. 5/10
401
ELECTRICAL
Event Code 436
ACCESS 4
ACCESS 4 Proportional High Speed Lower Valve
TILT CA411
(PCV2) Open Circuit
1=----o-o--i30
SIDESHIFT
Raise and lower are disabled. ~::--.....:........jsvs 29
REACH
.---{S\i'R}------'----<>-o-i 28
An open circuit exists in either the PCV2 coil or the pos-
itive or negative wiring to the solenoid. Yl---"'.l.J:.£:l>/""l24
ACCESS 4 supplies a constant positive to the coil and v/---=-----'..........U-j 25
1--~I.>&1..lj26
27
coil driver output.
negative. Probe for +BV on PCV2. With truck keyed
ON, +BV should be present at both sides of the coil.
• If: +BV is not present at PCV2.

ACCESS 4 CA41 04.
• If: +BV is not present at CA41 04.
• If: +BV is present at CA41 04.
- Then repair or replace wiring from CA41 04 to

PCV2.
Figure 21818
• If: +BV is present at PCV2 on one side only.
- Then PCV2 coil is open, replace PCV2.
• If: +BV is present at both sides of PCV2.
- Then check the voltage at CA411-6 for +BV.
• If: +BV.

voltage again at CA411-6 while testing the out-
put in Analyzer Menu A4.4.2. Voltage should
drop to 18-20 Vdc.
M4.8-1457-070 Crown 2009 PF17432-70 Rev. 5110
01 Rev. 5/10
402
ELECTRICAL
Event Code 438

ACCESS 4
ACCESS 4 Proportional Mast Valve (PCV1) Open
Circuit TILT ~~11
SIDESHIFT
Raise and lower are disabled. l----O--o---i 29
REACH
R)-----'----Q>-O---l28
An open circuit exists in either the PCV1 coil or the pos-
coil driver output.
negative. Probe for +BV on PCV1. With truck keyed
• If: +BV is not present at PCV1.

ACCESS 4 CA41 0-4.
• If: +BV is not present at CA41 0-4.

PCV1.
Figure 21818
• If: +BV is present at PCV1 on one side only.
- Then PCV1 coil is open, replace PCV1.
• If: +BV is present at both sides of PCV1
• If: +BV.

drop to 18-20 Vdc.
Crown 2009 PF17432-71 Rev. 5110 M4.8-1457-071

01 Rev. 5/10
403
ELECTRICAL
Event Code 439
Event Code 439

ACCESS 4
Open Circuit
SIDE~~~FT ~:411
Accessory hydraulics are disabled. """,=------O.---{svs 29
~\_---=-~ R_6EA::...:.Co_H.:...j
..." 28
An open circuit exists in either the PVA coil or the pos-
coil driver output.
negative. Probe for +BV on PVA. With truck keyed ON,
• If: +BV is not present at PVA.

ACCESS 4 CA41 0-4.
• If: +BV is present at CA410-4.

PVA.
Figure 21818
• If: +BV is present at PVA on one side only.
- Then PVA coil is open, replace PVA.
• If: +BV is present at both sides of PVA.
• If: +BV.

drop to 18-20 Vdc.
M4.8-1457-072 Crown 2009 PF17432-72 Rev. 5110
01 Rev. 5/10
404
ELECTRICAL
Event Code 442 ~ CAUTION

ACCESS 4 Inner Brake (BRK1) Coli Open Circuit BRK1 may be very hot.
Traction is disabled. Step 1: Carefully check BRK1 coil to see if it is very hot.
One of the wires to BRK1 inner coil is open; current is • If: BRK1 is very hot.
less than 1 A.
- Then allow BRK1 to cool, and verify proper
Step 1: Monitor BRK1 resistance and current feedback BRK1 air gap and that bolts are tightened.
in Analyzer Menu A3.4.19.2 (current) and A3.4.19.3
(resistance). Current is less than 1 A and resistance is • If: Settings are incorrect.
more than 6 ohm.
- Then check BRK1 adjustment.
• If: Resistance is more than 6 ohm.
• If: BRK1 adjustment is OK.
- Then disconnect ACCESS 4 CA41 0 and check
- Then test the output in Analyzer Menu A4.4.18
wire continuity from CA41 0-6 and CA41 0-7 to
for current and resistance.
the inner coil.
• If: BRK1 releases normally.
• If: Wiring or connections are open.
- Then check the wiring from ACCESS 4
CA41 0-6 and CA41 0-7 to the inner coil.
• If: Wiring or connections are OK.
- Then replace BRK1 coil.
- Then monitor event code.

ACCESS 4
• If: BRK1 does not release and its current level is

approximately 2 A.
- Then BRK1 has a mechanical issue, repair or
replace BRK1.
ACCESS 4
Figure 21821
Event Code 443

ACCESS 4 Inner Brake (BRK1) Coli Resistance Hot
(Brake Is dragging)
BRK1 coil resistance is high, more than operating
Figure 21821
range. Check BRK1 for over temperature or a connec-
tion issue. Current and resistance can be verified in An-
alyzer Menu A3.4.19.
Crown 2009 PF17432-73 Rev. 5110 M4.8-1457-073

01 Rev. 5/10
405
ELECTRICAL
Event Code 444

ACCESS 4 Inner Brake (BRK1) Resistance High ACCESS 4 Outer Brake (BRK1) Coli Open Circuit
Limp traction only. (Limited travel speed, usually Traction is disabled.
1.61 km/h [1 mph] or less.)
One of the wires to BRK1 outer coil is open; current is
BRK1 coil resistance is higher than expected in a nor- less than 3 A. Current and resistance can be verified in
mal hot brake as with Event Code 443. Though the re- Analyzer Menu A3.4.18.
sistance is very high, it is not an open circuit. Check
Step 1: Disconnect ACCESS 4 CA410 and check the
BRK1 for over temperature or a connection issue. Cur-
resistance at the outer coil from CA41 0-8 to CA41 0-12.
rent and resistance can be verified in Analyzer Menu
A3.4.19. • If: Resistance is more than 5 ohm.
- Then check wire continuity from CA41 0-8 and
Lt CAUTION CA41 0-12 to the outer coil.
BRK1 may be very hot and may bum skin. • If: Wiring or connections are open.
Follow troubleshooting steps for Event Code 443. - Then repair or replace as needed.

ACCESS 4
ACCESS 4
Figure 21821
36V
'----;-1+ I" I
~---'
Figure 21821
M4.8-1457-074 Crown 2009 PF17432-74 Rev. 5110
01 Rev. 5/10
406
ELECTRICAL
CJ\OWf\ Event Code 446
Event Code 446

ACCESS 4
ACCESS 4 Outer Brake (BRK1) Coil Resistance Hot
(Brake is dragging)
LL CAUTION
BRK1 may be very hot and may bum skin.
Step 1: Carefully check BRK1 coil to see if it is hotter Figure 21821
than normal.
• If: BRK1 is hotter than normal. Event Code 447

- Then allow BRK1 to cool, and verify proper
ACCESS 4 Outer Brake (BRK1) Resistance High
BRK1 air gap and that bolts are tightened.
Limp traction only. (Limited travel speed, usually
• If: Settings are incorrect. 1.61 km/h [1 mph] or less.)
- Then check BRK1 adjustment. BRK1 coil resistance is higher than expected in a nor-
mal hot brake as with Event Code 446. Though the re-
- Then test the output in Analyzer Menu A4.4.17 BRK1 for over temperature or a connection issue. Cur-
for current and resistance. rent and resistance can be verified in Analyzer Menu
A3.4.18.

CA41 0-8 and CA41 0-12 to the outer coil.
LL CAUTION
BRK1 may be very hot and may burn skin.


approximately 5 A.
replace BRK1.
Crown 2009 PF17432-75 Rev. 5110 M4.8-1457-075

01 Rev. 5/10
407
ELECTRICAL
Event Code 448 CRown
Event Code 448 Step 1: Use Utilities Menu U1.1 to verify software is
Version 8 or higher.
ACCESS 4 Caster Brake (BRK2) Coli Open Circuit • If: Incorrect.
Traction is disabled. - Then update software.
One of the wires to BRK2 outer coil is open; current is Step 2: Carefully check BRK2 coil to see if it is hotter
less than 0.5 A. Current and resistance can be verified than normal.
in Analyzer Menu A3.4.20.
• If: BRK2 is hotter than normal.
Step 1: Key truck OFF. Disconnect ACCESS 4 CA411
and check the BRK2 outer coil resistance from - Then allow BRK2 to cool, and verify proper
CA411-34 to CA411-35. BRK2 air gap and that bolts are torqued to 6.0
- 6.4 Nm (53 - 57 in Ib).
- Then check wire continuity from CA411-34 and

• If: Settings are incorrect.
CA411-35 to the outer coil. Check for corrosion - Then check BRK2 adjustment.
on connector pins.
• If: Wiring or connections are open.
- Then testthe output in Analyzer Menu A4.4.19.
- Then replace BRK2 coil. CA411-34 and CA411-35 to the coil.

ACCESS 4

approximately 5 A.
replace BRK2.
Figure 21822
Event Code 449 ACCESS 4
ACCESS 4 Caster Brake (BRK2) Coli Resistance is

Hot (Brake is dragging)
Figure 21822
it CAUTION
BRK2 may be very hot and may burn skin.
M4.8-1457-076 Crown 2009 PF17432·76 Rev. 5110
01 Rev. 5/10
408
ELECTRICAL
Event Code 450

ACCESS 4
ACCESS 4 Caster Brake (BRK2) Resistance High
BRK2 coil resistance is higher than expected in a nor-
mal hot brake as with Event Code 449, though the re-
BRK2 for over temperature or a connection issue. Cur-
rent and resistance can be verified in Analyzer Menu
A3.4.20.
it CAUTION
BRK2 may be very hot and may bum skin. Figure 21821

Event Code 452
ACCESS 4 ACCESS 4 Outer Brake (BRK1) Coil Resistance
Low
BRK1 coil resistance is at least 30% lower than nomi-
nal, but not shorted.
Step 1: Check the coil for low resistance in Analyzer
Menu A3.4.18.3, or by inspecting the coil for possible
Figure 21822 turn-ta-turn shorts.
• If: Issue is found with the coil.

Event Code 451
ACCESS 4 Inner Brake (BRK1) Coil Resistance
Low
ACCESS 4
BRK1 coil resistance is at least 30% lower than nomi-
nal, but not shorted.
Step 1: Check the coil for low resistance in Analyzer
tum-ta-turn shorts.
• If: Issue is found with the coil.

Figure 21821
Crown 2009 PF17432·77 Rev. 5110 M4.8-1457-077

01 Rev. 5/10
409
ELECTRI€AL
Event Code 453 Step 2: With truck keyed OFF and CA609 discon-
nected, connect one meter lead to the white wire and
one to the orange wire. Check the resistance of the
ACCESS 4 Caster Brake (BRK2) Resistance Low
outer coil.
1.61 km/h [1 mph] or less.) • If: Resistance is less than 3 ohm.
BRK1 coil resistance is at least 30% lower than nomi- - Then check wire continuity from CA41 0-6 and
nal, but not shorted. CA41 0-7 to the inner coil.
Step 1: Check the coil for low resistance in Analyzer • If: Wiring or connections are in need of repair.
turn-to-turn shorts. - Then repair or replace as needed.
• If: Issue is found with the coil. • If: Wiring or connections are OK.
_ Then replace BRK2 coil. - Then replace BRK1 coil.

ACCESS 4 - Then replace ACCESS 4.
ACCESS 4
Figure 21822
Event Code 454

ACCESS 4 Inner Brake (BRK1) Coli Shorted
Figure 21821
One of the wires to BRK1 outer coil is shorted to +BV.
Current and resistance can be verified in Analyzer
Menu A3.4.19. At 200 C (68 0 F) coil resistance in Event Code 455
A3.4.19.3 should be 2.49 - 55.2 ohms.
Step 1: Key truck OFF. Disconnect BRK1 harness at ACCESS 4 Inner Brake (BRK1) Coli Shorted
CA609. Key truck ON. Traction is disabled.
• If: Event Code changes to open (Event Code 442). One of the wires to BRK1 outer coil is shorted to BNEG.
- Then short is in BRK1 or BRK1 wiring. Proceed Menu A3.4.19.
to Step 2.
- Then short is in wiring between CA609 and
ACCESS 4 or internal to ACCESS 4. Proceed
to Step 3.
Crown 2009 PF17432-78 Rev. 5110

M4.8-1457-078
01 Rev. 5/10
410
ELECTRICAL
CJ\OWI' Event Code 456
Event Code 456

ACCESS 4
ACCESS 4 Outer Brake (BRK1) Coli Shorted
One of the wires to BRK1 outer coil is shorted to +BV.
Menu A3.4.18.
Step 1: Key truck OFF. Disconnect BRK1 harness at
CA609. Key truck ON.
- Then short is in BRK1 or BRK1 wiring. Proceed

to Step 2.
Figure 21821
- Then short is in wiring between CA609 and Event Code 457
ACCESS 4 or internal to ACCESS 4. Proceed
to Step 3.
ACCESS 4 Outer Brake (BRK1) Coil Shorted
Step 2: With truck keyed OFF and CA609 discon-
nected, connect one meter lead to the yellow wire and
one to the blue wire. Check the resistance of the outer One of the wires to BRK1 outer coil is shorted to BNEG.
coil. Current and resistance can be verified in Analyzer
Menu A3.4.18.
• If: Resistance is less than 3 ohm.
- Then check wire continuity from CA410-8 and
CA410-12.
Event Code 458
• If: Wiring or connections are in need of repair.
- Then repair or replace as needed. ACCESS 4 Outer Brake (BRK1) Coil Suppression
Shorted
Flyback suppression has shorted. Current and resis-
• If: Resistance is more than 3 ohm. tance can be verified in Analyzer Menu A3.4.18.
- Then replace ACCESS 4. Follow troubleshooting steps for Event Code 456.
Crown 2009 PF17432-79 Rev. 5110 M4.8-1457-079

01 Rev. 5/10
411
ELECTRICAL
ACCESS 4 Caster Brake (BRK2) Coli Shorted ACCESS 4 Caster Brake (BRK2) Coli Shorted
Traction is disabled. Traction is disabled.
One of the wires to BRK2 coils is shorted to BNEG. One of the wires to BRK2 coils is shorted to +BV. Cur-
Current and resistance can be verified in Analyzer rent and resistance can be verified in Analyzer Menu
Menu A3.4.20. A3.4.20.
Step 1: Key truck OFF. Disconnect BRK2 harness at Follow troubleshooting steps for Event Code 459.
CA610. Key truck ON.
• If: Event Code changes to open (Event Code 448). Event Code 461
- Then short is in BRK2 or BRK2 wiring. Proceed
to Step 2. ACCESS 4 CAN Communication Issue with
ACCESS 3
- Then short is in wiring between CA61 0 and ACCESS 4 CAN bus communication with ACCESS 3
ACCESS 4 or internal to ACCESS 4. Proceed was lost. ACCESS 4 is reporting lost communication
to Step 3. with ACCESS 3.
Step 2: With truck keyed OFF and CA610 discon- Follow troubleshooting step for Event Code 304.
nected, connect one meter lead to the red/white wire
and one to the green/white wire. Check the resistance
of the coils. Event Code 462
• If: Resistance is less than 6 ohm.
ACCESS 4 Steer Feedback (RPS1) Power Supply
- Then check wire continuity from CA411-35 and Out of Range (High)
CA411-34.
• If: Wiring or connections are in need of repair. Step 1: Key the truck ON. Using a DVOM, connect the
- Then repair or replace as needed. positive lead to ACCESS 4 CA412-35 and the negative
lead to ACCESS 4 CA412-33 to check the voltage.
• If: Wiring or connections are OK. Voltage measured should be 5 V.
- Then replace BRK2 coil. • If: Voltage is OK.
• If: Resistance is more than 6 ohm. - Then verify the RPS1 circuit is not shorted to
positive.
• If: The positive circuit is not shorted.
- Then verify that POT1, POT2 & POT3 circuits

ACCESS 4
are not shorted to positive.
• If: POT1, POT2, & POT3 circuits are OK.
- Then replace RPS1.
• If: RPS1 is OK and event continues.
Figure 21822
M4.B-1457-0BO Crown 2009 PF17432-80 Rev. 5110
01 Rev. 5/10
412
ELECTRICAL

ACCESS 4 Steer Feedback (RPS1) Power Supply ACCESS 4 Height Encoder (ECR2) Input Issue
Out of Range (LOW)
Raise is disabled.
ECR2 input changes without mast movement.
Step 1: Key the truck ON. Using a DVOM, connect the
Step 1: Use Analyzer Menu A2.4.23 to verify input
positive lead to ACCESS 4 CA412-35 and the negative
does not change unless mast moves. Nominal value
lead to ACCESS 4 CA412-33 to check the voltage.
5.3V.
Voltage measured should be 5 V.
• If: Voltage is OK.

• If: Display indicates input voltage is changing with
mast at rest.
- Then verify the positive RPS1 circuit is not
- Then use a DVOM to verify voltage input is
shorted to negative.
changing. Connect the negative meter lead to
• If: The negative circuit is not shorted. ACCESS 4 CA412-9 and the positive meter
lead to CA412-11 (Channel A). Then repeat,
- Then verify that POT1, POT2 & POT3 circuits with the positive meter lead on CA412-10
are not shorted to negative. (Channel B). Input should not change if mast is
not moving.
• If: POT1, POT2, & POT3 circuits are OK.

• If: Input is changing.
- Then check the wiring and ECR2 and repair or

• If: RPS1 is OK and event continues. replace as needed.
Then replace ACCESS 4.
• If: Input is OK.
ACCESS 4
CAMS
+VIRED 1
GNDIBLK 21------'
AJlNHT 3 f---+-----i 11
BIBLU 4 10
+BV BNEG
Figure 21823
Crown 2009 PF17432~1 Rev. 5110 M4.8-1457-081

01 Rev. 5/10
413
ELECTRICAL
ACCESS 4 Height Encoder (ECR2) Input Issue ACCESS 4 Height Encoder (ECR2) Input Issue
Raise is disabled. Raise is disabled.

ECR2 input does not change with mast movement. ECR2 is counting backward.
Step 1: Use Analyzer Menu A2.4.23 to verify input Step 1: Key truck ON. Use Analyzer Menu A2.4.23.1.
changes as mast moves. to verify input counts. Counts should increase consis-
tentlyas mast is raised (will reset to 0 and begin again
• If: Display indicates input voltage is changing. when count reaches 32), counts should decrease con-
- Then replace ACCESS 4. sistently as mast is lowered.
• If: Display indicates input voltage is not changing • If: Input counts are inconsistent.
with mast movement. - Then use a DVOM to verify voltage input pulse
- Then use a DVOM to verify voltage input is is changing. Connect the negative meter lead
changing. Connect the negative meter lead to to ACCESS 4 CA412-9 and the positive meter
ACCESS 4 CA412-9 and the positive meter lead to CA412-11 (Channel A). Then repeat,
lead to CA412-11 (Channel A). Then repeat, with the positive meter lead on CA412-10
with the positive meter lead on CA412-10 (Channel B). Input should change as mast
(Channel B). Input should not change if mast is moves.
not moving. • If: Voltage input pulse is inconsistent.
• If: Input is not changing. - Then check ECR2 and associated wiring and
- Then check the wiring and ECR2 and repair or repair or replace as needed.
replace as needed. • If: Input is OK.

ACCESS 4
ACCESS 4
CA645
" <.!> w +V/RED 1
~ 0 ~~ GNDIBLK 2 I-------.J CA645
()C/) t; ::>
w Z LLi n. A1WHT 3 1----f-----l11 +VlRED 1
~alPl
'-- B-'-.IB_LU----'-4--J 10 GND/BLK 2 I - - - - - l
A1WHT 3 1----f-----l11
+BV BNEG
BIBLU 4 10
+BV BNEG
36V
Figure 21823 L----l+ II II
f-----J
Figure 21823
M4.8-1457-082 Crown 2009 PF17432-82 Rev. 5110
01 Rev. 5110
414
ELECTRICAL
"CJ\OWr. Event Code 467

ACCESS 4 Height Reset Switch (HGTRS2) Input ACCESS 4 Steer Tiller Sensor (ECR7) Supply Volt-
Issue age Issue
Raise is disabled. Traction is disabled.
Step 1: Key truck ON. Use Analyzer Menu A2.4.2 to ECR7 supply voltage is outside the normal range (hy-
verify HGTRS2 is closed (0 V) below mast staging and draulic steer trucks only).
open (3 V) above mast staging.
Step 1: Key truck ON. Check ECR7 supply voltage.
• If: Display indicates HGTRS2 input is incorrect. Connect positive meter lead to CA408-1 and negative
meter lead to CA408-4. Supply voltage should be 5 V.
- Then check switch operation with DVOM to
verify HGTRS2 input voltage. Connect nega- • If: 5 V.
tive meter lead at ACCESS 4 CA411-33
- Then replace ECR7.
(COMM) and ACCESS 4 CA411-4. Check volt-
age with switch open and closed. • If: More than 5 V.
• If: Input voltages are incorrect. - Then trace the wiring back to ACCESS 4
CA412-20 and CA412-23 for an open circuit.
- Then check HGTRS and associated wiring.
Repair or replace as needed. • If: Wiring and connections are OK.
• If: Input voltages are correct. - Then replace ACCESS 4.
ACCESS 4
ACCESS 4
CA411
___-O-~:>-'-'-'''-'-'-''''_j 4 CA408
+VIRED 1
BIBLU 2 1 - - - - '
AlWHT 3 I---+-------i 17
GNDIBLK 4
20
Figure 21824 +BV BNEG
Figure 21825
Crown 2009 PF17432-83 Rev. 5110 M4.8-1457-083

01 Rev. 5/10
415
ELECTRICAL
Event Code 469 CROWl)
ACCESS 4 Height Encoder (ECR2) Supply Voltage ACCESS 4 Accessory Pot (POT3) Power Supply
Issue Issue
Raise is disabled. POT3 supply voltage is outside the normal range (5 V).
ECR2 supply voltage is outside the normal range Reach and sideshift are disabled.
(11.3 V).
Step 1: Key truck ON. Check POT3 supply voltage.
Step 1: Key truck ON. Check ECR2 supply voltage. Connect the positive meter lead to ACCESS 4
Connect the positive meter lead to CA64S-1 and the CA412-19 and the negative meter lead to CA412-16 for
negative meter lead to CA64S-2. Supply voltage should Sv.
be 11.3 V.
• If: S V.
• If: 11.3 V.
- Then wiring or POT3 is shorted, repair or re-
- Then replace ECR2. place wiring or POT3.
• If: More than 11.3 V. • If: Not S V.

- Then trace the wiring back to ACCESS 4 - Then disconnect the wires at CA412-19 and
CA412-9 and CA412-12 for an open circuit. CA412-16 and recheck the voltage at
ACCESS 4.
• If: Wiring and connections are OK.

• If: ACCESS 4 power supply is not S V.
ACCESS 4
ACCESS 4
CA412
CA645 81------.
+VlRED 1 7 f - - - - - c TRACTION
POT1
GNDIBLK 2 f------" 1.7 K
AlWHT 3 I--~-----i 11 51-------'
BIBLU 4 10
19 1-----+-----,
+BV BNEG
18 f - - - - t - - c RAISEILOWER
POT2
UK
161--++----'
ACCESSORY
Figure 21823 31 t----t---.? POT3
L.-_---" 1.7 K
+BV BNEG
Figure 21826
M4.8-1457-084 Crown 2009 PF17432-84 Rev. 5110
01 Rev. 5/10
416
ELECTRICAL
Event Code 471

ACCESS 4 Raise and Lower Potentiometer (POT2) ACCESS 4 Raise and Lower Potentiometer (POT2)
Input Out of Range (High) Input Out of Range (Low)
Raise and lower are disabled. Raise and lower are disabled.
Step 1: Key the truck ON. Monitor POT2 voltage in An- Step 1: Key the truck ON. Monitor POT2 voltage in An-
alyzer Menu A2.4.19.1. Expected range is approxi- alyzer Menu A2.4.19.1. Expected range is approxi-
mately 0.7 V to 4.5 V. mately 0.7 V to 4.5 V.
• If: The voltage movement is erratic. • If: The voltage movement is erratic.
- Then replace POT2. - Then replace POT2.
• If: The voltage movement is smooth with operation • If: The voltage movement is smooth with operation
of hydraulic function request. of hydraulic function request.
- Then recalibrate the potentiometer in Calibra- - Then recalibrate the potentiometer in Calibra-
tion Menu C1.2 while holding the handle firmly tion Menu C1.2 while holding the handle firmly
in stops. in stops.
Step 2: If Event continues, then key truck OFF. Discon- Step 2: If Event continues, the key truck OFF. Discon-
nect the wiper input at ACCESS 4 CA412-18. Key truck nect the wiper input at ACCESS 4 CA412-18. Key truck
ON. Event code should change. ON. Event code should change.
• If: Event code changes. • If: Event code changes. .
- Then check the wiring from CA412-18 to POT2 - Then check the wiring from CA412-18 to POT2
for a short to +BV. for a short to BNEG.
• If: No short is found. • If: No short is found.
ACCESS 4 ACCESS 4
CA412 CA412
8f-----"""L 8~---"""L
7 f------<::: TRACTION 7 I - - - - _ C TRACTION

POT1 POT1
1.7 K 1.7 K
5f------J 5 f------J
19f--~"'--
.. 19 f-----tf-----,
18 t----+--c RAISE/LOWER 181------+---~RAISEILOWER
POT2 POT2
1.7 K 1.7 K
16 f--....-l---J 16 f---.4---J
ACCESSORY ACCESSORY
31 f----f-----..<:> POT3 311---+-----..? pon
1.7 K l..--_----' 1.7 K
+BV BNEG +BV BNEG
Crown 2009 PF17432-85 Rev. 8110 M4.8-1457-085

02 Rev. 8/10
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ELECTRICAL
Event Code 473 Cl\OWI'
ACCESS 4 Accessory Pot (POT3) Input Out of ACCESS 4 Accessory Pot (POT3) Input Out of
Range (High) Range (Low)
Reach and sideshift are disabled. Reach and sideshift are disabled.
Step 1: Key the truck ON. Monitor POT3 voltage in An- Step 1: Key the truck ON. Monitor POT3 voltage in An-
alyzer Menu A2.4.20.1. Expected range is approxi- alyzer Menu A2.4.20.1. Expected range is approxi-
mately 0.7 V to 4.5 V. mately 0.7 V to 4.5 V.
• If: The voltage movement is erratic. • If: The voltage movement is erratic.
- Then replace POT3. - Then replace POT3.
• If: The voltage movement is smooth with acces- • If: The voltage movement is smooth with acces-
sory position operation. sory position operation.
- Then recalibrate the potentiometer in Calibra- - Then recalibrate the potentiometer in Calibra-
tion Menu C1.3 while holding the handle firmly tion Menu C1.3 while holding the handle firmly
in stops. in stops.
Step 2: If Event continues, then key truck OFF. Discon- Step 2: If Event continues, then key truck OFF. Discon-
nect the wiper input at ACCESS 4 CA412-31. Key truck nectthe wiper input at ACCESS 4 CA412-31. Key truck
ON. Event code should change. ON. Event code should change.
• If: Event code changes. • If: Event code changes.
- Then check the wiring from CA412-31 to POT3 - Then check the wiring from CA412-31 to POT3
for a short to +BV. for a short to BNEG.
• If: No short is found. • If: No short is found.

ACCESS 4 ACCESS 4
CA412 CA412
8f-----""""L 8f-----""""L
7 f - - - - - < : C TRACTION 7 f - - - - - < : C TRACTION
POT1 POT1
UK 1.7 K
5 f-------J 5 f-------J
19 f------tf---""""L 19 f------tf---""""L
18 f----+--<:C RAISEIlOWER 18 f----+--<:C RAISEllOWER
POT2 POT2
1.7 K UK
16 f--.....-If-----J 16 f--.....-I----J
ACCESSORY ACCESSORY
31 f - - + - - _ ? POT3 31 f - - + - - _ ? POT3
L.-_~ 1.7K L.-_~ 1.7K
+BV BNEG +BV BNEG
M4.8-1457-086 Crown 2009 PF17432.a6 Rev. 8110
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ELECTRICAL
l!J\owra Event Code 475

ACCESS 4 Load Sensor (LS) Input Out of Range ACCESS 4 Load Sensor (LS) Input Out of Range
(High) (Low)
All functions are enabled. All functions are enabled.
Step 1: Key truck ON. Check LS counts in Analyzer Step 1: Check LS counts in Analyzer Menu A2.4.25
Menu A2.4.25 with load on forks. Transducer range is with load on forks. Transducer range is approximately
approximately 4 - 20 mA depending on the load. Verify 4 - 20 mA depending on the load. Verify reading
reading changes consistently with a different load. changes with a different load.
• If: Reading is more than 20 mA. • If: Reading is less than 4 mAo
- Then proceed to Step 2. - Then proceed to Step 2.
• If: LS input is within the 4 - 20 mA range. • If: LS input is within the 4 - 20 mA range.

Step 2: Key truck ON. Using a DVOM, check the volt- Step 2: Check the voltage across LS wires at CA612-1
age across LS wires. Connect the positive meter lead and CA612-2.
to CA612-2 and the negative meter lead to CA612-1.
• If: 12 Vdc.
• If: 12 V.
- Then replace LS.
- Then replace LS.
• If: Voltage is outside the 4 - 20 mA range.
• If: Not approximately 12 V.
- Then check the voltage at ACCESS 4
- Then check the voltage at ACCESS 4. Connect CA412-25 and CA412-26.
the positive meter lead to CA412-26 and the
negative meter lead to CA412-25. • If: Voltage is within the 4 - 20 mA range.
- Then repair the wiring from CA412-25 and
• If: 12 V.
CA412-26 to CA612-1 and CA612-2.
- Then repair the wiring from CA412-25 and
CA412-26 to CA612-1 and CA612-2. • If: Voltage is outside the 4 - 20 mA range.

• If: Not approximately 12 V.

ACCESS 4
CA412
ACCESS 4 25l---~~---4RJ
CA412 26 1------'~_____4lll
25 f----------<~---t1C
+BV BNEG
26 f-----'~---+IC
+BV BNEG
36V
L.----:1+ IIII
f-----' Figure 21827
Figure 21827
Crown 2009 PF17432~7 Rev. 5110 M4.8-1457-087

01 Rev. 5/10
419
ELECTRICAL
ACCESS 4 Hydraulic Steer Sensor (RPS1) Not Cal- ACCESS 4 Traction Potentiometer (POT1) Power
ibrated Supply Shorted to BNEG
Full traction is disabled. Traction is disabled.
Step 1: Calibrate RPS1 in Calibration Menu C2.8. Step 1: Check POT1 power supply for a short to BNEG
at ACCESS 4 CA412-5.
• If: Short exists.
- Then replace RPS1 and calibrate again in Cal-
ibration Menu C2.8. - Then repair or replace wiring as needed.

Event Code 478 - Then replace ACCESS 4.
ACCESS 4 Accelerometer Not Calibrated

Full traction is disabled. ACCESS 4
Step 1: Park the truck on a level surface and calibrate CA412

81----~
the sensor in Calibration Menu C2.5.
7 f - - - - - ? TRACTION
POT1
• If: Event code continues. 1.7 K
51-----:l
191----~
18 f----+-____.? RAISEILOWER
Event Code 479 POT2
1.7K
161--.-+------..:l
ACCESS 4 Incorrect Battery Voltage
ACCESSORY
All functions are enabled. 311----+---.> POT3
L.-_~ 1.7K
Battery voltage exceeds 48 V (24 V models) or 50 V +BV BNEG
(36 V models).
36V
Step 1: Verify battery voltage is correct. L.-_....,..j+ IIII f----J
• If: Battery is OK and event code continues. Figure 21826
Event Code 486

ACCESS 4 Invalid Cutout Configuration
Lift and lower are disabled.
Step 1: Review or reset Calibration Menu C1 settings
for cutouts in the Service Menu.

- Then contact factory.
M4.8-1457-088 Crown 2009 PF17432-M Rev. 5110
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ELECTRICAL
Event Code 488

ACCESS 4 Traction Potentiometer (POT1) Power ACCESS 4 Traction Potentiometer (POT1) Wiper
Supply Shorted to +BV Out of Range (Low)
Step 1: Check POT1 power supply for a short to +BV Step 1: Key the truck ON. Monitor POT1 voltage in An-
at ACCESS 4 CA412-8. alyzer Menu A2.4.18.1. Expected range is approxi-
mately 0.7 V to 4.5 V.
• If: The voltage movement is erratic.
- Then replace POT1 .
• If: The voltage movement is smooth with operation
of Traction request.
- Then recalibrate POT1 in Calibration Menu
ACCESS 4 C1.1.
CA412 Step 2: If Event continues, then check POT1 power
81-----L supply for a short to BNEG at ACCESS 4 CA412-7.
7 I - - - - - c ' TRACTION
POT1
1.7 K • If: Short exists.
5f------'
19 f------4If----..
181---t---c: RAISE/LOWER
POT2
1.7 K
16 1---.-1---'
ACCESSORY
311---+-----.c POT3 ACCESS 4
1.7 K
CA412
+BV BNEG
81-------...
7 I - - - - - c TRACTION
POT1
1.7 K
5f---------'
Figure 21826
19 f------4If-----,
18 1 - - - - + - - < RAISE/LOWER
POT2
1.7K
16 I--~I-----'
ACCESSORY
311--+-----.2' POT3
1.7 K
+BV BNEG
Figure 21826
Crown 2009 PF17432-89 Rev. 8110 M4.8-1457-089

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ELECTRIGAL
ACCESS 4 Traction Potentiometer (POT1) Wiper ACCESS 4 Reverse (RS) and Forward (FS) Switch
Out of Range (High) Mismatch
Step 1: Key the truck ON. Monitor POT1 voltage in An- Step 1: Check RS and FS inputs in Analyzer Menus
alyzer Menu A2.4.18.1. Expected range is approxi- A2.4.16 and A2.4.17.
mately 0.7 V to 4.5 V.
• If: Both inputs are high ("1 ").
• If: The voltage movement is erratic.
- Then check input voltage at ACCESS 4
- Then replace POT1. CA412-14 and CA412-15.
• If: The voltage movement is smooth with operation • If: Both inputs are 5 V.
of Traction request.
- Then repair or replace RS and FS, or wiring.
- Then recalibrate POT1 in Calibration Menu
C1.1. • If: Both inputs are not 5 V.
Step 2: If Event continues, then check POT1 power - Then replace ACCESS 4.
supply for a short to +BV at ACCESS 4 CA412-7.

ACCESS 4
CA412
8f-----L Figure 21829
7 1 - - - - _ < : ' TRACTION
pon
UK
5 f-------..J
191-----+----,
18 f-----t--<' RAISEIlOWER
POT2
UK
161---.+----'
ACCESSORY
31 f---+----.? POT3
UK
+BV BNEG
Figure 21826
M4.8-1457-090 Crown 2009 PF17432-90 Rev. 8110
02 Rev. 8/10
422
ELECTRICAL

ACCESS 4 Forward Switch (FS) Closed In Reverse ACCESS 4 Reverse Switch (RS) Closed In Forward
Direction Direction
This event code indicates FS is possibly shorted. This event code indicates RS is possibly shorted.
Step 1: Check FS inputs in Analyzer Menu A2.4.17. Step 1: Check RS inputs in Analyzer Menu A2.4.16.
• If: Input is high ("1 H). • If: Input is high ("1 ").
- Then check input voltage at ACCESS 4 - Then check input voltage at ACCESS 4
CA412-14. CA412-15.
• If: Input is 5 V. • If: Input is 5 V.
- Then repair or replace FS or wiring. - Then repair or replace RS or wiring.
• If: Input is not 5 V. • If: Input is not 5 V.
Event Code 494

ACCESS 4 Calibration Issue
ACCESS 4 is unable to calculate calibration data.
Step 1: Calibrate all truck functions.
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ELECTRICAL
ACCESS 4 Calibration Issue ACCESS 4 Steer Sensor (RPS1) Not Counting
All functions are disabled. Full speed traction is disabled.
ACCESS 4 is unable to obtain calibration data; chang- Step 1: Monitor RPS1 voltage in Analyzer Menu
ing software can log this event code. A2.4.21.1 while steering the truck.
Step 1: Calibrate all truck functions. • If: Voltage does not follow steer movement.
• If: Event code continues. - Then verify the Power Supply voltage is ap-
proximately 5.3 V in Analyzer Menu A2.4.21.2.
• If: Correct.
Event Code 496 - Then use Calibration Menu C2.8 to recalibrate
RPS1. Then repeat Step 1.
ACCESS 4 Performance Settings Issue
• If: Voltage still does not follow steer movement.
ACCESS 4 performance set up issue; changing soft- CA412-34 to RPS1.
ware can log this event code.
• If: The wiring and connections are OK.
Step 1: Key truck OFF and back ON.
- Then replace RPS 1 and calibrate using Cali-
• If: Event code continues. bration Menu C2.8.
- Then reset all performance settings in Service
• If: Issue continues.
Menu.

ACCESS 4
Event Code 497

ACCESS 4 Features Settings Issue
CA412
33
ACCESS 4 features set up issue; changing software 341---+----~tiD
can log this event code. 35 t----+---'-=-'-tQ
Step 1: Key truck OFF and back ON.

+BV BNEG

- Then reset all features settings in Service
Menu.
Figure 23829
M4.8-1457-092 Crown 2009 PF17432-92 Rev. 5110
01 Rev. 5/10
424
ELECTRICAL
Event Code 500
Event Code 500

ACCESS 5
ACCESS 5 AC Over Current
RPS1 CA651
Travel is disabled. CE~ti9
Higher than normal current is sensed at ACCESS 5 ter-
minals U, V or W.
Possible cause: shorted power cables or M4 windings.
Step 1: Check power cables for shorts to truck frame.
Disconnect the battery connector and disconnect each
of the power cables from ACCESS 5. One at a time,
check the resistance between the power cable and
truck frame.
• If: Cables are shorted.

Figure 21830
• If: Cables are OK.
Step 2: Issue still exists.
• If: M4 windings and cables do not show a connec-

tion to truck frame.
- Then issue could be intermittent or higher re-
sistance than meter can detect.
Step 3: Check ACCESS 5 terminal resistance to truck
frame. Keep power cables disconnected from
ACCESS 5. Check the resistance of each phase termi-
nal to truck frame.
• If: Any terminal is shorted.
- Then replace ACCESS 5 (reconnect cables to

M4 and recalibrate RPS1 in Calibration Menu
C4.1).
• If: ACCESS 5 is OK.

Step 4: Issue still exists.
• If: Event code continues or becomes intermittent.

- Then replace M4.
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ELECTRICAL
Event Code 501
ACCESS 5 AC Short Circuit
Travel is disabled.
Short circuit is sensed between M4 power cables, M4
cables or ACCESS 5 power stage terminals. Key truck
OFF, disconnect battery and ensure ACCESS 5 capac-
itors are fully discharged (turn and hold the key switch
to the start position a minimum of 10 seconds and
place a digital volt-ohm multimeter [DVOM] across the
+BVand BNEG terminals to discharge ACCESS 5 ca-
pacitors).
Step 1: Check U, V and W cables for loose connec-
tions or incorrect wiring at ACCESS 5. Repair or re-
place as needed.
Step 2: Check for abrasions and shorts between U, V
and W cables. Repair or replace as needed.
Step 3: Disconnect U, V and W cables from
ACCESS 5. Check the resistance between each of the
ACCESS 5 phase terminals. Typical resistance is
40-50,000 ohm.
• If: Resistance is much lower than typical resis-

tance.
- Then replace ACCESS 5 and recalibrate RPS1
in Calibration Menu C4.1.
• If: Resistance value is correct.

- Then replace M4.
ACCESS 5
RPS1 CA651
Q::==~9
Figure 21830
M4.8-1457-094 Crown 2009 PF17432-94 Rev. 5110
01 Rev. 5110
426
ELECTRICAL
Event Code 502 • If: Cables and connections are OK.

ACCESS 5 DC Bus Charging Timeout
Step 5: Measure the voltage drop across FU12.
Travel is disabled.
This event code can occur at start-up if ACCESS 5 de-
• If: FU12 voltage drop is 0.5 V or greater.
tects that its DC bus voltage (measured at +BV and - Then repair FU12 holder connections or re-
BNEG terminals) is significantly less than its key switch place FU12.
voltage at ACCESS 5 CA651-1 ~ The DC bus pre-
charges to approximately 1 V less than +BV via the key
switch and PTC-Diode circuit located on the distribu- ACCESS 2
tion panel. Check for additional event codes. +
Step 1: Check cable connection at ACCESS 5 +BV ter-

minal.
ACCESS 5
• If: Damaged or missing. DISTRIBUTION

PANEL
CA651
1
- Then repair or replace as needed. TR2
CR5 +To
'" ¢
• If: Terminal and cable connection is OK. 6A200 39
CA203
- Then proceed to Step 2. 12 ED1
Step 2: With truck key ON and ED1 not pulled in, mea- 1'-----...,,+111111---------'
_ 36V
sure the voltage at ACCESS 5 +BV to BNEG terminals.

Figure 21831
• If: Voltage is approximately +BV.
• If: Voltage is much lower than +BV.

Step 3: Check FU12.
• If: FU12 is open.
- Then replace FU12.
• If: FU12 is OK.

Step 4: Check the path from ACCESS 5 +BV terminal
to the pre-charge circuit. This includes the +BV termi-
nal, fuse block terminals, ED1 terminals, associated
wiring and CA203-12 on the distribution panel. Ensure
the threads are OK and the ED1 terminals are torqued
to 18 Nm (24 ft Ib). Inspect the wiring and connector
contacts. Check the voltage at each point to determine
where the connection to the source has been dis-
rupted.
• If: Cables and connections are disrupted or miss-

ing.
Crown 2009 PF17432-95 Rev. 5110 M4.8-1457-095

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ELECTRI€AL
Event Code 503 • If: Wire terminals are loose or the wire is damaged.
Event Code 504 - Then repair or replace harness.
ACCESS 5 DC Bus High Battery Voltage

• If: Harness is OK.
Travel is disabled. - Then proceed to Step 5.
DC voltage to ACCESS 5 (between +BV and BNEG Step 5: Check the power connections of ED1.
terminals) is 68.73 V or greater. Check for ACCESS 2
• If: Connections are loose or corroded.
and 3 over voltage Event Codes 223 and 323.
- Then repair or replace terminals.
Step 1: Check the voltage at battery terminals with the
battery disconnected. • If: Connections are tight.
• If: Voltage is more than 48 V. - Then proceed to Step 6.
- Then incorrect battery is installed, change bat- Step 6: Check the condition of FU4 and battery termi-
tery. nals for good connections.
• If: Voltage is less than 39 V. • If: Connections are loose or corroded.
- Then proceed to Step 2. - Then repair or replace terminals or FU4.

Step 2: Check for Event Codes 223 and 323. • If: Connections are tight.
• If: Event Codes 223 and 323 have not logged. - Then replace the battery to ensure battery is
OK.
• If: Event Codes 223 and 323 have logged.

• If: Issue still exists.

Step 7: Inspect ED1 terminal threads for excess wear
Step 3: See if ED1 has opened during a regen brake
and repair or replace as needed. Torque ED1 bolts to
with the battery at full charge.
3.4 Nm (2.5 ft Ib), do not over tighten.
• If: Battery has recently come off of the charger.
- Then battery can temporarily go over the limit
with a harsh regen brake.
• If: Battery just came off charger and performed a

regen brake. ACCESS 2
+
- Then the battery is fully charged to maximum
and will drop in voltage within a few minutes of
normal use. ACCESS 5
DISTRIBUTION
• If: Truck has not been charged recently. PANEL CA651
1
TR2
- Then proceed to Step 4. CR5 +T"
0<1 ¢
6A200 39
Step 4: Determine if ED1 is OK (check tips, return
CA203
spring, etc).
12
36V
• If: ED1 needs repair. L.-----:;:i+1 ill II - - - - - - - - J
- Then repair or replace ED1.
Figure 21831
• If: ED1 is functioning properly.
- Then check the wiring going to the ED1 coil.
M4.8-1457-096 Crown 2009 PF17432-96 Rev. 5110
01 Rev. 5/10
428
\
ELECTRICAL
Event Code 505

ACCESS 2
ACCESS 5 DC Bus Low Battery Voltage at Control-
+
ler
All traction is disabled.
ACCESS 5
Step 1: Key the truck ON. Using a DVOM, connect the DISTRIBUTION
CA651
positive lead to ACCESS 5 +BV and the negative lead PANEL
1
to ACCESS 5 BNEG. Voltage measured should be TR2
CR5 +T·
+BV. .. ¢
6A200 39
• If: Voltage is lower than +BV. CA203
12
- Then proceed to Step 2. 36V
---~+IIIIIf - - - - - - - - - '
Step 2: Ches:k the condition ED1 (check tips, return
spring, etc). Figure 21831
• If: ED1 needs repair.

- Then repair or replace ED1.
• If: ED1 is functioning properly.
- Then check the wiring going to the ED1 coil.
• If: Wire terminals are loose or the wire is damaged.
- Then repair or replace the harness.
• If: The harness is OK.

Step 3: Check the power connection of ED1.
• If: The connections are loose or corroded.

- Then repair or replace the terminals.
• If: The connections are tight.

Step 4: Check the condition of the battery terminals
and for good connections.
• If: The connections are loose or corroded.

- Then repair or replace the terminals.
• If: The connections are tight and the issue contin-

ues.
Step 5: Check battery condition for possible bad cell
under load. Replace the battery and monitor the event.
• If: The condition continues.

Crown 2009 PF17432-97 Rev. 5110 M4.8-1457-097

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429
ELECTRICAL
Event Code 506 • If: Wheel rotates smoothly through its entire range.

ACCESS 5 Steer Motor (M4) Temperature High
Step 4: Key truck ON. Since wheel position was man-
Travel is disabled. ually moved, Event Code 554 will likely occur. View M4
M4 temperature is above 180° C (356° F). TS4 is em- current in Service Menu, Level 2, Analyzer Menu
bedded in M4 windings and the analog input is brought A2.5.2 (reading is in A x 10). With drive tire off floor,
into ACCESS 5. slowly turn steer tiller while viewing M4 current.
Step 1: Check M4 temperature in Service Menu, Level • If: Current is more than 10 A.
2 or 3, Analyzer Menu A2.5.3.1.
- Then M4, gear box or linkage is not turning
• If: 180° C (356° F) or greater at time of event code freely. Repair or replace as needed.
or M4 is hot to touch.
• If: Current is less than 10 A.
- Then M4 is likely overheating. Proceed to Step
2. - Then proceed to Step 5.
Step 5: Check for loose connections and broken wires
• If: M4 is warm or cool, or TS4, wiring or ACCESS 5
at ACCESS 5 connector. Visually inspect ACCESS 5
has an issue. connector to ensure pins are fully seated.
• If: Connection issue is found.
• If: M4 temperature is much less than 180° C
- Then repair or replace harness.
(356° F) at time of event code.
Step 2: With battery disconnected and ACCESS 5 ca- - Then proceed to Step 6.
pacitors discharged (turn and hold the key switch to the Step 6: Key truck OFF and check the resistance of TS4
start position a minimum of 10 seconds and place a at ACCESS 5 CA651 between CA651-4 and
digital volt-ohm multimeter [DVOM] across the +BV CA651-16. Typical resistance is 550 ohm at 22° C
and BNEG terminals to discharge ACCESS 5 capaci- (72° F). Disconnect CA651 from ACCESS 5 and mea-
tors), check terminal connections and cables at sure the resistance from CA651-4 and CA651-16.
ACCESS 5 +BV, BNEG, and U, V and W cables.
• If: Resistance is above 1200 ohm.
• If: Connections are loose.
- Then torque to 6 Nm ± 0.3 Nm (4.4 ft Ib ±
0.2 ft Ib). • If: Resistance is less than 700 ohm.
• If: Connection terminal issue is found. - Then proceed to Step 8.
- Then repair or replace cables. Step 7: Determine if truck is under a heavy-duty cycle
or high ambient temperatures.
• If: Terminals are OK.
• If: Truck is overheating due to these conditions and
- Then proceed to Step 3. performance is degraded.
Step 3: Check steering components for obstructions - Then allow the truck to cool down and verify
that may bind or prevent wheel motion. Follow the rec- FAN1 is operating correctly.
ommendations in front of the Service and Parts Manual
to jack up and block the truck frame with the drive tire • If: Truck is not overheating due to the above condi-
off the floor. With the truck keyed OFF, manually rotate tions.
the drive tire through its entire steer range.
• If: Wheel binds at any point within steer range.
- Then examine M4, gearbox, and gearing to find

source of binding and repair or replace.
M4.8-1457-098 Crown 2009 PF17432-ge Rev. 5110
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ELECTRICAL
Step 8: Replace M4.
Then replace ACCESS 5 and recalibrate RPS1

ACCESS 4 ACCESS 5
CA411
31
M4
w GNDIBLK CA653
en"
""'w
::::lo +VIRED 1
+5V
3
11. GND
0
CX)u ANlHT 2 4
~z CHA
~w B/GRN 3 5
CHB
4 6
ECR4 5
6
THERM
16
Figure 21832
Crown 2009 PF17432·99 Rev. 5110 M4.8-1457-099

01 Rev. 5/10
431
ELECTRICAL
Event Code 507 Step 3: Check mounting bolts on ACCESS 5. Bolts are
located at each of the four corners of ACCESS 5 and
should be torqued to 6 Nm ± 0.3 Nm (4.4 ft Ib ±
ACCESS 5 Heatslnk Over Temperature
0.2 ft Ib).
Travel is disabled.
• If: Bolts are loose.
ACCESS 5 heatsink temperature is above 125 0 C
(259 0 F). - Then disconnect ACCESS 5 from the power
unit wall and blow or wipe ACCESS 5 and wall
Step 1: Check the heatsink temperature in Service surfaces clean. Mount ACCESS 5 onto power
Menu, Level 2 or 3, Analyzer Menu A2.5.3.2. unit wall and torque to above specifications.
• 0 0
If: 125 C (259 F) or greater at time of event code • If: Bolts are tight.
and heatsink is hot.
- Then ACCESS 5 is likely overheating. Proceed
to Step 2. Step 4: Determine if truck is under a heavy-duty cycle
or high ambient temperatures.
• If: Heatsink is warm or cool.
• If: Truck is overheating due to these conditions and
- Then ACCESS 5 likely has an issue. Proceed performance is degraded.
to Step 7.
- Then allow the truck to cool down, verify FAN 1
0
• If: Heatsink temperature is much less than 125 C is operating correctly and proceed to Step 5.
0
(259 F) at time of event code.
• If: Truck is not overheating due to the above condi-
- Then proceed to Step 7. tions.
Step 2: Key truck OFF, disconnect battery and ensure - Then proceed to Step 7.
ACCESS 5 capacitors are fully discharged (turn and
hold the key switch to the start position a minimum of Step 5: Follow the step in Event Code 506 to check for
10 seconds and place a digital volt-ohm multimeter M4 or drive linkage mechanical issues.
[DVOM] across the +BV and BNEG terminals to dis-
charge ACCESS 5 capacitors). Check terminal con-
• If: Steering system is binding.
nections on ACCESS 5 and FU4. Check +BV, BNEG, - Then repair or replace as needed.
and U, V and W cables for excessive wear.
• If: Steering system is not binding.
• If: Connection issue is found.
- Then torque to 6 Nm ± 0.3 Nm (4.4 ft Ib ±
0.2 ft Ib). Step 6: Replace ACCESS 5 and recalibrate RPS1 in
Calibration Menu C4.1.
• If: Connection terminals issue is found or cables
show excessive wear. • If: Issue still exists.
- Then repair or replace cables. - Then proceed to Step 7.

Step 7: Replace M4.
• If: Terminals and cables are OK.
M4.8-1457-100 Crown 2009 PF17432·100 Rev. 5110
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ELECTRICAL
Event Code 511

ACCESS 4 ACCESS 5
ACCESS 5 Open Drain Outputs from High Current
CA411
31 Travel is disabled.
M4 Replace ACCESS 5.
~o:: GNDIBLK CA653
+5V 3
5~ +VIRED 1
~8 AfWHT 2 GND 4
:!::~ B/GRN 3 CHA 5

$ CHB 6
4
ECR4 5
61-+----'
TH
L.-....:..:c:..:E::.:
R::..::
M----116
Figure 21832
Event Code 508

ACCESS 5 15 V Supply Voltage Low
Travel is disabled.
Replace ACCESS 5.
Event Code 509

ACCESS 5 5 V Supply Voltage Out of Range
Travel is disabled.
Replace ACCESS 5.
Event Code 510

ACCESS 5 Calibration Issue
Travel is disabled.
Replace ACCESS 5.
Crown 2009 PF17432-101 Rev. 5110 M4.8-1457-101

01 Rev. 5/10
433
ELECTRleAL
Event Code 512 CJ\OWr\
Event Code 512 • If: Wiring, contact or connector damage or wear is
found.
Tiller Sensor (RPS2) Out of Range Low - Then repair or replace as needed.
Travel is disabled.
• If: All wiring, contacts, crimps and connectors are
One or both of the RPS2 channels is shorted or close OK.
to 8NEG.
Step 1: In Analyzer Menus A2.5.6.2 and A2.5.6.3, view
both of the RPS1 and RPS2 output signals while rotat- Step 4: Check for opens, shorts and issues with con-
ing the tiller. tacts and connectors in the Channel 8 RPS2 wires.
Verify condition and integrity of the RPS2 brown wire,
• If: 80th Channel A and Channel 8 outputs are be- CA652-6 contacts, associated wiring and CA651-10.
low the short circuit limit of 75 counts. Verify contacts are properly crimped and seated in the
connectors.
• If: Wiring, contact or connector damage or wear is
• If: Only Channel A output is below the short circuit
found.
limit of 75 counts.
- Then check Channel A wiring. Proceed to Step
3. • If: All wiring, contacts, crimps and connectors are
OK.
• If: Only Channel 8 output is below the short circuit
limit of 75 counts. - Then replace RPS2.
- Then check Channel 8 wiring. Proceed to Step

4. RPS2 CA652
BlU - OUTA"
Step 2: Check RPS2 power at ACCESS 5 CA651-3 ~~b~~~~~---::Bo=.lK=:-+D1J.. GND AI
and splice 18. +5V A\ RED ~ +5V AI
+5V B WHT l. +5 vB""
GROUND B-1 GRN .! GND BI
• If: RPS2 is 5 V. UTPUT B 7 BRN ~ OUT BI I
.2.
~
-J
- Then check the Channel A and Channel 8 wir-
ing in Steps 3 and 4.
, , SPLICE/I.)1PLlCE1S:,l,
• If: RPS2 is well below 5 V. 1 ~a:: M4

1
I." I C~53
3w GNDlBlK I -
,a:: Q.C +VlREDI-"'!'" 1 +5V ~
- Then disconnect the wire from CA651-3 and () co8
Iw N Z AlWHT 1-,
1 I-'- CH A I
2 bl-¥!.!..tl~-I---I--++------'
repeat supply measurement at CA651-3.
: ~w B/GRN 1-,
dl:ltTH~~I~::!""M-I--X~I+----,
• If: Voltage is below approximately 5 V. 1
1 I
~", « YElf'
TS4 BlK 1
~I:a
~~~GN~D+--_.....I
J
L l,,;;, -J
CA654
(t
RPS1 RED,.,..,. =- +5 V "
• If: Voltage is 5 V. WHITEI:J! ~I ANALOG I
BLACK I'~ ~I GND I
'W.::: ~
- Then check sensor (RPS1, RPS2 or ECR4) by o,J
connecting them one at a time. Repair or re-

place as needed.
Step 3: Check for opens, shorts and issues with con- f'l f'l f'l-i'l- f'l f'l i'l Pi C'l
tacts and connectors in the Channel A RPS2 wires. 1615114113112r1m(fgTsT7T61514131211 t~

ACCESS 5
Verify condition and integrity of the RPS2 blue wire, +BV BNEG
CA652-1 contacts, associated wiring and CA651-11. © ©
Verify contacts are properly crimped and seated in the
connectors. Figure 21833
M4.8-1457-102 Crown 2009 PF17432-102 Rev. 5110
01 Rev. 5/10
434
ELECTRICAL
l!J\OWr. Event Code 513
Event Code 513 Step 4: Check for opens, shorts and issues with con-
tacts and connectors in the Channel B RPS2 wires.
Tiller Sensor (RPS2) Out of Range High
CA652-6 contacts, associated wiring and CA651-10.
Travel is disabled. Verify contacts are properly crimped and seated in the
connectors.
One or both of the RPS2 channels is shorted or close
to 5 V. • If: Wiring, contact or connector damage or wear is
Step 1: In Analyzer Menus A2.5.6.2 and A2.5.6.3, view found.
both of the RPS1 and RPS2 output signals while rotat- - Then repair or replace as needed.
ing the tiller.
• If: Both Channel A and Channel B outputs are at or
OK.
above the high limit of 1020 counts.
• If: Only Channel A output is at or above the high RPS2 CA652

limit of 1020 counts. BlU ,... OUTA"
UTPUT A'\ BlK GNDAI J.
GROUNDA
\ RED +5VAt J.
+5V~1 WHT d +5 vFfl"
3. +5VB
GROUND B~I GRN ~ (;ND B I
UTPUT B':/ BRN ~ OUTBI 1
• ~ --;;r
If: Only Channel B output is at or above the high
limit of 1020 counts.
1
SPLlCE17
- Then check Channel B wiring. Proceed to Step
4.
Step 2: Check RPS2 BNEG connections. Check wire,
crimp, contact and connector integrity at ACCESS 5
,--------'
1
1'<1"
15
Iw
I
~o::
5W GNDlBlK -
11.8
~u
~aJ
AfWHT -.l
B/GRN _ ~"3
I'
M4 1
2
I
+V/RED _...!... J.
C~53
4"
+5 V
CHA t
t HB t
"
I
Xi
CA651-4 and splice 17. I
I
I I
;l;
l.::
1
•
T~
« VEL
BlK
....:. ::1
~
THERM7
J
GND
• If: Wiring is OK and RPS2 BNEG is 0 V. L _________ ~ 'f
CA654
- Then check the Channel A and Channel B wir- RPS1 RED ~
ing in Steps 3 and 4. (;c. WHITE I:Jf

1:Jt
+5V "
ANALOGI
• If: RPS2 supply voltage is not approximately

BLACK
\:::J.:: I=V
GND I
..
BNEG.
- Then replace ACCESS 5. P ,P ,P P"l
I I i"ll"i
1611511411311211111 0191817161514131211
Step 3: Check for opens, shorts and issues with con-
ACCESS 5
tacts and connectors in the Channel A RPS2 wires. +BV BNEG
Verify condition and integrity of the RPS2 blue wire, © ©
Verify contacts are properly crimped and seated in the Figure 21833
connectors.
• If: Wiring, contact or connector damage or wear is

found.

OK.
Crown 2009 PF17432·103 Rev. 5110 M4.8-1457-103

01 Rev. 5/10
435
ELECTRICAL
Event Code 514 CJ\OWr\
Event Code 514 Step 4: Check for opens. shorts and issues with con-
tacts and connectors in the Channel 8 RPS2 wires.
Tiller Sensor (RPS2) Output Invalid
Travel is disabled. Verify contacts are properly crimped and seated in the
connectors.
One of the RPS2 signals' voltage is invalid or the chan-
nel wires are reversed. • If: Wiring, contact or connector damage or wear is
Step 1: In Analyzer Menus A2.5.6.2 and A2.5.6.3. view found.
both of the RPS1 and RPS2 output signals while rotat- - Then repair or replace as needed.
ing the tiller.
• If: All wiring. contacts, crimps and connectors are
• If: 80th Channel A and Channel 8 outputs are
OK.
changing while rotating the tiller.
• If: Channel A output is constant while Channel 8

changes.
RPS2
UTPUTA:\ BlK
BlU
CA652
-.J-
OUT A I'
GNDAI
GROUND A
.\ RED 1- +5VAI
+5V~1 WHT 1- +5VEt',..
3. +5VB ..! GNDBI
GROUND B7 GRN
UTPUTB7 BRN ~ OUTBI
• If: Channel 8 output is constant while Channel A ~
"
changes. I
SPLlCE17
- Then check Channel 8 wiring. Proceed to Step
4.
Step 2: Verify channel wiring connections. Channel A:
RPS2 blue wire. CA652-1, associated wiring and
r--------'
1 ~o:
11rl ret)
1 ::::m
M4
AlWHT _~ '2
1
'...r 5w GNDlBlK r- 1 C~53
10: 11.8 +VIRED '-~
B/GRN -h- '3

1 +5 V
CH A 1
CH B 1
_rr-r- '4 THERM~
,..
I.
Xi
CA651-11; Channel 8: RPS2 brown wire, CA652-6, as- I ;Z
sociated wiring and CA651-10. I
I 1
~ • < VEL
T~
BlK 1 t
-.=-~ >/
GND
L _________ .... "
• If: RPS2 blue wire connects to CA651-10 and CA654

RPS1 RED
RPS2 brown wire to CA651-11.
T WHITE
BLACK
I:
I:
1 :1
2 :1
+5V "
ANALOGI
GND 1
- Then channel wiring is reversed, repair wiring. ~
3
" I
• If: Channel wiring is correct

ni"lf"U'i i"Ii"I nn
Step 3: Check for opens. shorts and issues with con- 16115/14113/1211111 0191817161514131211
tacts and connectors in the Channel A RPS2 wires. ACCESS 5

+BV BNEG
Verify condition and integrity of the RPS2 blue wire. © ©
Verify contacts are properly crimped and seated in the Figure 21833
connectors.
• If: Wiring. contact or connector damage or wear is

found.
• If: All wiring. contacts, crimps and connectors are

OK.
M4.8-1457-104 Crown 2009 PF17432-104 Rev. 5110

01 Rev. 5/10
436
ELECTRICAL
Event Code 515

RPS2 CA652
Wheel Position Sensor (RPS1) Out of Range BLU
l' OUTA",
UTPUTA~ BLK GNDAI
GROUND A "2
Travel is disabled. .\ RED
'3 +5VAI
+5v~1 WHT +5 VB"",
+5VB '4 GND BI
RPS1 signal voltage is outside the acceptable range. GROUND B-/ GRN 5 OUTBI
UTPUTB/ BRN "6
....- "
Step 1: Check RPS1 wiring for shorts and opens. Ver-
ify wires, connectors, contacts and crimps. 5 V: RPS1
l
xi'
SPLlCE17
red wire, CA654-1, splice 18, associated wiring and ---------, /
CA651-3; BNEG: RPS1 black wire, CA654-3, splice ~a:: M4
1
17, associated wiring and CA651-4; signal: RPS1 ""'w GNDIBLK I-- I CA653
white wire, CA654-2, associated wiring and CA651-9. ~ 1r§ +V/RED I--~ '1+5 V '"
1rl re u AN'IHT '-~ '2
CH A I
~aJ I f..,.- CH B I
• ~ B/GRN -IT ~ THERM~
If: Wiring issue is found.
1
~>..'< YELlrr
....TS4 BLK I
~
~p GND
J
- Then repair wiring as needed.
--------- .! "
CA654

RPS1
t RED
WHITE
BLACK
CT"':'"
I:J!
I:}a-
+5V "
ANALOGI
GND I
Step 2: In Analyzer Menu A2.5.5.1, view RPS1 signal

= "
,.----
voltage while moving the drive tire from stop to stop.
• If: RPS1 voltage remains within the acceptance i'li"l rFl i"If'i
1611511411311211111 0191817161514131211
range of 45 to 900 counts.
ACCESS 5
+BV BNEG
© ©
• If: RPS1 voltage is less than 45 counts or more
Figure 21833
than 900 counts.
- Then replace RPS1 and recalibrate in Calibra-
tion Menu C4.1.
Crown 2009 PF17432-105 Rev. 5110 M4.8-1457-105

01 Rev. 5/10
437
ELECTRICAL
Event Code 517 • If: ACCESS 5 sensor voltage remains at 0 V with
CA652, CA653 and CA654 all disconnected.
ACCESS 5 M4 Electronic Power Steering Motor - Then replace ACCESS 5.
Encoder (ECR4) Out of Range
Step 3: Power is present at ACCESS 5, but not at
Travel is disabled. CA653. Find the wiring or harness issue by checking
This is typically the result of a loss of one of the ECR4 connectors CA651-3, CA651-4, CA653-1, CA653-6
channels or power or ground connection. and associated wiring. Examine the wiring for breaks or
scrapes, the contacts for good crimps and the connec-
NOTE tors for proper insertion and retention.
ECR4, RPS1 and RPS2 share the same 5 V power • If: Wiring, contact or connector issue is found.
supply from ACCESS 5.
Step 1: Check the 5 V power supply and ground con-
Step 4: Check ECR4 Channel A and Channel B con-
nections by measuring voltage from CA653-1 to
nections at CA651-5 and CA651-6, associated wiring,
CA653-6.
CA653-2 and CA653-3 and the wiring between CA653
• If: 5 V is present at CA653. and M4. Examine the wiring for breaks or scrapes, the
contacts for good crimps and the connectors for proper
- Then proceed to Step 4. insertion and retention.
• If: Power supply voltage is not present at CA653. • If: Wiring, contact or connector issue is found.
- Then check for 5 V supply at ACCESS 5 - Then repair or replace as needed.
CA651-3 (positive) and CA651-4 (negative).
• If: Wiring and connections are OK.
• If: Power supply voltage is not present at
ACCESS 5.
Step 5: Follow the recommendations in front of the
Service and Parts Manual to jack up and block the
• If: 5 V is present at ACCESS 5. truck frame with the drive tire off the floor. Key the truck
ON and view ECR4 Channel A and B signals in Ana-
- Then proceed to Step 3. lyzer Menus A2.5.1.2 and A2.5.1.3 while manually ro-
Step 2: Inspect for sensors that may short ACCESS 5 tating (steering) the drive tire.
sensor power to ground. While measuring the voltage
across CA651·3 to CA651-4, disconnect ECR4, RPS1
• If: Either channel remains constant while moving
the tire.
and RPS2 one at a time.
- Then replace M4.
• If: ACCESS 5 sensor voltage changes from 0 to
5 V while disconnecting CA654. • If: Both channels change while rotating the tire.
- Then if wiring from RPS1 to CA654 is OK, re- - Then replace ACCESS Sand recalibrate RPS1
place RPS1. in Calibration Menu C4.1.

5 V while disconnecting CA652.
- Then if wiring from RPS2 to CA652 is OK, re-
place RPS2.

5 V while disconnecting CA653.
- Then if wiring from M4 to CA653 is OK, replace
M4.
M4.8-1457-106 Crown 2009 PF17432-106 Rev. 5110
01 Rev. 5110
438
ELECTRICAL
l!J\OWr. Event Code 518 Event Code 519
RPS2 CA652
BlU
UTPUT A\. BlK '1 OUTA,..
Event Code 522
GROUND A
'.\ RED
~ GNDAI
+5VAI
+5V~1 WHT fJ +5VB",..
+5VB f4 GND BI
ACCESS 5 Internal Current Regulator Out of Range
GROUND B-1 GRN f5 OUTBI
UTPUTB/ BRN f5 1
Travel is disabled.
"
I
'-'-
The current regulator is outside the range of the set

SPLlCE17
Xi
value.
,--------' /
I ~a: M4 I Step 1: Check battery state of charge and condition
I ..Jw GND/BlK I- I CA653
IU
~ iro 1,-
0 +V/RED I-~...!
+5 V
(HA I
,.. (insufficient battery charge or condition may log this
Iw ~~ AlWHT I-I-r 2 event code).
I :!::w B/GRN 1-11 ~ (H B I
~ .rtT lc
I
I
I I
~ . < VEL
TS4 BlK
4
fc~
I ~
ERMX
GND
J • If: Battery charge and condition are OK.
L _________ ~ "
CA654
RPS1 RED~::;; +5V ,.. Step 2: Verify the drive tire is unobstructed as de-
(T ~
WHITE I:JI
I:Jt
BLACK '\:I.:::
ANALOG I
GND I
scribed in Event Code 506.
" • If: No obstruction is present.
.-----
f'li'ii'ii'i f'li'i " I" Step 3: Verify integrity of RPS2 wiring.
16151411311211111 0191817161514131211
ACCESS 5 • If: RPS2 wiring is OK.
+BV BNEG
© © - Then proceed to Step 4.

Figure 21833 Step 4: Verify integrity of ACCESS 5 power cable con-
nections.
Event Code 518 • If: ACCESS 5 power cable connections are OK
Event Code 519 and event code continues.
ACCESS 5 Internal Calibration Time Out in Calibration Menu C4.1.
Step 1: Recalibrate ACCESS 5 using the Calibration ACCESS 5
Menu - C4. Monitor event. RPS1 CA651
• If: The event continues. CE:~t19

Event Code 520 RPS2

(COMMAND)
Event Code 521

ACCESS 5 Internal Sensor Error
Step 1: Rekey the truck and monitor the event.
• If: The event continues. Figure 21830
Crown 2009 PF17432-107 Rev. 5110 M4.8-1457-107

01 Rev. 5/10
439
ELECTRICAL
Event Code 523 • If: The gears are properly aligned.

ACCESS 5 ECR4 Position Regulation Issue
Step 4: View the output of RPS1 in Calibration Menu
Traction is disabled. C4.1. Perform a RPS1 calibration to verify hard stop
This is an internal control loop issue that occurs if the voltages but don't save the results. Use the right arrow
motor position feedback does not correspond to button to display the RPS1 voltages at the CW and
ACCESS 5 commands as if the tire is obstructed. CCW hard stops. The expected range of the CW stop
is 0.62 V to 1.06 V and that of the CCW stop is 3.95 V
Step 1: Check steering components for obstructions to 4.38 V. The RPS1 voltage shall increase smoothly
that may bind or prevent wheel motion. Follow the rec- with tire movement from CW stop to CCW stop.
ommendations in front of the Service and Parts Manual
to jack up and block the truck frame with the drive tire • If: Hard stop voltages fall outside the specified
off the floor. With the truck keyed OFF, manually rotate ranges and the gear is properly aligned.
the drive tire through its entire steer range.
• If: Wheel binds at any point within the allowable tion Menu C4.1.
range of motion.
• If: Hard stop voltages fall within the specified
- Then examine M4, gearbox and gearing to find ranges.
the source of the binding and repair or replace.
• If: Wheel rotates smoothly throughout its entire
Step 5: View the RPS1 voltage as the drive tire is
range. moved from the CW stop to the CCW stop.
• If: RPS1 voltage does not increase smoothly and
Step 2: Check the steering operation for contact with continuously with tire movement.
steering hard stops. Rotate the tiller to move the drive
tire completely through its range of motion several - Then replace RPS1 and recalibrate in Calibra-
times. tion Menu C4.1.
• If: The steer mechanism contacts a steer stop (re-

sulting in Event Code 523). ACCESS 5
RPS1 CA651
- Then proceed to Step 3. CA653 ECR4
CE:::::::;:t1 9
1 +VIRED m~
• If: Steer mechanism does not hit a hard stop. 2 ANlJHT ~~
o
3 B/GRN o~
- Then verify operation of ECR4 as described in !:llfnm
Event Code 517. 6 GND/BLK
RPS2
(COMMAND)
Step 3: The RPS1 gear is installed such that the gear
alignment hole coincides with the drive carriage align-
ment hole when the drive tire is rotated to the hard stop
(check Service and Parts Manual- Brake Maintenance
for appropriate hard stop). During RPS1 calibration,
ACCESS 5 learns the locations of the two hard stops
(within an acceptable tolerance range) and sets the
drive tire allowable range of motion to within few de-
grees of these stops. Check that the RPS1 gear is Figure 21834
properly aligned as described above.
• If: The holes are not aligned, verify gears are not
damaged (if damaged, repair or replace).
- Then properly align the gear and recalibrate
RPS1 in Calibration Menu C4.1.
M4.8-1457-108 Crown 2009 PF17432-108 Rev. 5110
01 Rev. 5110
440
ELECTRICAL

ACCESS 5 Steer Motor (M4) Open ACCESS 5 Speed Regulation Error
Step 1: Visually inspect ACCESS 5 power terminal This is an internal control loop issue that occurs if the
connections for proper wiring and tightness. M4 speed feedback does not correspond to
ACCESS 5 commands. An obstructed drive tire, re-
• If: Any terminals are loose. versed M4 power cables or an issue with ECR4 can
- Then tighten to 6 Nm (4.4 ft Ib). trigger this event code.
Step 1: Check the M4 power cable connections to
• If: Any cables are missing or damaged.
ACCESS 5.
• If: Power cables are reversed.
• If: All cable connections are OK. - Then correct cables.
• If: Power cables are correct.
Step 2: Check continuity of M4 windings and power ca-
bles. Disconnect the U, V and W cables from the - Then proceed to Step 2.
ACCESS 5 terminals. Verify continuity (1 ohm or less) Step 2: Check for drive tire obstructions as described
from U to V, V to Wand W to U. in Event Code 523.
• If: Any measurement is open or high. • If: No obstructions are found .
- Then replace M4. - Then proceed to Step 3.
• If: Continuity is correct. Step 3: Follow the steps for Event Code 517 to check
for ECR4 issues.
ACCESS 5
RPS1 CA651
CA653 ECR4
ACCESS 5 GE:~T{9 1 +V/RED m~
2 ANlHT ~~
o
3 B/GRN o;g
!Bfnm
6 GNDIBLK
+BV BNEG
© ©
Figure 21835
Figure 21834
Crown 2009 PF17432-109 Rev. 5110 M4.8-1457-109

01 Rev. 5/10
441
ELECTRICAL
Event Code 526 • If: Event Codes 125, 305 or both have logged in
addition to 527.
ACCESS 5 Internal Speed Supervision Error - Then the issue is between ACCESS 5 and the
All traction is disabled. distribution panel. Check connectors, contact
crimps, insertion and retention and wires at
Step 1: Rekey the truck and monitor the event. ACCESS 5 CA651-23, CA650-4 and CA205-6
• If: The event continues. on the distribution panel for the CAN_H signal,
and CA651-15, CA650-3 and CA205-7 for the
- Then replace ACCESS 5. CAN_L signal.
Step 2: If wiring appears to be correct and the event
Event Code 527 code persists, check the CAN bus termination resis-
tance between CAN_H and CAN_L wires. Disconnect
CA651 from ACCESS 5 and verify CA205 is connected
ACCESS 5 CAN Error with ACCESS 3
and fully seated into the distribution panel, and that
Traction is disabled. CA405 is connected and fully seated into ACCESS 1.
Measure the resistance on the harness connector be-
This event code occurs if ACCESS 5 does not receive
tween CA651-23 and CA651-15. The resistance
a CAN message from ACCESS 3 for 100 ms (typical
should be 60 ohm.
message intervals are 16 ms). Other related event
codes are 125 (ACCESS 1 lost ACCESS 5 CAN mes- • If: Resistance is 120 ohm.
sage) and 305 (ACCESS 3 lost ACCESS 5 CAN mes-
sage). Before checking for wiring issues, key truck - Then one of the terminating resistors is miss-
OFF, disconnect battery and ensure ACCESS 5 capac- ing. Proceed to Step 3.
itors are fully discharged (turn and hold the key switch
to the start position a minimum of 10 seconds and • If: Resistance is 60 ohm.
place a digital volt-ohm multimeter [DVOM] across the - Then proceed to Step 5.
+BVand BNEG terminals to discharge ACCESS 5 ca-
pacitors). Note: ACCESS 5 CAN timeouts will occur if Step 3: Verify CA405 is connected and fully seated into
the truck features are misconfigured as hydraulic steer. ACCESS 1 and that CA205 is disconnected from the
If Event Code 527 logs, then the CAN bus is connected distribution panel. Measure the resistance on the har-
between ACCESS 1 and ACCESS 5 but may be inter- ness between CA205-6 and CA205-7. Resistance
mittent. should be 120 ohm.
Step 1: Check for Event Codes 305 and 125 in addition • If: Resistance is much more than 120 ohm.
to 527.
• If: Only Event Code 527 has logged.
• If: Resistance is 120 ohm.
- Then the issue is between ACCESS 3 and the
distribution panel. Check connectors, contact
crimps, insertion and retention and wires at
ACCESS 3 CA401-23 and CA205-3 on the dis-
tribution panel for the CAN_H signal, and
CA401-15 and CA205-10 for the CAN_L sig-
nal.
M4.8-1457-110 Crown 2009 PF17432-110 Rev. 5110
01 Rev. 5/10
442
ELECTRICAL
Step 4: Disconnect CA405 from ACCESS 1 and verify Event Code 528
CA205 is connected and fully seated into the distribu-
tion panel. Measure the resistance on the harness be-
ACCESS 5 Issue - Invalid Event Code - Not Used
tween CA405-8 and CA405-9. Resistance should be
120 ohm. Traction is disabled.
• If: Resistance is much more than 120 ohm. • If: ACCESS 5 is reporting an issue that is not de-
fined.
- Then check the distribution panel termination.
Verify jumper J1 is installed. - Then contact factory.
• If: J1 is installed.
• If: J1 is not installed.
- Then install J1.
• If: Resistance is 120 ohm.

Step 5: Connect all connectors, connect battery, key
truck OFF and back ON and verify issue still exists.

- Then replace ACCESS 5and recalibrate RPS1
ACCESS 1
DISTRIBUTION PANEL
CA405
~
J1 ~-(;--+------i 8 AINH
120 OHM
I§:Q] CAN H TP7 ,.---<E----;~ 9 RESISTOR
1200HM
RESISTOR~
r-e CAN L
CAN L TP8 ACCESS 3
CA2~ ~01
1f- .---+---+---7-----i~
-
2
~f--+--+-----+---7----t@J
4 .===~
5 ACCESS 5
6 f-- _ CA650 CA651
f- :c'T ~
~h ~'2 I ~
8 L+-+++---HO'3 ~
9
f--
~~ -EJ
10 f - -
I--
11 +BV BNEG
I--
~
121----'
©©
Figure 21836
Crown 2009 PF17432-111 Rev. 5110 M4.8-1457-111

01 Rev. 5/10
443
ELECTRICAL
Event Code 550
ACCESS 5
ACCESS 5 Steering Feedback (RPS1) No Move- RPS1
5V CA651
ment with Tiller Command from RPS2 ot+-==AN:-:;;A,:=L=.OG=------+_--i 9
GND
RPS1 feedback is indicating no drive tire movement
with valid RPS2 Steering Command Position Sensor.
Step 1: Inspect steer linkage to feedback gear and ver-
ify magnet and gear rotate freely, with tire movement,
below the stationary mounted RPS1.
• If: Steer linkage is not connected or moving freely.
• If: Steer linkage is OK.
- Then proceed to Step 2. Figure 21837
Step 2: View RPS1 output in Analyzer Menu A2.5.5.1

(in counts) while rotating the tiller. The range is about
100 to 900 at the CW stop, to -8100 at the CCW stop
and should change with wheel movement. If the wheel
does not move with the tiller, follow the recommenda-
tions in front of the Service and Parts Manual to jack up
and block the truck frame with the drive tire off the floor
and rotate tire manually.
• If: Count is not changing or is jumping erratically

with tire position.
• If: Count appears to change smoothly with tire mo-

tion.
- Then monitor for subsequent issues, indicating
intermittent connections, and proceed to Step
3.
Step 3: Inspect RPS1 harnessing for shorts and
opens. Check connectors, contact crimps, insertion
and retention and wires at ACCESS 5 CA651-9,
CA654-2 and the white sensor wire for the signal line;
CA654-1, splice 18 and the red sensor wire for the 5 V
line; and CA654-3, splice 17 and the black sensor wire
for the ground line.
• If: Wiring issue is found.

tion Menu C4.1.
M4.8-1457-112 Crown 2009 PF17432-112 Rev. 5110
01 Rev. 5/10
444
ELECTRICAL
Event Code 551

ACCESS 5 Steering Feedback (RPS1) Movement
with No Tiller Movement (RPS2)
RPS1 feedback indicates drive tire movement of about
45 degrees without RPS2 tiller sensor input command.
• If: Drive tire has been manually rotated with truck

keyed ON during service.
- Then key truck OFF and back ON to clear the
event code.
• If: Drive tire has moved due to a collision with an

obstruction.
- Then check for and repair any damage.
• If: Tire rotates without tiller command.
- Then check RPS1 and RPS2 for issues.
• If: RPS1 and RPS2 are OK.
- Then replace ACCESS 5 or M4.
ACCESS 5
RPS1 CA651
GE=~l-19
RPS2
(COMMAND)
Figure 21830
Crown 2009 PF17432·113 Rev. 5110 M4.8-1457-113

01 Rev. 5/10
445
ELECTRIGAL
Event Code 552 • If: Gear is properly aligned.

ACCESS 5 Steering Feedback (RPS1) Signal Out of tion Menu C4.1.
Range (Low)
• If: RPS1 signal stays well above 66 counts.
RPS1 feedback voltage is below the acceptable output - Then replace ACCESS 5 and recalibrate RPS1
range. The RPS1 output voltage range is 0.35 V (- 66 in Calibration Menu C4.1.
counts) to 4.65 V (- 874 counts). A RPS1 power loss,
signal line short, issue with RPS1 or ACCESS 5 or mis-
aligned RPS1 gear could log this event code. ACCESS 5
5V CA651
Step 1: View RPS1 output in Analyzer Menu A2.5.5.1 tll->-!,"AN""A""'LO""'G"'-------I-_--l 9
GND
(in counts) with the tire positioned away from both hard
stops.
• If: RPS1 signal is less than 66 counts.
• If: RPS1 signal is within the acceptable range.

Figure 21837

tion Menu C4.1.
• If: Issue persists after replacing RPS1.

(in counts) while positioning the tire close to the hard
stops.
• If: RPS1 signal gets very close to or below 66

counts.
- Then verify RPS1 gear alignment as described
in Event Code 523.
• If: Gear is out of alignment.
- Then align RPS1 gear and recalibrate in Cali-

bration Menu C4.1.
M4.8-1457-114 Crown 2009 PF17432-114 Rev. 5110
01 Rev. 5/10
446
ELECTRICAL

ACCESS 5 Steering Feedback (RPS1) Signal Out of tion Menu C4.1.
Range (High)
• If: RPS1 signal stays well below 874 counts.
- Then replace ACCESS 5 and recalibrate RPS 1

RPS1 feedback voltage is above the acceptable output
range. The RPS1 output voltage range is 0.35 V (- 66 in Calibration Menu C4.1 .
counts) to 4.65 V (- 874 counts). A RPS1 power loss,
signal line short, issue with RPS1 or ACCESS 5 or mis-
ACCESS 5
aligned RPS1 gear could log this event code.
5V CA651
Step 1: View RPS1 output in Analyzer Menu A2.5.5.1 t:lI-+~ANAL~~O~G_-+--~ 9
GND
(in counts) with the tire positioned away from both hard
stops.
• If: RPS1 signal is more than 874 counts.

RPS2
- Then proceed to Step 2. (COMMAND)
• If: RPS1 signal is within the acceptable range.

Figure 21837

tion Menu C4.1.

(in counts) while positioning the tire close to the hard
stops.
• If: RPS1 signal gets very close to or above 874

counts.
- Then verify RPS1 gear alignment as described
in Event Code 523.

bration Menu C4.1.
Crown 2009 PF17432-115 Rev. 5110 M4.8-1457-115

01 Rev. 5/10
447
------------ -----------------------------
ELECTRICAL

ACCESS 5 Steering Feedback (RPS1) Offset Error tion Menu C4.1.
This event code is the result of an issue between the
ACCESS 5
tire position reported by ACCESS 5 and that calculated 5V CA651
by ACCESS 3. Upon keying the truck ON, the reported t:J+-+-=AN;.;Al~O~G -+-~ 9
GND
wheel position must be within 10° of its position at key
OFF. During run time operation the reported wheel po-
sition must remain within 25° of the position computed
by ACCESS 3. This event code will log if the tire posi-
tion is moved during service. In this case key the truck RPS2
(COMMAND)
and back ON to clear the event code.
(in counts) while moving the tire from stop to stop.
• If: RPS1 signal stops changing or jumps erratically

while the tire is moving.
Figure 21837
• If: RPS1 signal changes smoothly with tire move-
ment.
Event Code 600
Step 2: Inspect RPS1 harnessing for shorts and Invalid Event Code from ACCESS 2 Module· Not
opens. Check connectors, contact crimps, insertion Used
and retention and wires at ACCESS 5 CA651-9, All functions are disabled.
CA654-1, splice 18 and the red sensor wire for the 5 V The event code reported is not defined in the vehicle
line; and CA654-3, splice 17 and the black sensor wire code. Contact factory.

tion Menu C4.1.

Step 3: Verify RPS1 gear alignment as described in
Event Code 523.

bration Menu C4.1.
M4.8-1457-116 Crown 2009 PF17432-116 Rev. 5110
01 Rev. 5/10
448
ELECTRICAL

ACCESS 2 Internal Voltage Out of Range ACCESS 2 Output Voltage Low
All functions are disabled. Hydraulic functions are disabled.
An under voltage or over voltage has occurred. M2 output voltage is lower than expected during PWM.
This alarm signals an issue with the M2 connections or
Step 1: Disconnect and check power cable connec-
M2 power circuit in ACCESS 2.
tions to ACCESS 2. Torque to 15 Nm (11 ft Ib).
Step 1: Check M2 cables and internal connections for
• If: Cables are OK. continuity.
- Then check FU4, FU9 and FU11. • If: M2 cables and internal connections are OK.
• If: Fuses are shorted. - Then check power cable connections to D and
A on M2, and P- and +BV on ACCESS 2.
Step 2: Check P2 wiring for good connections and
• If: Fuses are OK. check the voltage at P2 to verify ACCESS 2 is trying to
- Then check battery or cells under load. pull in P2.
• If: Battery is not operating. • If: All is OK.
- Then recharge or repair battery. - Then the issue is with ACCESS 2.
• If: Battery is OK and event code continues. • If: The issue occurs after P2 closes (closes and
quickly opens back again), or if the issue occurs
- Then replace ACCESS 2. during truck operation.
- Then check power cable connections to D and
ACCESS 2 A on M2, and P- and +BV on ACCESS 2. Also
FU4
CA425
check M2 windings for leakage to frame and P2
SA contactor tips for a good connection.
=--~33
FU9
+BV p- BNEG • If: All is OK.
800 A
FU11 ACCESS 2
300 A
BNEG
Figure 21838 ©
Figure 21839
Crown 2009 PF17432-117 Rev. 5110 M4.8-1457-117

01 Rev. 5/10
449
ELECTRICAL
Event Code 603 • If: Cables are OK.
ACCESS 2 Output Voltage High
Hydraulic functions are disabled.
ACCESS 2
M2 output voltage is higher than expected during
PWM. This alarm signals an issue with the M2 connec- +BV p- BNEG
tions or M2 power circuit in ACCESS 2. This diagnostic
is only carried out when M2 is running.
©
Step 1: Check M2 cables and internal connections for
continuity.
• If: M2 cables and internal connections are OK.

Figure 21840
- Then check M2 windings for leakage or a short
to the frame (10,000 ohm minimum). Event Code 605
• If: M2 windings are OK.
ACCESS 2 Incorrect Standby Current
- Then check power cable connections to D and
A on M2, and P- and +BV on ACCESS 2. Travel and hydraulics are disabled.
This diagnostic is a check to see if the M2 current is 0
in standby. If it is more than 0 in standby, the event
- Then replace ACCESS 2. code is logged.
Step 1: Check for loose cable connections at
ACCESS 2 and M2.
ACCESS 2
• If: Cables are loose.
- Then repair as needed.
BNEG • If: Cables are OK.

© - Then replace ACCESS 2.
ACCESS 2
Figure 21839 +BV p- BNEG

©
Event Code 604
ACCESS 2 Hydraulic Motor (M2) Current Low
Hydraulic functions are disabled.
Figure 21840
This event code occurs when M2 is running and signals
the M2 current sensor is reading near 0 when running.
Current feedback reading is incorrect.
Step 1: Check for loose cable connections at
ACCESS 2 and M2.
• If: Cables are loose.

- Then repair as needed.
M4.8-1457-118 Crown 2009 PF17432-118 Rev. &10
01 Rev. 5/10
450
ELECTRICAL
Event Code 606

ACCESS 2
ACCESS 2 Contactor (P2) Driver Shorted
CA425
High speed lift is disabled. ~--I 26 CONTACTOR COIL SINKING DRVR
L -_ _----:..._~ 27 +BV SOURCE
P2 contactor coil is shorted and ACCESS 2 is unable
to close P2. +BV p- BNEG
Step 1: Check that the P2 contactor coil wires are not

© © ©
shorted, especially the negative wire being shorted to
Figure 21841
BNEG.
• If: Wires are shorted. Event Code 608
ACCESS 2 Contactor (P2) Coil Shorted
• If: Wires are OK.
High speed lift is disabled.
- Then check the resistance of the P2 contactor
P2 contactor coil or wiring to the coil is shorted.
coil for a short (should be approximately 55
ohm). Step 1: Check that the P2 contactor coil wires are not
shorted, especially the negative wire being shorted to
• If: P2 contactor coil is shorted. +BV.
- Then replace P2. • If: Wires are shorted.
• If: P2 contactor coil is OK. - Then repair or replace as needed.
- Then replace ACCESS 2. • If: Wires are OK.
- Then check the resistance of the P2 contactor
ACCESS 2 coil for short (should be approximately
CA425 55 ohm).
1------i26 CONTACTOR COIL SINKING DRVR
L.-------:...------i 27 +BV SOURCE • If: P2 contactor coil is shorted.
+BV p- BNEG - Then replace P2.

© © © • If: P2 contactor coil is OK.
Figure 21841 - Then replace ACCESS 2.
Event Code 607

ACCESS 2
CA425
ACCESS 2 Contactor (P2) Driver Open
>----126 CONTACTOR COIL SINKING DRVR
High speed lift is disabled. L -_ _----=--_~ 27 +BV SOURCE
P2 driver is unable to pull in P2. +BV p- BNEG
The driver in the P2 contactor driver circuit is damaged

© © ©
internal to ACCESS 2, replace ACCESS 2.
Figure 21841
Crown 2009 PF17432-119 Rev. 5110 M4.8-1457-119

01 Rev. 5/10
451
- - - - - _ .. _. ------------
ELECTRI€AL
ACCESS 2 Hydraulic Motor (M2) Stalled ACCESS 2 Incorrect Battery Voltage
All hydraulic functions are disabled. All hydraulic functions are disabled.
This event code occurs when the speed output from The battery voltage at ACCESS 2 at power up is too
ACCESS 2 is not equal to the speed read back from high or low.
ECR3. This could be an issue with ECR3, ACCESS 2
Step 1: Verify battery voltage is correct.
or wiring. ECR3 input to ACCESS 2 can be monitored
in Analyzer Menu A2.2.1. • If: Battery voltage is correct.
Step 1: Check ECR3 wiring for shorts. - Then verify truck model is correct in Features
Menu F3.1.
• If: Wiring is shorted.
- Then repair or replace as needed. • If: Truck model is correct.
- Then check battery for issue with cells.

- Then check ECR3 12 Vdc power supply at • If: Battery is OK.

CA426-1 and CA426-2. - Then measure the voltage at ACCESS 2
CA425-33 and BNEG.
• If: 11.3 Vdc is not present.
- Then trace the wiring back to ACCESS 2 at • If: Battery voltage is OK.
CA425-1 and CA425-2. - Then replace ACCESS 2.
• If: 11.3 Vdc.
- Then repair or replace wiring to CA426. ACCESS 2
FU4
CA425
• If: 11.3 Vdc is not present. 5A
lCll--~33
• If: 11.3 Vdc

36V
- Then replace ECR3. L.- -J+ II i11---------.J
Figure 21842
ACCESS 2
+BV P- BNEG
©©©
Figure 21847
M4.8-1457-120 Crown 2009 PF17432-120 Rev. 5/10
01 Rev. 5/10
452
ELECTRICAL
Event Code 614

ACCESS 2 CAN Bus Disconnect DISTRIBUTION PANEL ACCESS 2
CA204
ACCESS 2 is not receiving any CAN messages. 1 CAN H TP7
CA425
1200HM ~ r+----7--i 18
All hydraulic functions are disabled. 2 RESISTOR~ r-+-+--+---l 19 Cl
3 CAN L TP8
Step 1: Key truck ON and check the status of 4
~©
CD
ACCESS 2 and ACCESS 4 indicator lights. 5 CA205
6 2
• If: ACCESS 2 and ACCESS 4 indicator lights are
7
ON and event code continues. 8 4 ACCESS 4

10
• If: ACCESS 2 and ACCESS 4 indicator lights are 11
11
OFF. 12

ACCESS 2 at CA402-1 and BNEG, and Figure 21843
Step 2: Check CAN wires and connections.
CAN H: Check ACCESS 2 CA425-18 to the distribu-
tion panel CA205-2, and CA205-4 to ACCESS 4
CA412-2.
CAN_L: Check ACCESS 2 CA425-19 to the distribu-
tion panel CA205-11, and CA205-9 to ACCESS 4
CA412-1.

and CAN_L at TP7 and TP8 on the distribution panel;
resistance should be 60 ohm.
• If: 0 ohm.
and fuses.

tween TP7 and TP8.

• If: 120 ohm.

Crown 2009 PF17432-121 Rev. 5110 M4.8-1457-121

01 Rev. 5/10
453
ELECTRICAL
ACCESS 2 Current Sense Out of Range ACCESS 2 Hydraulic Motor (M2) Shorted· DC
Hydraulic Models
All hydraulic and traction functions are disabled.
The internal ACCESS 2 current sensor is outside the
acceptable range.
NOTE
Step 1: Disconnect and check power cable connec-
tions to ACCESS 2. Torque to 16 Nm (12 ft Ib). Software versions prior to VB may randomly exhibit
Event Code 620 as a nuisance.
Step 1: Key the truck OFF. Remove the FU9 jumper
- Then key truck OFF and back ON. cable from the M2 D position. Rekey the truck and
check to see if event is resolved.
• If: The event is resolved.
- Then check for a short in the FU9 circuit.
Event Code 619 • If: There is no change in the event.
- Then continue to step 2.

ACCESS 2 Watchdog Event
Step 2: Check the M2 motor cables from ACCESS 2 p-
All hydraulic functions are disabled. and ACCESS 2 +8 for shorts.
Step 1: Verify the power cable wiring to ACCESS 2 is
• If: Short is found.
correct.
- Then disconnect the motor and determine
• If: It is incorrect. whether the short is in the motor or the motor
- Then repair as needed. cables. Replace or repair components as nec-
essary.
• If: It is correct.
• If: No short is found .
- Then verify ED1 contactor tips are OK and that
ED1 is operating property. - Then replace ACCESS 2.
• If: ED1 is not operating properly.

ACCESS 2
- Then repair or replace as needed. FU4
CA425
5A
• If: ED1 is OK. =-------l 33
FU9
+BV P- BNEG
- Then key truck OFF and back ON. 800 A
36V
L..------....,.l+ Iii II------------l
Figure 21838
M4.8-1457-122 Crown 2009 PF17432·122 Rev. 5110
01 Rev. 5110
454
ELECTRICAL
cnOWrl Event Code 621
Event Code 621

ACCESS 2 P2 Contactor Coil Driver Shorted· DC
Hydraulic Models
All hydraulic and traction functions are disabled.
Step 1: Key the truck ON. Hold the operator presence
switch closed. Using a DVOM, connect the positive
lead to P2+ and the negative lead to ACCESS 2 B-.
• If: BV is present.
• If: BV is not present.
- Then repair cable connections.

Step 2: Key the truck OFF. Disconnect the circuit at
ACCESS 2. Using a DVOM, connect one lead to
ACCESS 2 CA425-26 and the other lead to ACCESS 2
CA425-27. Check for approximately 28 ohms.
• If: Short is present.
- Then disconnect the wiring at the P2 coil and

determine whether there is a short in the coil or
the wiring. Repair or replace components as
needed.
• If: No short is present.
ACCESS 2
CA425
r=5=92=3 -f---j26
2923 .-------------127
Figure 23830
Crown 2009 PF17432-123 Rev. 5110 M4.8-1457-123

01 Rev. 5/10
455
ELECTRICAL
Event Code 800 • If: Voltage stays at +BV.

Invalid Event Code from ACCESS 4 Module - Not
Used
All functions are disabled. ACCESS 4
TILT CA411
The event code reported is not defined in the vehicle vn=----Q--Q---430
code. Contact factory. SIDESHIFT
....,,=------'---iSVS 29
REACH 28
Event Code 801

ACCESS 4 Bypass Solenoid (SVBY) Coil Open Cir-
cuit
Raise is disabled.
An open circuit exists in either the SVBY coil or the pos-
coil driver output.
negative. Probe for +BV on SVBY. With truck keyed
• If: +BV is not present at SVBY.
- Then check the positive wiring at ACCESS 4

CA41 0-4.
• If: +BV is not present at CA41 0-4. Figure 21818

SVBY.
• If: +BV is present at SVBY on one side only.
- Then SVBY coil is open, replace SVBY.
• If: +BV is present at both sides of SVBY.
• If: +BV.

should drop to 18-20 Vdc.
M4.8-1457-124 Crown 2009 PF17432-124 Rev. 5.'10
01 Rev. 5110
456
ELECTRICAL
Event Code 802

ACCESS 4
ACCESS 4 Raise Solenoid (SCV) Coil Open Circuit
TILT CA411
Full speed raise is disabled. 30
•--=--=--~ SVS SIDESHIFT
29
An open circuit exists in either the SCV coil or the pos- REACH
'R>------O.----<:>-O~ 28
coil driver output.
negative. Probe for +BVon SCV. With truck keyed ON,
• If: +BV is not present at SCV.

CA41 0-4.

SCV.
• If: +BV is present at SCV on one side only. Figure 21818
- Then SCV coil is open, replace SCV.
• If: +BV is present at both sides of SCv.
• If: +BV.

Crown 2009 PF17432-125 Rev. 5110 M4.8-1457-125

01 Rev. 5/10
457
ELECTRI€AL
Event Code 803
ACCESS 4
ACCESS 4 Lower Solenoid (SVL) Coil Open Circuit
TILT CA411
Raise and lower is disabled. .f=----o-~ 30
SIDESHIFT
--=:o---,-{SVS 29
An open circuit exists in either the SVL coil or the pos- REACH
R)------=-------O""-O---i 28
coil driver output.
negative. Probe for +BV on SVL. With truck keyed ON,
• If: +BV is not present at SVL.

CA41 0-4.

SVL.
• If: +BV is present at SVL on one side only. Figure 21818
- Then SVL coil is open, replace SVL.
• If: +BV is present at both sides of SVL.
• If: +BV.

output in Analyzer Menu A4.4.1 O. Voltage
M4.8-1457-126 Crown 2009 PF17432-126 Rev. 5110
01 Rev. 5/10
458
ELECTRICAL
Event Code 804

ACCESS 4
ACCESS 4 Accessory Solenoid (SVA) Coli Open
TILT CA411
Circuit >-----o--o---l30
SIDESHIFT
Reach tilt and sideshift is disabled. ,>--....:0--<>---1 29
REACH 28
An open circuit exists in either the SVA coil or the pos-
coil driver output.
negative. Probe for +BV on SVA. With truck keyed ON,
• If: +BV is not present at SVA.

CA41 0-4.

SVA.
Figure 21818
• If: +BV is present at SVA on one side only.
- Then SVA coil is open, replace SVA.
• If: +BV is present at both sides of SVA.
• If: +BV.

Crown 2009 PF17432-127 Rev. 5110 M4.8-1457-127

01 Rev. 5/10
459
-----------------------------------
ELECTRICAL
Event Code 805
ACCESS 4
ACCESS 4 Reach Solenoid (SVR) Coil Open Circuit
TILT CA411
Raise and lower are disabled. 1=-----0-0--130
SIDESHIFT
l---o--o---j 29
An open circuit exists in either the SVR coil or the pos- REACH
RJ---'-------Q>-()--j28
coil driver output.
negative. Probe for +BV on SVR. With truck keyed ON,
• If: +BV is not present at SVR.

CA41 0-4.
- Then repair or replace wiring from CA41 0-4 to 36V

SVR. + IIII
• If: +BV is present at SVR on one side only. Figure 21818
- Then SVR coil is open, replace SVR.
• If: +BV is present at both sides of SVR.
• If: +BV.

M4.8-1457-128 Crown 2009 PF17432-128 Rev. 5110
01 Rev. 5110
460
ELECTRICAL
Event Code 806

ACCESS 4
ACCESS 4 Sideshift Solenoid (SVS) Coli Open Cir-
TILT CA411
cuit }=----o--Q---i 30
SIDESHIFT
Raise and lower are disabled. ----=:::::------'--{:SVS 29
REACH
RI------'----cl-O~ 28
An open circuit exists in either the SVS coil or the pos-
coil driver output.
negative. Probe for +BV on SVS. With truck keyed ON,
• If: +BV is not present at SVS.

CA41 0-4.

SVS.
Figure 21818
• If: +BV is present at SVS on one side only.
- Then SVS coil is open, replace SVS.
• If: +BV is present at both sides of SVS.
• If: +BV.

Crown 2009 PF17432-129 Rev. 5110 M4.8-1457-129

01 Rev. 5/10
461
ELECTRICAL
Event Code 807
ACCESS 4
ACCESS 4 Tilt Solenoid (SVT) Coli Open Circuit
TILT ~:411
•--=---=--~ SVS SIDESHIFT
29
An open circuit exists in either the SVT coil or the pos- REACH
'RI------O..-Q---<~ 28
coil driver output.
negative. Probe for +BVon SVT. With truck keyed ON,
• If: +BV is not present at SVT.

CA41 0-4.
- Then repair or replace wiring from CA41 0-4 to 36V

SVT. + 1111
• If: +BV is present at SVT on one side only. Figure 21818
- Then SVT coil is open, replace SVT.
• If: +BV is present at both sides of SVT.
• If: +BV.

M4.8-1457-130 Crown 2009 PF17432-130 Rev. 5110
01 Rev. 5/10
462
ELEtTRICAL
Event Code 808

ACCESS 4
ACCESS 4 Fan (FAN1) Open Circuit
CA41 0
FAN1 is disabled. 4
An open circuit exists in either FAN1 or the positive or

negative wiring to FAN1.
ACCESS 4 supplies a constant positive to FAN1 and
by tracing the positive through FAN1 and back to the
driver output.
negative. Probe for +BV on FAN1. With truck keyed
ON, +BV should be present at both sides of FAN1.
Figure 21819
• If: +BV is not present at FAN1.

CA41 0-4.

FAN1.
• If: +BV is present at FAN1 on one side only.
- Then FAN1 is open, replace FAN1.
• If: +BV is present at both sides of FAN1.
• If: +BV.
Crown 2009 PF17432-131 Rev. 5110 M4.8-1457-131

01 Rev. 5/10
463
ELECTRICAL
Event Code 809
ACCESS 4 Horn (HN) Open Circuit
Hom is disabled.
An open circuit exists in either HN or the positive or
negative wiring to HN.
ACCESS 4 switches negative to HN. Test by tracing
the positive through HN and back to the driver output.
negative. Probe for +BV on HN. With truck keyed ON,
+BV should be present at both sides of HN.
• If: +BV is not present at HN.
- Then check the positive wiring back to K1 via

TP4 on the distribution panel.
• If: +BV is not present at TP4.
• If: +BV is present at TP4.
- Then repair or replace wiring from TP4 to HN.
• If: +BV is present at HN on one side only.
- Then HN internal circuit is open, replace HN.
• If: +BV is present at both sides of HN.
- Then check the voltage at CA41 0-5 for +BV.
• If: +BV.
voltage again at CA41 0-5 while testing the out-
drop to 12 Vdc.
DISTRIBUTION
PANEL
•
TP4
oK1
Figure 21844
M4.8-1457-132 Crown 2009 PF17432-132 Rev. 5110
01 Rev. 5/10
464
ELECTRICAL
Event Code 810

ACCESS 4
CA41 0
Coli Open Circuit
4
CA411
An open circuit exists in either the ED1 coil or the pos- }----"~.!JoLl.l1
itive or negative wiring to the coil.

ACCESS 4 supplies a constant positive and
ACCESS 3 switches negative to the coil. Test by trac-
ing the positive through the coil and back to the coil
driver output.
I
negative. Probe for +BV on ED1. With truck keyed ON, Figure 21819
• If: +BV is not present at ED1.

CA411-1.
• If: +BV is not present at CA411-1 .
• If: +BV is present at CA411-1.
- Then repair or replace wiring from CA411-1 to

ED1.
• If: +BV is present at ED1 on one side only.
- Then ED1 coil is open, replace ED1.
• If: +BV is present at both sides of ED1.
- Then check the voltage at ACCESS 3 CA401-2

+BV.
• If: +BV.
voltage again at CA401-2. Voltage should drop
to 18-20 Vdc.
Crown 2009 PF17432-133 Rev. 5110 M4.8-1457-133

01 Rev. 5/10
465
ELECTRICAL
ACCESS 4 Steer Input (ECR7) Not Counting· ACCESS 4 Hydraulic Motor (M2) Feedback Error
Hydraulic Steering Models (ECR3) • AC Hydraulic Models
Full speed traction is disabled. All traction is disabled.
ACCESS 4 senses steer tire movement from RPS 1 Step 1: Use Analyzer Menu - A2.2.1.2 to view the con-
without steer command input at ECR7. sistency of the M2 feedback from ECR3 during hydrau-
lic operation.
Step 1: Key the truck ON. Verify the ACCESS 4 soft-
a
ware is at least Version in Utilities Menu - U1.1. • If: The counts are not consistent with the motor
speed.
• If: The software is not up to date.
- Then check the white CH A wire from ECR6 to
- Then update the software to va or higher. CA613-3 and to ACCESS 2 CA402-5. Then
• If: The software is at least Version 8. check the blue CH B wire from ECR6 to
CA613-4 and to ACCESS 2 CA402-6. Check
- Then proceed to Step 2. the wire condition, pin positions, etc. Repair or
Step 2: Use Analyzer Menu - A2.4.22 to view the tiller replace as necessary.
command sensor inputs from ECR7 while commanding
• If: The counts are not consistent and the wires and
steer input. Proper ECR7 resolution is approximately
connections are OK.
200 counts per tiller revolution.
- Then replace M2.
• If: There the counts are not consistent with the
movement. • If: The counts are consistent and the wiring is OK.
- Then replace ECR7. - Then replace ACCESS 4.
• If: The counts are consistent with the movement.
- Then proceed to Step 3. ACCESS 2
Step 3: Use Analyzer Menu - A2.4.2.1 to view the steer

feedback sensor (RPS1) inputs while turning the steer-
~ ~~ CA613
ing. The normal inputs from RPS1 to ACCESS 4 are
, (!) W +12VIRED 1 1
0.7 Vand 105° (fully clockwise) and 4.4 Vand 80° (fully
counter-clockwise), nominal supply voltage is 5.3 V.
~ ~~~ GND/BLK 2 2 I--------.J
frl ZwW« a.co AlWHT 3 3 ~'------~ 5
~ B/BLU 4 4~---1
• If: The inputs are not consistent with the move-
CJ) al
6
ment.
tion Menu - C2.8.
• If: The inputs are consistent with the movement Figure 23831
and event continues.

M4.8-1457-134 Crown 2009 PF17432-134 Rev. 5110
01 Rev. 5/10
466
ELECTRICAL
Event Code 815

ACCESS 4 Invalid Reach Calibration
Reach/retract functions are disabled.
Step 1: Starting with the reach extended 80% for
breakout, use Calibration Menu - C2.4 to recalibrate
the accessory valve.
• If: The reach will not calibrate correctly.
- Then replace the PVA valve and return to the

start of Step 1.
Step 2: Monitor the event code.
• If: The event continues.
Event Code 816

ACCESS 4 Invalid Height Encoder (ECR2) Calibra-
tion
Raise function is disabled.
Step 1: Use Calibration Menu - C2.1 to recalibrate
ECR2.
Crown 2009 PF17432-135 Rev. 5110 M4.8-1457-135

01 Rev. 5/10
467
ELECTRICAL
Event Code 817 Step 5: Using a DVOM, with the truck keyed ON, con-
nect the positive lead to ACCESS 4 CA411-4 and the
negative lead to ACCESS 4 CA411-33. The voltage
ACCESS 4 Free Lift Switch (FLS) Not Open When
should be 13 V above staging and 0 V below staging.
Mast Staged
Full speed traction and raise are disabled. • If: Voltage is not as expected.
- Then repair or replace switch (HGTRS2) or wir-

NOTE ing (mast cable) as necessary.
This event may occur intermittently in freezers if • If: Voltage is correct.
HGTRS2 is not shimmed close enough to the mast (ap-
proximately 0.20 - 0.25 in) - Then proceed to Step 6.
Step 1: Key the truck ON. Use the Analyzer Menu - Step 6: Monitor event.
A2.4.12 to check FLS inputs to ACCESS 4 during mast
=
staging; 0 switch open (switch is not activated) and 1 • If: Event continues.
= switch closed (switch is activated). - Then replace ACCESS 4.
• If: FLS inputs are not as expected.
- Then proceed to Step 2. ACCESS 4

CA411
• If: FLS inputs are as expected. .-----cr''-O---~ 4

Step 2: Using a DVOM, with the truck keyed ON, con-
nect the positive lead to ACCESS 4 CA411-20 and the -..--------133
negative lead to ACCESS 4 CA411-33. The voltage
+BV BNEG
should be 5 V with FLS open and 0 V with FLS closed.
• If: Voltage is not as expected.
- Then repair or replace switch (FLS) or wiring

(mast cable) as necessary. Figure 23832
• If: Voltage is correct.

Event Code 818
Step 3: Use the Analyzer Menu - A2.4.2 to check ACCESS 4 Accelerometer Internal Timeout Error
HGTRS2 inputs to ACCESS 4 during mast staging; 0 = Full speed traction is disabled.
switch open (switch is not activated) and 1 = switch
closed (switch is activated). Step 1: Verify ACCESS 4 module is mounted properly
and securely. Move the truck to a level floor. The top of
• If: HGTRS2 inputs are not as expected. the battery box must be level within 2°. Use Calibration
Menu - C2.5 to recalibrate the accelerometer. Rekey
the truck and monitor the event code.
• If: HGTRS2 inputs are as expected.
Step 4: Verify HGTRS is shimmed to approximately 5-
6 mm (0.20-0.25 in) in freezer condition applications.
• If: HGTRS2 shimming is correct and event contin-

ues.
M4.8-1457-136 Crown 2009 PF17432-136 Rev. 5110
01 Rev. 5/10
468
ELECTRICAL
Event Code 819

ACCESS 4 Accelerometer Incline Error
Verify the truck is on a level surface.
Event Code 820

ACCESS 4 Accelerometer Incline Error
Verify the truck is on a level surface.
Event Code 821

ACCESS 4 Load Sense (LS) No Calibration
NOTE
Loading software requires the Load Sense Transducer
(LS) to be calibrated.
Step 1: Use Calibration Menu - C2.2 to calibrate LS.
• If: LS has been calibrated and event continues.
- Then replace LS and recalibrate.
• If: Event continues after LS has been replaced and

calibrated.
Crown 2009 PF17432-137 Rev. 5110 M4.8-1457-137

01 Rev. 5/10
469
CRown
Notes:
470
~---------------------
mewn
BRAKE
471
I
CJ\OWI'
Notes:
472
BRAKE
CROWl' Brake System
Brake System it CAUTION

There are two sources of drive wheel braking on the The customer shall verify that the stopping distance in
RRiRD 5700 and RRiRD 5700S series, a 3-stage, any part of the application doesn't prevent the operator
spring applied, electromagnetically released, friction from performing a specific task safely, or result in brak-
disc brake (BRK1) on the traction motor (M1) armature ing characteristics that are significantly different from
shaft and dynamic motor braking, typically called re- other similar vehicles being used in the facility. An al-
generative braking. The RRiRD 5700S has additional ternative is for the customer to train the operator to re-
braking in an electromagnetically applied, friction disc duce travel speed and/or allow for longer stopping dis-
brake (BRK2) in the caster wheel. tances.
When the operator makes a brake request, by releas-
ing either of the two left pedals or by applying the cen- To check stopping distance
ter pedal, ACCESS 3 determines the amount of brak- (Caster brakes are only used on RRiRD 5700S trucks.)
ing force to be applied based on the known truck
weight (includes battery and maximum allowable fork 1. Use ACCESS 1 to set the drive brake (P6) and
load) and the maximum allowable speed for the partic- caster brake (P7) values to the factory default val-
ular travel direction and fork height. The total braking ues of 6 (P6) and 6 (P7). Travel with no load, on a
effort is shared between the drive tire and the caster level, smooth, dry, concrete surface, at maximum
tire (RRIRD 5700S only) based on the known weight acceleration from zero to top speed in the forks first
distribution. The traction tire portion is further split be- direction and apply the brakes. Use A2.3.1.3 in the
tween the motor regenerative braking and BRK1. The ACCESS 1 menu to monitor the truck speed.
motor regenerative portion is made as large as practi- 2. Verify the stopping distance, from the maximum
cal in order to reduce wear on BRK1. BRK1 and BRK2 speed, is within the distance listed in Chart 1 with
effort can be electronically adjusted through the Perfor- no caster tire slide and with minimal drive tire slide.
mance Menu (P6 and P7) in order to address tire slide
for floor condition and application. 3. Use the ACCESS 1 Performance Menus to make
brake adjustments to the drive brake (P6) and the
caster brake (P7) to address tire slide for specific
Stopping Distance floor condition and application. These settings may
be reduced if the standard setting results in tire
Verify the actual truck stopping distance as listed in
slide in the application. If the floor conditions will
Chart 1 before making changes. If the truck no longer
accom.modate a more aggressive braking force,
meets the required stopping distance, complete the fol-
then the settings may be increased. The adjust-
lowing adjustments prior to programming P6 and P7 in
ments affect the brake force in both travel direc-
the ACCESS 123® Menus: tions when the forks are below the free lift height.
• Articulation Adjustment. Refer to Drive Unit - Dis-
assembly and Assembly section.
• Compare truck weight (FA) and max load weight

(F3.3) to the data plate. Refer to ACCESS 123
Menus - Features Menus.
• Drive brake torque gap adjustment. Refer to

Torque Gap Adjustment in this section.
• Condition of the drive tire.
Crown 2009 PF1743~1 Rev. 5110 M5.0-1457-001

02 Rev. 5110
473
BRAKE
Brake System CJ\OWI'
Chart 1 - Stopping Distance
Forks First Maximum Speed Maximum Stopping Distance

Model kmlh mph
meters feet
(+0.01-0.1 ) (+0.01-0.1 )
RR5715-35 10.14 6.3 2.59 8.5
RR5715-40 10.14 6.3 2.59 8.5
RR5725 10.94 6.8 2.90 9.5
RR5795 11.10 6.9 2.90 9.5
RD5725 10.94 6.8 2.90 9.5
RD5795 11.10 6.9 2.90 9.5
M5.0-1457-002 Crown 2009 PF17433-2
474
BRAKE
CJ\OWrl Brake System
Drive Brake (BRK1) 2. Use low pressure air to remove any dirt between
the armature (9) and magnet coil and body (3).
Air Gap Adjustment 3. If the truck is equipped with an external traction en-
coder (ECR1) on top of the brake assembly, re-
Refer to Figure 21880 move the encoder to minimize the risk of damage.
The air gap is the distance between the brake armature 4. Loosen the locknut (7) on the motor shaft (6).
(9) and the magnet coil and body (3) with the brakes
applied. As the brake pads (10) and rotor (5) wear nor- 5. Turn the hex nut (8) down until the air gap (4) is
mally, the air gap (4) will increase and should be read- 0.25 mm (0.010 in) at its tightest location. One
justed, or parts checked and replaced, when it exceeds complete turn of the nut changes the gap 1.4 mm
1.0 mm (0.040 in). (0.056 in). A 1/6 (60 degree) turn changes the gap
0.235 mm (0.009 in).
NOTE 6. Torque the locknut (7) to 122 Nm (90 ft Ib).
If the air gap (4) measures more than 1.0 mm 7. Install the encoder, if applicable. Apply blue thread
(0.040 in), the brake may not release properly. If the locking adhesive to the set screw.
brake pad (10) thickness is less than 2.8 mm
8. Remove the wheel chocks and check for proper
(0.110 in), replace the brake pads and rotor (5).
operation.
1. Chock the load wheels. Open the power unit doors
to access the brake (BRK1) on top of the traction
motor (1).
r;:::.::::::::=::::::::;;:::c:==::;:::;t_9
4---. 1r'-'r"'--~1I-rT-....:o..:.......;......;..,.......;......J
t==~==:;t~'10
-+- ~+--'11
3~!!---!~
1 ~
Figure 21880
Crown 2009 PF17433-3 M5.0-1457-003
475
BRAKE I
Torque Gap Adjustment be necessary to replace components and the gap may
need to be reset to factory specifications. The torque
Refer to Figure 21880 gap varies based on the truck's gross vehicle weight
(GVW). Refer to the truck capacity plate for the truck's
The torque gap (12) is the distance between the torque
adjuster plate (2) and the magnet coil and body (3). GVW as equipped with maximum battery and capacity
load. Use Chart 2 to determine the correct torque gap.
The torque plate is factory preset and no adjustment is
required, however, through routine maintenance it may
Chart 2 Torque Gap Adjustment
Torque Gap GVW (capacity load and maximum battery

mm inch kg Ib
0.00 0.00 greater than 6960 greater than 15350
0.50 0.02 6645 - 6960 14650 - 15349
1.00 0.04 6330 - 6644 13950 - 14649
1.50 0.06 5990 - 6329 13200 - 13949
2.00 0.08 5670 - 5989 12500 -13199
2.50 0.10 5350 - 5669 11800 - 12499
3.00 0.12 5010 - 5349 11050 - 11799
3.50 0.14 4695 - 5009 10350 -11049
4.00 0.16 4375 - 4694 9650 -10349
4.50 0.18 4035 - 4374 8900-9649
5.00 0.20 less than 4035 less than 8900
Crown 2009 PF1743~

M5.0-1457-004
476
BRAKE
CROWl' Brake System
Brake Assembly
Refer to Figure 21881
Before assembling the brake (BRK1), inspect all com-
ponents for wear, grooves, nicks or other damage. If
any abnormal wear or damage appears that may affect
brake operation, replace with new parts. Assemble the
brake as follows:
1. Turn the torque adjuster plate (14) down as far as
possible to reduce spring force.
2. Apply a light coat of multi-purpose grease
(063002-024) to the motor end cap threads and on
top of the torque adjuster plate (14). Be careful not
to contaminate brake pads with grease.
3. Position the magnet coil and body (13) on the mo-
tor so the coil wires (10) for 24 V trucks, or (13) for
36 V trucks, are positioned as shown.
4. Apply blue thread locking adhesive to the three
screws (15) and secure the magnet to motor.
5. Assemble springs (11), inner armature (9) and
outer armature (8) to the magnet body (13). Apply
a light coat of multi-purpose grease (063002-024)
to entire bottom of brake pad plate assembly (5).
Be careful not to contaminate brake pads with
grease.
6. Install the compression spring (7) over the arma-
ture shaft.
7. Slip the rotor (6) on the motor shaft, hub first.
8. Thread the hex nut (4) onto the motor shaft. Turn
the hex nut (4) down until the rotor (6) moves down
and almost touches the brake pads. The air gap
adjustment will be made later.
9. Thread the locknut (3) onto the motor shaft. Add
f1atwasher(s) (2) and place retaining ring (1) on
motor shaft.
10. Set torque adjuster gap to its original factory set-
ting. Refer to Torque Gap Adjustment procedures
in this section.
11. Connect the wire harness to the brake assembly.
12. Adjust the air gap. Refer to Air Gap Adjustment
procedures in this section.
13. Check brake operation and stopping distance. Re-
fer to Stopping Distance in this section. Figure 21881
Crown 2009 PF17433-5 M5.0-1457-005
477
BRAKE
Chart 3 Troubleshooting Brake System
Problem Probable Cause Remedy

Air gap greater than 1.0 mm (0.040 in) Adjust Air Gap
Check floorboard switches
Open circuit in brake circuitry or wiring
Brakes will not release and all associated wiring
Arm.ature movement restricted by dirt,
Clean with low pressure air
foreign material
Air gap greater than 0.25 mm (0.010 in) Adjust
Replace mounting plates or
Brake pad mounting plate or rotor distorted
Brake drag rotor
Armature rt;lovement restricted by dirt,
Clean with low pressure air
foreign material
Correct stopping distance
Incorrect stopping distance adjustment
(P6 and P7)
Brakes grab
Brake pad mounting plates or rotor distorted
rotor
Adjust (see P6/P7 Section
Incorrect stopping distance adjustment
Stopping distance too long M4.3)
Brake pad loose or soiled with grease Replace brake pad
Brake pad mounting plates or rotor distorted
Abnormal noise and chatter when rotor
brakes applied Brake pads worn out, loose, soiled with
Replace brake pad
grease, foreign material embedded
Rotor thin, cracked or spline worn Replace rotor
Abnormal braking force for lift height
or brakes applied without request Check and repair all switches
Open circuit in brake circuitry or wiring
and associated wiring
M5.0-1457-006 Crown 2009 PF1743~
478
BRAKE
CROWl' Brake System
Caster Brake (BRK2) this section for detailed instructions on adjusting brak-
ing via ACCESS 1.
The caster brake is applicable to RRIRD 57005 trucks
only.
Lh WARNING
Do not attempt to remove or install the caster wheels
Two electromagnetically applied disc brakes (BRK2) and brakes if the power unit is not properly blocked.
(10) are located in the caster wheel assembly. Caster Risk of serious injury or even death may occur. Refer
brakes on all models are factory preset and are not me- to Control of Hazardous Energy - Lifting and Blocking
chanically adjustable. Refer to Stopping Distance in for detailed instructions.
10-
U 1
Figure 21882
Crown 2009 PF17433-7 Rev. 5110 M5.0-1457-007

02 Rev. 5/10
479
BRAKE
Caster Wheel and Brake Removal 4. Chock the load wheels and drive tire.
Refer to Figure 21882. 5. Loosen, but do not remove the caster wheel lug
bolts.
1. With no load on the forks, move the truck to a se-
cure, non-traffic maintenance area with a level 6. Refer to Control of Hazardous Energy section. Lift
floor. and block the rear of truck approximately 150 mm
(6 in) to allow for caster removal.
2. Tum the key switch OFF and disconnect the bat-
tery.
7. Remove the caster brake w~eels.
3. Lockout/Tagout truck as described in the Control of

Hazardous Energy section.
Figure 24055
8. Remove the wire cover (2) from the caster wheel

assembly (6) and unplug both electric brake con-
nectors, PC643 and PC644. Refer to Figure
24055.
9. Note the wire color and pin positions in connectors
JC643 and JC644 (1). Use extraction tool 062706
to remove the pins from the two connectors.
10. Use a hydraulic lift truck jack to support and lower
the caster and brake assembly during removal.
Remove the screw (7) holding the pin (8) in posi-
tion and then remove the caster and brake assem-
bly (9) from the truck. Retain the f1atwashers (4)
and all other parts for reassembly.
Crown 2009 PF17433-a Rev. 5110

M5.0-1457-008
02 Rev. 5/10
480
BRAKE
CJ\OWI' Brake System
11. Remove the retaining ring (1) from the axle. Refer Drum and Bearing Assembly
to Figure 24056.
12. Remove the spacer (2) and the drum & bearing as- Bearing Installation
sembly (3) from the axle. Refer to Figure 21904.
13. Remove the three screws (4) that hold the disc
brake (5) to the axle. Remove the disc brake as
• Before installing the bearings (1), thoroughly clean
needed. the brake drum bearing bores (2). Any burrs, dirt,
etc. must be removed before installing new bear-
ings.
• A press, vise or hammer and hardwood block that

fully covers the bearing can be used to install the
bearing. Whatever method is used, be sure the in-
stallation force is distributed equally over the entire
bearing surface to prevent the bearing from being
misaligned.
• When installed properly, the outboard bearing is re-

cessed in the hub. If you are using a press or vise
to install the bearing, a spacer that is slightly
smaller in diameter than the bearing is needed. If
using a hammer, recess the bearing with a brass
punch.
Figure 24056
• After installing the bearings (1), check to be sure
Caster Wheel and Brake Inspection that the bearings are fully seated and rotate freely.
• Measure the thickness (1) of the disc brake (10),

composed of the magnetic coil and friction plate.
Replace the disc brake (10) if the dimension (1) is
less than 28 mm (1.1 in). The magnetic coil and
friction plate should always be replaced as a set.
• Inspect the surface of the brake coil. Replace the

disk brake if the electromagnetic coils are visible.
• Check to be sure the bearings in the brake drum

rotate freely. Refer to Bearing Installation in this 2
section for further information.
Figure 21904
Crown 2009 PF1743~9 Rev. 5110 M5.0-1457-009

02 Rev. 5/10
481
BRAKE
Caster Wheel and Brake Installation 1. Feed the connector and wiring from the disc brake
coil through the axle weldment. Position the coil on
Refer to Figure 21882. the axle weldment so that it is aligned with the
Instructions are for one side at a time. Refer to Control screw holes. Apply blue thread locking adhesive to
of Hazardous Energy for truck Lifting and Blocking pro- the three screws and attach the disc brake coil
cedures. from the axle side. Refer to figure 24057.
Figure 24057
2. Center the brake rotor on top of the coil. Center

four springs (1) on the tapped holes in the rotor.
Figure 24058
M5.0-1457-010 Crown 2009 PF17433-10 Rev. 5110
02 Rev. 5/10
482
BRAKE
CROWl' Brake System
3. Place f1atwashers (2) directly on top of the springs to rotate the drum to obtain the proper orientation.
as shown in Figure 24058. Refer to Figure 24059.
4. Install the drum & bearing assembly (1) onto the 5. After the brake drum is in place, check all four
axle making sure that the springs (2) are posi- springs and f1atwashers to make sure they are
tioned below the counterbored holes and that the properly positioned in the counterbored holes (5).
slots (3) on the side of the brake drum are lined up If any of them are cocked, use a screwdriver to
with the brake rotor tabs (4). It may be necessary seat them in the counterbored holes (6).
2 1
Figure 24059
6. Place the axle spacer (1) onto the axle. Refer to 8. Place the spacers with C-bore (3) in the brake
Figure 24060. counterbored holes with the counterbored side of
the spacers facing up.
7. Install the retaining ring (2) to secure the assembly
in position.
Figure 24060
Crown 2009 PF17433-11 Rev. 5110 M5.Q-1457-011

02 Rev. 5/10
483
BRAKE
Brake System CJ\OW"
9. Start a grooveless retaining ring (2) on a spacer 24061. Slowly close the vise until the retaining ring
(3). Put the retaining ring and spacer into the as- and spacer bottom out in the assembly tool. Do not
sembly tool (1), Crown part number 132417, mak- try to close the vise any further, to prevent damage
ing sure the lip (4) of the retaining ring is facing the to the spacer or assembly tool.
tool. Put the parts into a vice as shown in Figure
1 2
1 2
2 / !-~r{
~I-------
-----<
4
/
Figure 24061
10. Put a spacer and retaining ring assembly (1) into 11. Place flatwashers over the spacers.
each of the four holes in the brake assembly as
12. Install the springs and screws into the spacers.
shown in Figure 24062 with the lip of the retaining
Finger tighten the screws, then torque them to 6.5
ring facing down.
- 7.0 Nm (4.8-5.2 ft Ib).
Figure 24062
13. Tum the caster brake and axle assembly over and
assemble the second side in the same manner.
M5.0-1457-012 Crown 2009 PF17433-12 Rev. 5110
02 Rev. 5/10
484
BRAKE
CJ\OWI' Brake System
14. Push down on the top brake assembly to partially assembly to seat the bottom assembly. Turn the
seat the bottom assembly. Rotate the entire brake entire brake assembly over and repeat the process
assembly 180 and push down again on the top
0
to seat the second brake assembly.
Figure 24063
NOTE
Never set or drop the brake drum rotor assembly when
it is not in position on the axle. Doing so can change the
brake air gap and cause the brake or assembly issues.
Figure 24064
1 Bolt Head
2 Brake Drum Rotor Assembly
3 Brake Drum Rotor Assembly after being dropped on bold
heads
Crown 2009 PF17433-13 Rev. 5110 M5.0-1457-013

02 Rev. 5/10
485
BRAKE
Brake System l!I\OWI'
15. Use a hydraulic lift truck jack to raise the caster and 17. Install wires and pins into the connector bodies of
brake assembly (7) enough to feed the wires from JC643 and JC644 as previously removed.
JC643 and JC644 (1) through the hole in the axle.
18. Put the wire cover (2) on the assembly and secure
Raise the caster and brake assembly into position
it using one screw (3).
and mount it to the truck with the pin (9), making
sure the two f1atwashers (4) are in position before 19. Install the caster wheels (6). Finger tighten all lug
totally inserting the pin. Refer to Figure 24065. bolts (5), then torque them 60 to 75 Nm (45 to
55 ft Ib).
16. Use the screw (8) to secure the pin (9) and assem-
bly (7) in position.
. ~
O. I
/ /1 2
/
:
:
1
I
I'
/
/
/
I
tl/~~ 3
(/
/ / )
// ~
I /.~..........
I
I
4
I
I
I
I /
I %V/
L./·~. . . . .
4 5
,~
7
Figure 24065
20. Remove the jack stands or other blocking material.

21. Remove the wheel chocks.
22. Connect the battery and check truck operation, es-
pecially caster brake operation, referring to Stop-
ping Distance in this section.
M5.0-1457-014 Crown 2009 PF17433-14 Rev. 5110
02 Rev. 5/10
486
mown
STEERING
487
CROW"
Notes:
488
STEERING
CROWl' Hydraulic Steering System
Hydraulic Steering System Steer Tiller

Trucks equipped with a hydraulic steering system con- (Trucks Manufactured prior to 12/28/09)
sist of a hydrostatic steer control unit (SCU) coupled Refer to Figure 21901.
via hydraulic hoses to the steer motor (M4), used to
actuate the steering. The steer command allows the operator to interface
with the truck to control truck direction. Steering infor-
mation is monitored by ACCESS 4. A ball bearing sen-
Hydrostatic Steer Control Unit sor or encoder (ECR7) (9) is located on the shaft of the
tiller mount (7). ECR7 receives +5 V and BNEG from
The hydrostatic steer control unit (open center non-re-
ACCESS 4 with feedback from the sensor's two chan-
action) mounts in the power unit below the tiller. The
nels communicated back to ACCESS 4.
non-reaction unit maintains the steered position when
the operator releases the steering tiller by blocking the
cylinder ports in the neutral valve position. The opera-
tor must steer the traction/steer tire back to the straight
ahead position. The steering unit meters a proportional
amount of oil to M4 when the tiller is rotated. This pres-
surized oil is supplied by pump 1 to the appropriate
side of the steering motor determined by the rotation of
the steer control unit via the operator controlled steer-
ing tiller. When the steering tiller rotation is stopped, the
steer motor ports are blocked to maintain the steering
position. In the event that pump flow stops, the steer
control unit can be manually rotated to pump flow to the
appropriate motor port by turning the steering tiller in
the desired direction, thus allowing emergency steer-
ing.
Steer circuit relief pressure is non-adjusting and pre-
set to 59.850 kPa (1,250 psi). Normal steering pres-
sures are 19.150 - 28.730 kPa (400 - 600 psi).
Forward and Reverse Steering

The steering on your truck can be changed from for-
ward steering to reverse steering by reversing the hy-
draulic lines at the steer motor. Care should be exer-
cised when maintenance is performed on the steering
system to return the truck to the proper steering mode
upon completion.
NOTE
Prior to disassembly the service technician should de-
termine the steer direction of the truck, upon comple-
tion of the maintenance, steering direction should be 19 <!Ii>
checked to ensure that it is set for the desired direction <!!Jl
and functioning properly. 20~~
21 I
22
Figure 21901
Crown 2009 PF17434-1 Rev. 2110 M6.0-1457-001

02 Rev. 2110
489
STEERING
Hydraulic Steering System CROWl'
Steer Tiller Disassembly 7. Use two more f1atwashers (19), lockwashers (20)
and nuts (21) to assemble the tiller support (13) to
1. Key truck OFF.
the power unit.
2. Disconnect the battery and chock wheels.
8. Apply 061004-006 thread locking adhesive to two
3. Lockout/Tagout truck as described in Control of screws (12), then assemble the steer control unit
Hazardous Energy section. (23) to the tiller support (13) using the two screws
(12). Finger tighten the screws first, then torque
4. To remove the tiller support (13) from the power them to 49 - 57 Nm (36 - 42 ft Ib).
unit, remove the two screws (6) that assemble the
tiller mount (7) to the tiller (3). 9. Assemble the steer knob (1) to the tiller (3) using a
roll pin (2), lockwasher (4) and screw (5). Torque
5. Remove the two screws (12) that attach the steer the screw to 33.9 ± 6.8 Nm (25 ± 5 ft Ib).
control unit (23) to the tiller support (13).
10. Use two screws (6) to assemble the tiller mount (7)
6. Remove the two f1atwashers (19), lockwashers to the tiller (3).
(20) and nuts (21).
7. Remove the screw (17) and f1atwasher (16) that at-
tach the brace (18) to the tiller support (13).
8. Pull the tiller support (13) and tiller mount (7) out of
the steer control unit and out of the power unit.
9. Rotate the tiller mount (7) as needed to access the
retaining ring (8) and remove it from the tiller sup-
port (13).
10. Remove the tiller mount (7) with the retaining ring
(8), f1atwasher (10), ECR7 (9) and retaining ring
(11 ) still assembled to it from the tiller support (13).
Once removed from the tiller support, the items on
the tiller mount can be removed.
11. To remove the steer knob (1) from the tiller (3), re-
move the screw (5) and lockwasher (4). Remove
the roll pin (2).
Steer Tiller Assembly

1. Slide the retaining ring (8) then the f1atwasher (10)
onto the tiller mount (7).
2. Slide ECR7 (9) onto the tiller mount (7). Slide the
retaining ring (11) on the tiller mount (7) and snap
into place.
3. Slide the tiller mount (7) into the tiller support (13),
making sure that the wire from ECR7 (9) is oriented
correctly to go into its slot in the tiller support and
that the wire goes through the tiller support.
4. Rotate the tiller mount (7) as needed to snap the
retaining ring (8) into place.
5. Assemble the brace (18), if previously removed, to
the power unit using a screw (14), two f1atwashers
(15 and 19), a lockwasher (20) and nut (21).
6. Assemble the tiller support (13) to the brace (18)
using a screw (17) and f1atwasher (16).
Crown 2009 PF17434-2 Rev. 2110

M6.0-1457-002
02 Rev. 2110
490
STEERING
CJ\OWrl Hydraulic Steering System
The steer command allows the operator to interface

Steer Tiller
with the truck to control the truck direction. Steering in-
(Trucks Manufactured since 12/28/09) formation is monitored by ACCESS 4. A ball bearing
sensor (ECR7) (9) is located on the shaft of the tiller
mount (7). ECR7 receives +5 V and BNEG from
ACCESS 4 with feedback from the sensor's two chan-
nels communicated back to ACCESS 4.
1~
Steer Tiller Disassembly
I I
3"-.. I;.. . .J ~2 1. Key the truck OFF.
4 "-.. II
2. Chock the drive wheels and disconnect the battery.
~.-,'-~ Refer to the Control of Hazardous Energy - Lock-
outlTagout section of the Crown Service and Parts
={J (d)
5
J r:::i?
T Manual as needed.
6-J ~---7 3. LockoutlTagout the truck as described in the Con-
trol of Hazardous Energy - LockoutlTagout section
8 ~ ECR7
of the Crown Service and Parts Manual as needed.
10 ~- 9
11-;'''-. 4. Remove the console.
~12
5. Remove the two screws (6) that assemble the tiller
13-- "
,~I ={JI-(:"'"':'c)==- mount (7) to the tiller (3).
6. Remove the two screws (12) that attach the steer
control unit (23) to the tiller support (13).
7. Remove the two flatwashers (24), lockwashers
(25) and nuts (26).
8. Remove the screw (17) and flatwasher (16) that at-
tach the brace (18) to the tiller support (13).
9. Pull the tiller support (13) and the tiller mount (7)
out of the steer control unit and out of the power
unit.
10. Rotate the tiller mount (7) as needed to access the
retaining ring (8) and remove it from the tiller sup-
port (13).
11. Remove the tiller mount (7) with the retaining ring
(8), flatwasher (10), ECR7 (9) and retaining ring
(11) still assembled to it from the tiller support (13).
Once removed from the tiller support, the items on
the tiller mount, including the SCU spacer can be
Figure 23379 removed.
(a) Part of Power Unit 12. To remove the steer knob (1) from the tiller (3), re-
move the screw (5) and lockwasher (4). Remove
(b) Steer Control Unit
the roll pin (2).
(c) Torque 53 - 61 Nm (39 - 45 ft Ib)
(d) Torque 33.9 ± 6.8 Nm (25 ± 5 ft Ib)
Crown 2009 PF17434-3 Rev. 2110 M6.0-1457-003

02 Rev. 2/10
491
STEERING
Hydraulic Steering System l!J\OWI'
Steer Tiller Assembly 4. Remove the pinion gear (1).
1. Slide the ball bearing sensor, ECR7 (9), onto the

tiller mount (7). Slide the f1atwasher (10) onto the
tiller mount.
2. Slide the retaining ring (11) onto the tiller mount
and snap it into place.
3. Slide the tiller mount (7) into the tiller support (13)
making sure that the wire from ECR7 is oriented
correctly to go into its slot in the tiller support and
that the wire goes through the tiller support.
4. Rotate the tiller mount (7) as needed to snap the
retaining ring (8) into place.
5. Assemble the brace (19) to the tiller support (13)
using the screw (18) and f1atwasher (17).
6. Use two f1atwashers (24), lockwashers (25) and
nuts (26) to assemble the tiller support (13) to the
power unit.
7. Apply thread locking adhesive to the two screws
(12) and then assemble the steer control unit (27)
to the tiller support (13), with the SCU spacer (23)
between, using the screws. Finger tighten the
screws and then torque them to 49-57 Nm (36-
42 ft Ib).
8. Use the two existing screws (6) to assemble the Figure 21905
steer tiller (7) to the tiller (3).
9. Assemble the steer knob (1) to the tiller (3) using a Assembly of Steer Motor to Carriage
roll pin (2), lockwasher (4) and screw (5). Torque Refer to Figure 21905.
the screw to 33.9 ± 6.8 Nm (25 ± 5 ft Ib).
1. Lightly lubricate the pinion gear (1).
10. Use two screws (6) to assemble the tiller mount (7)
to the tiller (3). 2. From the bottom of undercarriage, insert the pinion
gear (1), making sure the teeth align with the teeth
11. Install the console. on the idler gear (2).
12. Connect the battery and remove the wheel chocks. 3. Press the bearing (2) onto the pinion gear, ensur-
13. Verify proper truck operation. ing the bearing is seated on shoulder of the pinion
gear. Install the retaining ring (4) on the pinion
gear.
Removing Steer Motor from Car-
4. Secure the assembled parts with the large retain-
riage ing ring (5). Check gear mesh for proper operation.
Refer to Figure 21905. 5. Lubricate the steering gears as required. Refer to
Planned Maintenance for lubricant type and fre-
1. Remove locknuts (10), compression springs (8)
quency.
and f1atwashers (9) from the threaded shafts (7).
Remove the threaded shafts. 6. Install the larger diameter of threaded shafts (7)
into the counter bored holes (8) of the undercar-
2. Carefully slide the steer motor (6) off of the car-
riage. Only one side shown. Torque the threaded
riage.
shafts to 31 ± 1.4 Nm (23.0 ± 1.0 ft Ib).
3. Remove the large retaining ring (5), bearing (3)
and small retaining ring (4).
M6.0-1457-004 Crown 2009 PF174344 Rev. 2110
02 Rev. 2110
492
STEERING
CJ\owr. Hydraulic Steering System
7. Apply a light film of grease to the male and female NOTE

splines of the steer motor (6) shaft. Brush the
grease into the roots and tips of the splines. RPS1 must be mounted with the potted side away from
the magnet. Failure to do so will affect truck operation
8. Install the steer motor (6) over the threaded shafts and calibration.
(7).
9. Place a compression spring (8) and f1atwasher (9) Steering Feedback Gear Alignment
over each of the threaded shafts and secure with
locknuts (1 O). Torque the locknuts to 31 ± 1.4 Nm Trucks with 42 In Power Unit
(23.0 ± 1.0 ft Ib).
1. Rotate the drive unit clockwise until it hits a hard
stop.
Figure 21906
2. Align the hole in the carriage with the hole in the

feedback gear.
Figure 21905
Steering Feedback Gear and Wheel

Position Sensor (RPS1)
The steering feedback gear works with the steer wheel
position sensor (RPS1) to communicate steering wheel
angle to ACCESS 4. The steering feedback gear as-
sembly rotates a small magnet as it moves. The mag- Figure 21907
net influences the signal that RPS1 provides. The sig-
nal indicates the angle of the steering wheel to
ACCESS 4, which is communicated to ACCESS 1 for
display to the operator or technician. It is important that
the feedback gear is aligned correctly for proper truck
function. Refer to ACCESS 123® Menus for steer
wheel position sensor calibration information.
Crown 2009 PF17434-5 Rev. 2110 M6.0-1457-005

02 Rev. 2/10
493
STEERING
Hydraulic Steering System CROWr.
Traction/Steer Tire Alignment and
RPS1 Calibration
Feedback from the steer wheel position sensor (RPS1)
is used to reduce truck travel speed when turning. It is
critical that the sensor is calibrated correctly and the
tire is aligned correctly. There is a 1 degree tolerance.
The C2.8~Wheel Position Sensor submenu provides a
means for ACCESS 4 to monitor the voltage range of
RPS1. This submenu applies only to trucks with hy-
draulic steering and will only be displayed if F3.7 is set
to Hydraulic. Complete the following steps to properly
align the steer tire.
NOTE
A builder's square or similar tool is necessary for
proper tire alignment. There is no mechanical align-
ment mark and the software tolerance allows less than
Figure 21908
1 degree of e"or. Splitting the voltage difference be-
tween fully CW and fully CCW is not accurate because
the ratio between the drive unit steering gear and the
sprocket on the shaft for the RPS1 sensor magnet is
not 1:1.
1. Enter the submenu. Use the up and down arrows
to select "SURE?Y". Press enter to confirm choice
(selecting "SURE?N" will return to C4.1). The Right
arrow can be pressed to display RPS1 voltage if
desired.
2. ACCESS 1 indicates "Steer wheel fully CW, press
enter" - Turn the tiller to rotate the traction/steer tire
fully clockwise, then press enter on ACCESS 1.
3. ACCESS 1 indicates "Steer wheel fully CCW,
press enter" - Turn the tiller to rotate the traction/
steer tire fully counterclockwise, then press enter
on ACCESS 1.
4. ACCESS 1 indicates "Center steer wheel, press
enter" - Turn tiller to rotate the traction/steer wheel
to within one degree of center. This procedure may
require two people to complete. To confirm wheel
is centered, use a carpenter's square, or other right
angled tool to align wheel with truck. Place one
edge of the tool against the back of the traction/
steer tire, aligning the other edge along the battery
box. Turn the tiller until the traction/steer tire and
battery box are aligned, then press enter. Refer to
Figure 21908.
5. ·Calibration accepted" or "Calibration failed" will be
necessary, restart calibration at step one.
M6.0-1457-006 Crown 2009 PF17434-e Rev. 2110
02 Rev. 2/10
494
STEERING
CROWl' Electronic Power Steering System
Electronic Power Steering 9. Slide the tiller mount (7) out of the top of the tiller
support (13) taking care not to lose the compres-
System sion spring (12) and wear rod (11) that are assem-
bled into the tiller support.
Electronic Power Steering System 10. To remove the tiller (3) from the tiller mount (7),
remove the two screws (6).
The electronic power steering system consist of a
3-phase AC motor (M4) coupled to the steering gear. 11. Remove the retaining ring (10) from the tiller mount
The motor is controlled by ACCESS 5 which is remove the ball bearing (9) and retaining ring (8).
mounted on the inside wall of the motor compartment. 12. To remove the steer knob (1) from the tiller (3) re-
ACCESS 5 and M4 are protected from over-current by move the screw (5) and lockwasher (4). Remove
FU12, located just below ACCESS 5. Steer command the roll pin (2).
is received via tiller sensor RPS2 and drive tire position
is determined by RPS 1.
1~
Steer Tiller
, I
The steer tiller allows the operator to interface with the
truck to control truck direction. Steering information is
3""-. ,;".J ~2
4 ""-. "
~.-''-~
monitored by ACCESS 5. A rotary position steering
feedback sensor (RPS2) (25) is connected to the tiller
J 6-~--7
mount (13). The tiller rotates a small magnet (20) which
influences the RPS2 signal. The signal indicates the 5
operator's steer command to ACCESS 5. RPS2 re-
ceives +5V and BNEG from ACCESS 5 with feedback
8 ~
from the sensor's two channels communicated back to
ACCESS 5. Refer to Figure 21902. ~ 9
~-10
11-(j ,
Steer Tiller Disassembly
13-- 12-~f/
1. Key truck OFF. 14
2. Disconnect battery and chock wheels. 15 ""i . .#'.
3. LockoutfTagout truck as described in Control of 16 -----~"""",, I'" ~19
Hazardous Energy section. ~~lj f-20:
4. Remove two f1atwashers (16), lockwashers (27) 17 /~ ~~
~-22
I
I
I
I
21
and nuts (28) to remove the tiller support (13) from
the power unit. 18 I 1"7r23 :
:24-, " RPS2 I
5. Remove the screw (17) and f1atwasher (16) that at- I ~25 J
tach the brace (18) to the tiller support. Remove • <:>: ''-....26" "
the tiller support assembly from the power unit. (a)-- I "
I
6. Remove the two screws (26) that mount RPS2 (25)
to the sensor mounting plate (22).
7. If further disassembly of the sensor assembly is re-
16 @ ,
$ ~ 16
quired, remove the two f1atwashers (23) and
screws (24) that secure the sensor mounting plate 27~~ ~27
(22) to the bottom of the tiller support (13). 28 28
8. From the bottom of the tiller support (13) remove
Figure 21902
the screw (21) that secures the magnet (20) to the
tiller support.
(a) Part of Power Unit
Crown 2009 PF17706-1 Rev. 8/09 M6.0-1457-100

01 Rev. 8/09
495
STEERING
Electronic Power Steering System CJ\OWI'
Steer Tiller Assembly
1~
1. Slide the retaining ring (8) onto the tiller mount (7).
2. Slide the ball bearing (9) onto the tiller mount (7).
Slide the retaining ring (10) onto the tiller mount , I
and snap into place. 3"-.... ,;---.J ~2
3. Assemble the steer knob (1) to the tiller (3) using a 4 "-.... "
roll pin (2), lockwasher (4) and screw (5). Torque
the screw to 33.9 ± 6.8 (25 ± 5 ft Ib).
~.-''-~
4. Use the two screws (6) to assemble the tiller mount 5 J 6-~--7
(7) to the tiller (3).
5. Fit the compression spring (12) and wear rod (11) 8 ~
into the hole on the tiller support (13). ~ 9
f:P-10
6. Slide the assembled tiller mount (7) into the tiller 11-tJ,
12-~t/
support (13). From the bottom, insert the magnet
(20) into the tiller mount. Using thread locking ad- 13--
hesive, secure with a screw (21 ). 14
7. Assemble the sensor mounting plate (22) to the 15 ~t . ~
bottom of the tiller support (13) using two flatwash-
16 ------~" / / / / / I'" ~19
J~20
ers (23) and screws (24).
------
~/j)'l J"
8. Assemble RPS2 (25) to the sensor mounting plate
(22) using two screws (26). 17 /w tS!f,~
~-22
I
I
I
I
21
18 ,-q-23:
NOTE 24-, " RPS2 I
~-25 I
RPS2 must be mounted with the potted side away from
(a)--
, <:>,~.6////)
_,
and calibration.
9. Assemble the brace (18), if previously removed, to til
the power unit using a screw (14), two flatwashers 16 @
(15 and 16), a lockwasher (27) and nut (28). $
10. Assemble the tiller support (13) to the brace (18) 27~~
using a screw (17) and flatwasher (16). 28
11. Use two more flatwashers (16), lockwashers (27)
and nuts (28) to assemble the tiller support (13) to Figure 21902
the power unit.
M6.0-1457-101 Crown 2009 PF17706-2 Rev. 8/09
01 Rev. 8/09
496
STEERING
CJ\OWrl Electronic Power Steering System
Removing Steer Motor from Assembly of Steer Motor to Carriage

Carriage Refer to Figure 21933.
Refer to Figure 21933. 1. Lightly lubricate the pinion gear (1).
1. Remove locknuts (10), compression springs (8) 2. From the bottom of the undercarriage. insert the
and flatwashers (9) from threaded shafts (7). Re- pinion gear (1). making sure the teeth align with the
move threaded shafts. teeth on the idler gear (2).
2. Carefully slide the steer motor (6) out of the car- 3. Press the bearing (S) onto the pinion gear, ensur-
riage. ing the bearing is seated on the shoulder of the pin-
ion gear. Install the small retaining ring (3) on the
3. Remove the large retaining ring (4) and bearing
pinion gear.
(S).
4. Secure the assembled parts with large retaining
4. Remove the small retaining ring (3) to remove the
ring (4). Check gear mesh for proper operation.
pinion gear (1).
5. Lubricate the steering gears as required. Refer to
Planned Maintenance for lubricant type and fre-
quency.
6. Install the larger diameter of the threaded shafts
(7) into the counter bored holes (11) of the under-
carriage. Only one side shown. Torque the shaft to
31 ± 1.4 Nm (23.0 ± 1.0 ft Ib).
7. Apply a light film of grease to the male and female
splines of the steer motor (6) shaft and pinion gear
(1). Brush the grease into the roots and tips of the
splines.
8. Install the steer motor (6) over the threaded shafts
(7).
9. Place a compression spring (8) and flatwasher (9)
over each of the threaded shafts and secure with
locknuts (10). Torque the locknuts to 31 ± 1.4 Nm
(23.0 ± 1.0 ft Ib).
Figure 21933
Crown 2009 PF17706-3 Rev. 6109 M6.0-1457-102

01 Rev. 8109
497
STEERING
Steering Feedback Gear and Wheel Steering Feedback Gear Alignment
Position Sensor (RPS1) Trucks with 1065 mm (42 in) Power Unit
The steering feedback gear works with the steer wheel 1. Rotate the drive unit clockwise until it hits a hard
position sensor (RPS1) to communicate steering wheel stop.
angle to ACCESS 5. The steering feedback gear as-
sembly rotates a small magnet as it moves. The mag-
net influences the signal that RPS1 provides. The sig-
nal indicates the angle of the steering wheel to
ACCESS 5, which is communicated to ACCESS 1 for
display to the operator or technician. It is important that
the feedback gear is aligned correctly and sensor
bracket is mounted as shown for proper truck function.
Refer to Steer Wheel Position Sensor in this section
and ACCESS 123® Menus for calibration information.
NOTE
RPS1 must be mounted with the potted side away from
and calibration. Figure 21906
2. Install steering feedback gear assembly, aligning

hole in carriage with hole in feedback gear.
II If
~/
Ib "-
Hi RPS1
I I
~
m
I I I
1(1)1
11..-1-1
,. -:I""J
.~
Figure 21907
3. Install retaining rings to hold gear in place.
Figure 22333
M6.0-1457-103 Crown 2009 PF177lJ6.4 Rev. 8109
01 Rev. 8/09
498
STEERING
l!J\OWfl Electronic Power Steering System
Trucks with 1220 mm (48 in) Power Unit {S Class} Traction/Steer Tire Alignment and
1. Rotate the drive unit counterclockwise until it hits a RPS1 Calibration
hard stop.
Feedback from the wheel position feedback sensor
(RPS1) is used to detect the angle of the traction/steer
tire and reduce the truck's travel speed when turning. It
is critical that the sensor is calibrated correctly and the
traction/steer tire is aligned correctly. There is a
1 degree tolerance.
The C4.1 Wheel Position Sensor submenu provides a
means for ACCESS 5 to monitor the voltage range of
the traction/steer wheel position sensor (RPS1). This
submenu applies only to trucks with electronic power
steering and will only be displayed if F3.7 is set to AC.
Complete the following steps to properly align the trac-
tion/steer tire.
Figure 21931 NOTE

2. Install steering feedback gear assembly, aligning A builder's square or similar tool is necessary for
the hole in the carriage with a hole in the feedback proper traction/steer tire alignment. There is no me-
gear. chanical alignment mark and the software tolerance al-
lows less than 1 degree of e"or. Splitting the voltage
difference between fully CWand fully CCW is not ac-
curate because the ratio between the drive unit steer-
ing gear and the sprocket on the shaft for the RPS1
sensor magnet is not a 1:1 ratio.
1. Enter the submenu. Use the up and down arrows
to select "SURE?Y". Press enter to confirm choice
(selecting "SURE?N" will return to C4.1). RPS1
voltage is displayed on the lower line of the display
during calibration.
2. ACCESS 1 indicates steer wheel fully CW, press
enter - Turn the tiller to rotate the traction /steer tire
is fully clockwise, then press enter on ACCESS 1.
Figure 21932
3. ACCESS 1 indicates steer wheel fully CCW, press
enter - Turn the tiller to rotate the traction/steer tire
3. Install retaining rings to hold gear in place. fully counterclockwise, then press enter on
ACCESS 1.
Crown 2009 PFl7706-5 Rev. 8/09 M6.0-1457-104

01 Rev. 8/09
499
STEERING
Electronic Power Steering System CAOWI'
4. ACCESS 1 indicates center steer wheel, press en-
ter - Tum the tiller to rotate the traction/steer tire to
within one degree of center. This procedure may
require two people to complete. To confirm the
traction/steer tire is centered, use a carpenter's
square, or other right angled tool to align the trac-
tion/steer tire with the truck. Place one edge of the
tool against the back of the traction/steer tire, align-
ing the other edge along the battery box. Turn the
tiller until the traction/steer tire and battery box are
aligned, then press enter. Refer to Figure 21908.
necessary, restart the calibration at step one.
Figure 21908
Crown 2009 PF1n~ Rev. 8/09

M6.0-1457-105
01 Rev. 8/09
500
STEERING
CJ\OWI' Hydraulic Steer Motor
Hydraulic Steer Motor 1. Using protective material on vise jaws, clamp mo-
tor in a vise so shaft is vertical and end cap is on
top. Clamp on mounting flange, using just enough
Disassembly clamping force to securely hold motor.
Cleanliness is extremely important when repairing hy- 2. Remove screws (6) from end cap (5) and disas-
draulic motors. Work in a clean area. Before discon- semble motor as shown in Figure 21925. Do not
necting hydraulic lines, clean port area of motor. Before disassemble geroler (4).
disassembly, drain oil from motor. Then plug ports and 3. Refer to Figure 21926. Unclamp motor and remove
thoroughly clean exterior of motor. Check output shaft, output shaft (3), thrust needle bearing (2) and
remove any burrs, nicks, or sharp edges. thrust bearing race (1).
Figure 21926
Figure 21925
1 Thrust Bearing Race
1 Seal
2 Thrust Needle Bearing
2 Drive
3 Output Shaft
3 Spacer Plate
4 Geroler 4. Clamp motor in vise so mounting flange is on top.
5 End Cap Clamp across port area. Do not clamp on motor
6 Cap Screw
housing. Use just enough clamping force to hold
motor securely.
Tools Required:
5. Remove screws securing mounting flange to motor
• Torque wrench, 34 Nm (25 ft Ib) capacity housing.
•
•
Ratchet wrench
5/16 in - 12 point heavy duty socket, 56 Nm

it CAUTION
Thread locking adhesive was applied to screws during
(41.3 ft Ib) capacity assembly. Do not exceed 56 Nm (41.3 ft Ib) ofremoval
• torque.
5/16 in - 6 poinUtorx (E10) heavy duty socket,
56 Nm (41.3 ft Ib) capacity Refer to Figure 21927. Since thread locking adhesive
was applied to screws, heat may have to be applied to
• Small flat blade screwdriver motor housing to loosen screws. Use propane torch
and apply just enough heat to remove screws (1). Do
• 3/16 in hex key
not overheat motor housing or mounting flange.
• Rubber hammer
Crown 2001 PFl3078-1 Rev. 6109

M6.2-1452-001
02 Rev. 6/09
501
STEERING
Hydraulic Steer Motor CJ\OWI'
1 2
Figure 21928
1 Pressure Seal
2 Back-Up Ring
3 Mounting Flange
4 Exclusion Seal
5 Seal Removal Tool
Steer Motor Assembly

Figure 21927 Check all mating surfaces. Replace any parts with
scratches or burrs that could cause leakage. Wash all
1 Exclusion Seal metal parts in clean solvent. Blow dry with low pressure
2 Mounting Flange air. Do not wipe parts dry with paper towels or cloth.
3 Back-Up Ring Lint in a hydraulic system will cause damage. Check
4 Pressure Seal
spline and chamfered area of output shaft; remove any
nicks, burrs, or sharp edges that could damage shaft
5 Seal
seals during assembly.
6 Cap Screw
7 Heat with a propane torch NOTE
6. Remove mounting flange (2) from motor housing. Always use new seals when assembling hydraulic mo-
7. Carefully remove exclusion seal (1), pressure seal tors. Lubricate new seals with clean petroleum jelly.
(4) and backup ring (3) from mounting flange (2). A Also, lubricate machined surfaces and bearings with
seal removal tool may be fabricated by bending clean hydraulic fluid.
and rounding the end of a small flat blade screw- 1. Remove all thread locking adhesive from mounting
driver, refer to Figure 21928. Be careful to not dam- flange screws and their threaded holes. Threads
age the mounting flange shaft bore. must be clean and dry before applying new thread
locking adhesive.
2. Refer to Figure 21926. Lubricate and install output
shaft (3), thrust needle bearing (2) and bearing
race (1) into housing. Do not allow oil to enter cap
screw threaded holes.
3. Refer to Figure 21927 for correct seal orientation.
Lubricate exclusion seal (1) and install in mounting
flange (2).
M6.2-1452-002 Crown 2001 PF13078-2 Rev. 6109
02 Rev. 6/09
502
STEERING
CJ\owr. Hydraulic Steer Motor
Motor Timing
1 2 12. Refer to Figure 21930. Align shaft timing dot (3)
with any bolt hole (5). Bolt hole will be used for tim-
ing reference.
3 I
~2
1
Figure 21929 3
4
1 Pressure Seal
2 Back-Up Ring
3 Mounting Flange 5
4 Exclusion Seal
4. Refer to Figure 21929. Lubricate and install

backup ring (2) and pressure seal (1). Be sure ex-
clusion seal (4) and pressure seal (1) are undam-
aged and properly seated.
5. Apply thread locking adhesive (061004-019) to
mounting flange cap screw threaded holes in mo- Figure 21930
tor housing.
1 Geroler
NOTE 2 Star Point
3 liming Dot
Thread locking adhesive must cure completely before
motor is put into service. Using primer reduces curing 4 Spacer Plate
time. F9r curing time, refer to thread locking adhesive 5 Threaded Hole for liming Dot Reference
manufacturer instructions.
13. Install spacer plate (4), and note position of
6. Install a protective sleeve over output shaft. Lubri- threaded hole in housing (aligned with timing dot
cate inner edges of exclusion and pressure seals. on shaft). Be sure slots in spacer plate provide pas-
Lubricate and install the 49 mm (1 15/16 in) diam- sage for hydraulic fluid as well as cap screws. If
eter o-ring seal on mounting flange. Slide mounting spacer plate is improperly installed
flange over shaft. (wrong-side-up). the motor will not operate.
7. Remove protective sleeve and install the four cap 14. Lightly stretch, lubricate and install the second of
screws. Torque cap screws. in a crisscross pat- three large diameter seals in geroler (1).
tern. to 28 Nm (20.7 ft Ib). Be sure output shaft re-
mains in housing. 15. Install geroler (1).
8. Securely clamp motor in vise so output shaft is ver- 16. Align any star point (2) with threaded hole (noted
tical and down. Clamp on mounting flange. for location of timing dot).
9. Pour clean hydraUlic fluid into motor to provide 17. Rotate the geroler (1 ) to align the screw holes.
start-up lubrication. 18. Lubricate and install the last of the three large di-
10. Lubricate and install one of the three largest diam- ameter seals in end cap groove.
eter seals in motor housing groove. 19. Install end cap and secure with cap screws.
11. Install drive. If splined ends of drive are different Torque cap screws. in a crisscross pattern, to
lengths, install longer end into shaft. 34 Nm (25 ft Ib).
Crown 2001 PF13078-3 Rev. 6/09 M6.2-1452-003

02 Rev. 6/09
503
CROWl'
Notes:
504
mown
LIFTING MECHANISM
505
CJ\OWI'
Notes:
506
LIFTING MECHANISM
CJ\owr. Mast
lines. Control ofHazardous Energy section provides in-

Mast formation for performing the above procedures along
with some additional information on other procedures
Torque Requirements dealing with truck maintenance. This section should be
read and reviewed prior to mast removal, installation
• The four, 20 mm (0.75 in) diameter bolts that fas- and maintenance as outlined in this section.
ten the lower portion of the power unit to the main- 1. Inspect each channel for the roller tracking path.
frame base plate torque must be 305 - 340 Nm The only area that should show wear is the back
(225 - 250 ft Ib). portion of the I-beam where the roller rides. Refer
to Figure 17058. The I-beam should not show
• The two, 15.8 mm (0.625 in) diameter bolts that
signs of any cutting or grooving. If grooving or cut-
fasten the upper portion of the power unit to the
ting is evident, it will normally take place at the side
mainframe torque must be 225 - 250 Nm (165 -
of the roller; 10 mm (0.375 in) from the channel
185 ft Ib).
face. If this type of wear is evident, a shim will have
• The four, 15.8 mm (0.625 in) diameter bolts that to be removed.
secure the removable load wheel assemblies to 2. Once an adjustment has been made by removing
the mainframe outriggers torque must be 225 - or adding shims, a recheck of the mast channel will
250 Nm (165 - 185 ft Ib). be required. To see the new wear pattern, clean
the channel with a solvent that will remove the lu-
• The four, 3/8-16 nuts that secure the free lift cylin-
bricant and then wipe with a cloth. Spray the chan-
der clamps (two for each clamp) and cylinder to the nel with a thin coat of paint. This will allow a visible
third stage mast torque must be 41 - 48 Nm (30 - indication of where the rollers are riding. Repeat as
35 ft Ib). required.
3. Once the mast meets requirements, lubricate the
Fork Adjustments mast with grease, Crown No. 063002-024 for stan-
dard or 063002-017 for freezer/corrosion applica-
• With the forks completely lowered and level, adjust tion. When the mast is raised near full extension, it
50 that the top surface of the fork tip is a maximum should not lean right or left; instead it should ap-
of 65 mm (2.5 in) from the floor. pear even and straight. If a leaning condition ex-
ists, it is a sign that the shimming is to loose or un-
• Maximum fork height is to be within ± 25 mm
balanced and will need to be adjusted.
(± 1.00 in) of the fork height specified on the truck
data plate.
Mast Testing (Assembled)
it WARNING
Wear appropriate items, such as safety glasses, when-
ever performing maintenance work. Do not place fin-
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 Channel Should Only Show Wear Here
weight information.
It will be necessary to disconnect and remove the bat- Figure 17058
tery from the truck, disconnect tift cylinders from the
mast, disconnect electrical connections and hydraulic
Crown 2009 PF17726-1 M7.0-1457-001
507
LIFTING MECHANISM
Mast CJ\OWl'
Flaking
It is not uncommon for a new mast to appear as if it is
flaking or peeling. This appearance is an indication the
rollers are seating to the mast channel and is consid-
ered normal. Eventually, this condition will disappear.
Grease applied to the channel will retain these parti-
cles.
Mast Staging Bumper Replacement

1. Refer to Figure 22030.
2. Raise the mast and replace bumper, item 53.
3. Lower the mast and check that mast bumpers con-
tact their stops at the same time. Adjust by adding
or removing shims as required. Use shim
060030-277 (0.8 mm [0.031 in] thick).
4. Apply thread locking adhesive to the bumper
screws and tighten.
Mast Dampening Screws

The mast dampening screws are located at the bottom
of the mainframe, top and bottom of the second stage
mast and at the top of the third stage mast.
ADJUSTMENT:
1. Refer to Figure 22030. Lower the mast completely.
2. Adjust the mast dampening screws, item 56, until
they just touch the mast roller directly behind each
screw. Apply thread locking adhesive to the
screws.
NOTE
ECR2 is standard on collapsed heights of more than
3025 mm (119 in) and optional on 3025 mm (119 in)
and below. HGTRS12 is not required if ECR2 is pres-
ent.
HGTS1 and HGTS2 are optional.
M7.0-1457-002 Crown 2009 PF1m6-2
508
LIFTING MECHANISM
CJ\OW" Mast
56
16 ) 13
(if ilfJ13 56
57
55
38
, I
.... 39 ( I
~ I I
"~
91 I I 34
63 I I
I "I 35
5 45 167
I 6
/
.... 82
v
56
4 91 63
74
75
76
13
70~~.... ....:~
69? .. I
FLS ~~I·JN.... 75 ............ ~
I /":J. 13
71~~ 36
Figure 22030
Crown 2009 PF17726-3 M7.0-1457-003
509
LIFTING MECHANISM
Mast CJ\OWI'
Disassembly 7. Removal of the free lift cylinder.
- Remove the guard, item 60.
it WARNING - Remove the hydraulic tube from the free lift cyl-
inder. Use a container to catch oil from the cyl-
Wear appropriate items, such as safety glasses, when- inder.
ever performing maintenance work. Do not place fin-
gers, hands or arms through mast or position them at - Use a cylinder clamp or braided strap around
pinch points. the cylinder just below the chain anchor and
In this section you may be required to lift and block the connect to a lifting device.
truck and mast or raise and lower different components - Remove the clamps, item 62, holding the free
for removal and installation. Make sure lifting device lift cylinder and remove the cylinder.
being lifted. Never work under or around a truck that is 8. Secure a lifting device to the third stage mast and
not properly secured. Refer to truck Data Plate for truck raise to obtain slack in the chains.
weight information. 9. Remove the guides, items 14, 15,40,41 & 57, from
It will be necessary to disconnect and remove the bat- the lift cylinders, right and left hand sides.
tery from the truck, disconnect tilt cylinders from the
mast, disconnect electrical connections and hydraulic 10. Remove the control cables, hydraulic lines, chains
lines. Control of Hazardous Energy section provides in- and pulleys from the top of the second stage mast
formation for performing the above procedures along and bottom of the third stage mast. Note the posi-
with some additional information on other procedures tion of all components; right and left hand sides are
dealing with truck maintenance. This section should be different.
read and reviewed prior to mast removal, installation 11. Use a lifting device to lift the third stage mast out of
and maintenance as outlined in this section. the top of second stage mast. Lay the third stage
1. Extend the reach assembly, disconnect and re- mast on the floor.
move the battery. 12. Remove ECR2, cable, spring and bracket, items
2. Remove the load backrest and forks from the car- 59,78,79 & 83. Or remove HGTS1 and HGTS2,
riage. item 81.
3. Remove the safety shield. 13. Connect a lifting device to the top cross brace of
the second stage mast. Raise slightly and remove
4. Refer to Figure 22030. Connect a lifting device to the screw and nut, items 46 & 47, that secure the
the carriage assembly and raise to get slack in the lift cylinder rams to the second stage mast. The
chains. Remove the yoke and chains, items 64 & seals at the top of the lift cylinders can be replaced
65, from the free lift cylinder. The seals at the top if required.
of the free lift cylinder can be replaced if required.
14. Raise the second stage mast until the stop block
on the mainframe can be accessed through the
NOTE
hole at the bottom of the second stage mast. Re-
The reach assembly can be kept in an upright position move the stop block, items 7 through 12, from the
much easier if it is extended. Block the reach assembly mainframe.
to prevent premature retraction.
15. Raise and remove the second stage mast from the
5. Disconnect the chains, control cables and hydrau- top of the mainframe. Lay the second stage mast
lic lines from the carriage assembly and lower the on the floor.
carriage to the floor.
16. Most repairs can be completed without removing
6. Connect the lifting device to the top cross-brace of the lift cylinders, however, if their removal is re-
the third stage mast and raise until the reach as- quired, remove the cross tube from the left lift cyl-
sembly can be slid forward to clear the mast. Lower inder and from the right hydraulic tube on the right
the mast to the collapsed position. lift cylinder. Use a container to catch the oil.
17. Remove the right hydraulic tube from the right lift
cylinder and from the mainframe. Use a container
to catch the oil.
M7.0-1457-004 Crown 2009 PF1Tf26.4
510
LIFTING MECHANISM
CJ\owr. Mast
18. Use a cylinder clamp or braided strap around the 5. Raise the rear of the truck enough to get a
left lift cylinder just below the anchor block and 100x100x900 mm (4x4x36 in) hardwood block un-
connect to the lifting device. der the base plate of the power unit and the base
plate of the mast assembly. This block should carry
19. Remove the cotter pin and clevis pin, items 43 &
the weight of the power unit and the mast assembly
44. when the mounting bolts are removed. The block is
20. Remove the left lift cylinder from the mainframe. positioned parallel with the base plates.
21. Repeat steps 18 through 20 to remove the right lift 6. Loosen the four, 20 mm (0.75 in) bolts at the base
cylinder. plate.
If the amount of overhead room will not allow the masts 7. Attach a lifting device to the top of the mainframe:
to be raised enough for removal, the mast assembly raise just enough to take the weight off of the hard-
will need to be unbolted from the power unit and laid wood block.
down. The following procedure should be followed if re-
8. Remove the two, 15.8 mm (0.625 in) bolts at the
moval from the power unit is necessary.
top of the power unit. The weight of the power unit
and mast assembly should be on the hardwood
& WARNING block at this time.
Wear appropriate items, such as safety glasses, when- 9. Remove the four, 20 mm (0.75 in) bolts across the
ever performing maintenance work. Do not place fin- base of the power unit.
gers, hands or arms through mast or position them at 10. Move the mast assembly away from the power
pinch points. unit.
truck and mast or raise and lower different components 11. Move the mast assembly to an area large enough
for removal and installation. Make sure lifting device to allow the mast to be laid down and disassem-
and sling are sufficiently rated to withstand the weight bled.
being lifted. Never work under or around a truck that is 12. Lower the mast assembly, with the outriggers up,
not properly secured. Refer to truck Data Plate for truck very carefUlly. Keep the lifting device directly over
weight information. the top of the mainframe while lowering to prevent
It will be necessary to disconnect and remove the bat- the base plate from sliding on the floor.
mast, disconnect electrical connections and hydraulic 13. Refer to the disassembly procedures in this section
lines. Control ofHazardous Energy section provides in- at this time if further disassembly is required.
formation for performing the above procedures along
with some additional information on other procedures NOTE
dealing with truck maintenance. This section should be
With the mast assembly laid down, the cylinder and
mast assemblies must be removed by making all hook
and maintenance as outlined in this section.
ups with the lifting device as near the center of the as-
1. Refer to Figure 22030, disconnect and remove the sembly as possible to maintain balance.
battery.
2. Remove the load backrest, forks and carriage as-
sembly. Refer to the previous disassembly proce-
dure.
3. Remove the safety shield and overhead guard.
4. Disconnect the cables and hydraulic lines from the
power unit to the mast assembly. Use a container
to catch the oil.
Crown 2009 PF17726-5 M7.0-1457-005
511
LIFTING MECHANISM
Mast CJ\OWI'
Assembly 10. Use a lifting device to raise the second stage mast
so the rollers are about 150 to 200 mm (6 to 8 in)
below the mounting holes for the stop block, item
NOTE 8, in the mainframe.
Before assembly, refer to torque requirements, fork ad-
11. Use a pry bar to shift the mast channels to one
justment and mast staging procedures located in the
side. Pry on the opposite side to shift it against the
first part of this section.
other side, then go back and pry on the original
side to shift it back again. This will seat the rollers
it CAUTION and force the opposite side tight against the mast
channel. This is necessary to allow for accurate
Always block masts when working on masts in an ele- roller to channel clearance measurement. Once
vated position, even though connected to a hoist. the mast has shifted, retain light pressure to hold
the mast from slipping back.
1. Refer to Figure 22030. Use a cylinder clamp or
braided strap around the right lift cylinder just be-
low the anchor block and connect to a lifting de-
vice.
& WARNING
Wear appropriate items, such as safety glasses, when-
2. Lift and position the right lift cylinder in the main- ever performing maintenance work. Do not place fin-
frame. Secure to the mainframe with the clevis pin gers, hands or arms through mast or position them at
and cotter pin, items 43 & 44. pinch points.
3. Using a lifting device, lift and position the left lift In this section you may be required to lift and block the
cylinder in the mainframe. Secure to the main- truck and mast or raise and lower different components
frame with the clevis pin and cotter pin, items 43 & for removal and installation. Make sure lifting device
44. and sling are sufficiently rated to withstand the weight
4. Connect the right hydraulic tube to the right lift cyl- not properly secured. Refer to truck Data Plate for truck
inder. weight information.
5. Install the left cross tube to the left lift cylinder and It will be necessary to disconnect and remove the bat-
right tube. tery from the truck, disconnect tilt cylinders from the
6. Clean the column roller studs at the top of the lines. Control of Hazardous Energy section provides in-
mainframe and bottom of the second stage mast. If formation for performing the above procedures along
any paint or rust is evident on the studs, remove with some additional information on other procedures
with an emery cloth and lubricate with grease, dealing with truck maintenance. This section should be
Crown No. 063002-024 for standard or read and reviewed prior to mast removal, installation
063002-017 for freezer/corrosion application. and maintenance as outlined in this section.
7. Install two shims on each of the four studs, two at 12. Measure the distance between the channel and
the top of the mainframe and two at the bottom of the roller, about 10 mm (0.375 in) from the channel
the second stage mast. Use shim 060030-085 on face. Always measure from the side the rollers are
RR 1585 kg (3500 Ib) capacity mast, or shim canted toward. If the dimension is greater than
060030-130 on RR 2040 kg (4500 Ib) and RD 0.79 mm (0.031 in) add another shim behind the
1360 kg (3000 Ib) capacity masts. Place one roller roller. If the dimension is less than 0.76 mm
on each stud. (0.030 in) and it does not appear to be tight, pro-
8. Attach a lifting device to the top cross member of ceed in checking the remaining channel rollers.
the second stage mast, lift and assemble the sec- Lower the second stage and check the running
ond stage into the mainframe. clearance. If shims need to be added, remove the
second stage mast, add shims as required, and in-
9. Once the mast has been reassembled, the column stall the second stage mast back into the main-
rollers' ride and clearance should be checked. frame.
M7.0-1457-006 Crown 2009 PF1n~
512
LIFTING MECHANISM l
CJ\OWI' Mast
13. Accurate measurements can only be checked from 1 2 Shims (Mast)

one side. Once the previously described dimen-
2 1 Shim (Carnage)
sions are obtained, the mast channel rollers for the
second stage to mainframe will be within tolerance. 3 2 Shims (Carnage)
When shims are installed it is always ideal to have 4 1 Shim (Mast)
an equal number of shims on each column roller 5 1 Shim (Mast)
stud. If an unequal number of shims are required, 6 2 Shims (Mast)
it is very important that an equal distribution of 7 1 Shim (Carnage)
shims per side be followed. Refer to Figure 22031.
8 2 Shims (Carnage)
9 1 Shim (Carnage)
Correct 10 2 Shims (Carnage)
I 11 1 Shim (Mast)
12 2 Shims (Mast)
~~ ~~
14. Brush grease on the mainframe and second stage
t
II II
rails, use Crown No. 063002-024 for standard or
~
II .... II.
~ 063002-017 for freezer/corrosion application.
2 3 15. Raise the second stage mast until the access hole
in the mast channel is aligned with the stop block
mounting holes.
16. Refer to Figure 22030. Assemble the stop blocks,
/ 1"'-4 items 7 through 12, to the mainframe and apply
V
"'" thread locking adhesive to the screws.
17. Secure the tops of the cylinders to the brackets on
the second stage mast using the 6.3 mm (0.25 in)
screw and nut, items 46 and 47.
18. Assemble HGTS1 and HGTS2, item 81, or ECR2,
cable, spring and bracket, items 59,78, 79 & 83, to
the mast.
Incorrect 19. Install two shims on each of the four studs, two
studs at the top of the second stage and two studs
at the bottom of the third stage mast. Use appropri-
ate shims as indicated in step 7 of Assembly. Place
one roller on each stud.
20. Attach a lifting device to the top cross member of
the third stage mast, lift and assemble the third
stage mast into the second stage mast.
21. Use a lifting device to raise the third stage mast so
the rollers are about 300 to 400 mm (12 to 16 in)
below the rollers at the top of the second stage
mast.
22. Use a pry bar to shift the third stage mast channels
to one side, then pry on the opposite side to shift it
5
against the other side, then go back and pry on the
original side to shift it back one more time. This will
seat the rollers and force the opposite side tight
against the second stage mast channel. Once the
mast has been shifted, retain light pressure to hold
the mast from slipping back.
Figure 22031
Crown 2009 PF17726-7 M7.0-1457-007
513
LIFTING MECHANISM
Mast CJ\OWI'
23. Measure the distance between the channel and NOTE
the roller as described in step 12. If shims need to
be added, remove the third stage mast and install Items 8 - 13 used only when truck is equipped with load
the shims as required. Install the third stage mast sensing and freezer/condition options.
back into the second stage mast and check the
running clearances.
24. Brush grease, Crown No. 063002-024 for standard
or 063002-017 for freezer/corrosion application, on
the second and third stage rails.
25. Assemble the lift chains and chain pulleys to the
second stage mast.
26. Connect the lift chains to the third stage mast.
27. Refer to Figure 17060-01. Assemble the hydraulic
hoses and pulleys, items 6 & 7, to the second stage
mast.
Figure 17061
30. Refer to 22030. Lower the mast completely. Use a

6 cylinder clamp or braided strap and put it just below
chain anchor bracket on the free lift cylinder. Con-
5 nect to a lifting device.
4 31. Inspect the free lift cylinder clamps, item 62, for fa-
tigue cracks and replace as required. If the clamp
is not the newest style clamp, part number 132466,
or if clamps were installed with the cut edges of the
clamp to the inside ofthe bend, replace the clamps
with new ones. Install both clamps with the cut
edges of the clamp to the outside of the bend and
torque the nuts as specified in first part of this sec-
tion.
32. Install two shims and one roller on each of the four
Figure 17060-01
studs on the reach assembly. Use appropriate
shims as indicated in step 7 of Assembly.
28. Refer to Figure 22030. Assemble the hose guides,
items 14, 15,40,41 & 57, to the lift cylinders, right 33. Attach a lifting device to the top cross brace of the
and left hand sides. third stage mast. Raise the mast and position the
reach assembly under the third stage mast and
29. Refer to Figure 17061-01. Install the control ca- lower the mast over the reach assembly.
ble(s) and pulley(s) on the second stage mast.
M7.0-1457-008 Crown 2009 PF17726-a
514
LIFTING MECHANISM
CJ\OW" Mast
34. Attach a lifting device to the reach assembly and 45. Remove the lifting device, install the battery and
raise the reach assembly up the mast about check truck operation.
1525 mm (60 in). Check the fit of the reach assem-
bly in the third stage mast with a pry bar to deter-
mine if it is tight. Continue to raise the reach as- LL WARNING
sembly up the mast and check the fit two or three AVOID HIGH PRESSURE FLUIDS - Escaping fluid un-
more times as it is raised. der pressure can penetrate the skin causing serious in-
35. Raise until the top roller of the reach assembly is jury. Relieve pressure before disconnecting hydraulic
about 300 mm (12 in) below the top of the third lines. Tighten all connections before applying pres-
stage mast. Use a pry bar to shift the reach assem- sure. Keep hands and body away from pin holes which
bly to one side and pry on the opposite side to shift eject fluids under high pressure. Use a piece of card-
it against the other side, then go back and pry on board or paper to search for leaks. Do not use your
the original side to shift it one more time. This will hand.
seat the rollers and force the opposite side tight Any fluid injected into the skin under high pressure
against the third stage mast channel. Once the should be considered as a serious medical emergency
reach assembly has been shifted, retain light pres- despite an initial normal appearance of the skin. There
sure to hold the reach assembly from slipping is a delayed onset ofpain, and serious tissue damage
back. may occur. Medical attention should be sought imme-
36. Measure the distance between the channel and type of injury.
the roller as described in step 12. Lower the reach Carriage hydraulic circuits need to be flushed after re-
assembly and remove it from the mast if the shims pair of reach cylinders and bled of all air. Before flush-
need to be changed. Install the reach assembly ing and bleeding of system inspect all hydraulic con-
back into the third stage mast and check clear- nections and verify that all filters are installed and
ances. hydraulic fluid levels are adequate for test. Hydraulic
37. Brush grease, Crown No. 063002-024 for standard system must be pressurized during the flushing and
or 063002-017 for freezer/corrosion application, on bleeding procedures.
the third stage rails.
38. Attach the free lift chains to the reach assembly. Flushing
39. Install the yoke on top of the free lift cylinder, route 1. Remove the hoses from the sideshift cylinder and
the free lift chain back to the mast, connect to the conned them together using a male connector.
mast.
2. Energize the SVS sideshift solenoid selector valve,
40. Refer to Figure 17060-01. Connect the reach actuate the manual valve at full speed in order to
hoses to the third stage mast, route through the pump hydraulic oil through the carriage hydraulics
yoke and connect them to the reach assembly. and then back through the filter.
41. Refer to Figure 17061-01. Install the control cable 3. Flush the carriage hydraulics for at least 2 minutes,
grip springs and harness clamps to the third stage reversing flow frequently.
mast, route the control cable(s} through yoke and
connect them to the reach assembly. 4. Reconnect the hoses to the sideshift cylinder.
42. Refer to Figure 22030. Assemble the guard, item

60, over the hydraulic tubes.
43. Install the load backrest and forks to the carriage.
44. Install the safety shield.
Lh CAUTION
Be sure all stops and safety devices are in place before
cycling the mast to check for proper operation.
Crown 2009 PF1n26-9 M7.0-1457-009
515
LIFTING MECHANISM
Mast CJ\OWl'
Bleeding 8. Refer to Figure 22032. Tighten the caps, item 4,
the tee fittings, item 3, at the top of the tilt and side-
shift manifold, item 1. Torque to 15.8 Nm
Lh WARNING (139.5 in Ib).
AVOID HIGH PRESSURE FLUIDS - Escaping fluid un- 9. Clean area thoroughly.
der pressure can penetrate the skin causing serious in-
jury. Relieve pressure before disconnecting hydraulic
lines. Tighten aI/ connections before applying pres-
hand.
is a delayed onset of pain, and serious tissue damage
type of injury.
Carriage hydraulic circuits need to be flushed after re-
pair of reach cylinders and bled of aI/ air. Before flush-
ing and bleeding of system inspect aI/ hydraulic con-
nections and verify that aI/ filters are instal/ed and
hydraulic fluid levels are adequate for test. Hydraulic
system must be pressurized during the flushing and
bleeding procedures.
1. Remove the tilt and sideshift manifold cover. Figure 22032
2. Use an absorbent towel or receptacle to collect the

oil.
3. Refer to Figure 22032. Loosen the caps, item 4,
from tee fittings, item 3, at the top of the tilt and
sideshift manifold, item 1.
4. To bleed air from the mast accessory hoses, ener-
gize retract at maximum speed. Hold retract ener-
gized for 30 seconds. This will flush all air out of the
mast accessory circuit.
5. Extend the reach carriage to the maximum exten-
sion and hold for 15 seconds. Retract the reach to
the home position at maximum speed and hold for
15 seconds.
6. Tilt the carriage up to the maximum extension and
hold for 15 seconds. Tilt it down to the home posi-
tion and actuate tilt down for 15 seconds.
7. Extend the sideshift cylinder to the maximum ex-
tension. Energize the sideshift right and hold for 15
seconds. Actuate the sideshift left at the maximum
speed to the home position and hold for 15 sec-
onds.
M7.0-1457-010 Crown 2009 PF1n26-10
516
LIFTING MECHANISM
CJ\OWf\ Lift Chains
Lift Chains
Lift chains are highly important components on fork lift
trucks. The chain system on your mast was designed
for efficient, reliable transmission of lifting force from
hydraulic cylinder(s) to the mast, platform (if present)
and forks. Safe, uninterrupted use of your lift truck de-
pends on the proper care and maintenance of the lift
chains.
Most complaints of unsatisfactory chain performance
can be traced directly to inadequate maintenance.
Highly stressed precision chains require periodic main- Roller and Leaf
tenance to deliver maximum service life. Chain Wear Scale
Inspection
After every 100 hours of truck operation, lift chains
should be inspected and lubricated. When used in an
extremely corrosive environment, inspect chains every
50 working hours. During inspection, check for the fol-
lowing:
Wear
As the chain flexes on and off pulleys, the joints gradu- Figure 16844
ally wear.
Chain wear can be measured by using a 106440 wear
The "stretch" a chain develops during usage is due to scale or a steel tape (Refer to Figure 16844). When
material being worn off of pin outside diameter and pin chains have elongated 3%. as represented on scale
hole inside diameter on the inside plates. "A" (19 mm [0.75 in] or 25 mm [1.0 in] pitch chain) or
scale "B" (16 mm [0.625 in] pitch chain) of the wear
scale, they should be discarded. On chain with 19 mm
(0.75 in) between pins, for example, 305 mm (12.0 in)
of chain contains 16 pitches or links. When 16 pitches
measure 314 mm (12.375 in) the chain should be re-
placed. On chain with 16 mm (0.625 in) between pins,
20 pitches or links equal 318 mm (12.5 in). When 20
pitches measure 327 mm (12.875 in) the chain should
be replaced. Crown currently uses 16 mm (0.625 in)
pitch (20 links in 318 mm [12.5 in)), 19 mm (0.75 in)
pitch (16 links in 305 mm [12.0 in)) and 25 mm (1.0 in)
pitch (12 links in 305 mm [12.0 in)) chain. When check-
ing chain wear, be sure to measure a segment of chain
that operates over a pulley. Do not repair chain(s) by
cutting out the worn section and splicing in a new
piece. If part of a chain is worn, replace lift chain(s). If
truck has a matched set of lift chains replace both
chains at same time.
Crown 1984 PF5856-1 Rev. 7/07 M7.5-18.0-001

08 Rev. 7/07
517
LIFTING MECHANISM
Lift Chains l!J\OWI'
Corroded Chain
(with Stress-Corrosion Cracks)
With Forks Lowered Figure 16846

Check Either Front Heavy motor oil serves both as a joint lubricant and
or Rear Pulley for corrosion inhibitor. During inspection, carefully exam-
Chain Wear ine external chain surfaces for the presence of an oily
film. Under certain operating or environmental condi-
tions it may be necessary to oil chains more frequently
than 100 hour intervals. In all cases, the external sur-
face of the chain must be protected with a film of oil.
Corroded chains should be inspected for cracked
plates. Outside plates are particularly susceptible to
stress corrosion cracking. If chains are heavily rusted
Figure 16845
or corroded they should be removed from the mast for
a thorough inspection for cracked plates. If plates are
Rust and Corrosion cracked, both chains on the truck must be replaced. Oil
Chains used on lift trucks are highly stressed precision chains when they are reinstalled on the mast.
components. It is very important that "as-manufac-
tured" ultimate strength and fatigue strength be main- Cracked Plates
tained throughout the chain service life.
The most common cause of plate cracking is fatigue
Corrosion will cause a major reduction in the load-car- failure. Fatigue is a phenomenon that affects most met-
rying capacity of lift chain or roller chain because cor- als and many plastics. After many repeated heavy
rosion causes side plate cracking. loads the plates may crack and the chains will eventu-
It is extremely important to protect lift chains from cor- ally break.
rosion, whether in service or in storage. The initial fac-
tory lubrication on chains is an excellent rust and cor-
rosion inhibitor. Factory lube is applied in a hot dip tank
to insure complete penetration into the joint. Do not
steam clean or degrease new chains. After the chain Fatigue Cracks
has been placed in service, factory lube must be SllP-
plemented by a maintenance lubrication program.
Refer to applicable lubrication and adjustment section Figure 16847
for your particular truck series andlor the lubrication in-
formation later in this section. Fatigue cracks are almost always found through the pin
holes perpendicular to the pitch line. (Refer to Figure
16847) Contrast this failure mode to the random fail-
ures caused by stress-corrosion cracking. (Refer to
Figure 16846) If any fatigue cracks are discovered dur-
ing planned maintenance (PM) inspections, both lift
chains should be replaced. Many apparently sound
plates will be on the verge of cracking, making chain
failure very likely.
M7.5-18.0-002 Crown 1984 PF5856-2 Rev. 7/07
08 Rev. 7/07
518
LIFTING MECHANISM
CJ\OWI' Lift Chains
Tight Joints
All joints in lift chain should flex freely. light joints resist
flexure, increase internal friction, thus increasing chain
tension required to lift a given load. Increased tension
accelerates wear and fatigue problems. Refer to Figure
16848.
o
light Joints Protruding & Turned Pin
light joints in lift chains can be caused by: Chain Side Wear
1. Bent pins or plates, A continuous wear pattern on pin heads and outside
2. Rusty joints, plates indicates misalignment. Misalignment can be
caused by two different factors: unequal chain tension
3. Peened plate edges. or nonalignment between pulleys and chain anchors.
Oil rusty chains and replace chains that appear bent or
peened. Peening of plate edges may be caused by • Unequal Chain Tension - When a lift chain is in-
worn pulleys, unusually heavy loads, or chain sliding stalled or adjusted, care should be taken to "load"
past a guide or obstruction in the mast. the chains evenly. When changing fork heel height
or platform height for example, the chain anchors
should be loosened until both forks come in contact
Protruding or Turned Pins with the floor. At this point both chains should dis-
Heavily loaded chains operating with little lube gener- play the same tension or slack. The chain anchor
ate tremendous friction between pin and plates (pin nuts should be tightened an equal number of revo-
and bushing in roller chain). In extreme cases, the fric- lutions on both chain anchors to put equal tension
tional torque in the joint can actually turn pins in the on chains. When the desired height setting is
press-fit outside plates. achieved the locking nut should be tightened to se-
cure setting.
If chain is allowed to operate in this condition, the pins
slowly work out of the chain, causing chain failure. • Non Alignment of Lifting Components - Non
Turned pins can be quickly spotted because the flats alignment of the pulley and chain due to incorrect
on the "V" heads are no longer in line. Refer to Figure shimming of the mast or bent or damaged mast or
16849, pin has turned 45 degrees. Chains with turned cylinder components can also contribute to chain
or protruding pins should be replaced immediately. side wear. A check for this condition is to place the
Never attempt to repair the chain by driving pins back truck on a level area in your maintenance area. Af-
into the chain. ter supporting the fork carriage, disconnect each
end of the lift chain at the chain anchor and visually
inspect its alignment with the anchor slots.
Crown 1984 PF5856-3 Rev. 7/07 M7.5-18.0-003

08 Rev. 7/07
519
LIFTING MECHANISM
Lift Chains CROWl'
Lift Chain Lubrication tremely severe service, may require more frequent lu-
brication to maintain an oil film on all chain surfaces.
The most important consideration in field maintenance
of lift chains is LUBRICATION. Hard working, heavily In dusty operating conditions, lubed chains will gather
dust. Even under these conditions wear life will be
loaded chains cannot be expected to give satisfactory
wear life without scheduled periodic lubrication. Like all greatly improved by periodic lubrication. Joints may ac-
bearing surfaces, the precision-manufactured, hard- quire a "paste" made up of oil and dirt, but joint wear
will still be much less than if the chain is allowed to run
ened-steel, joint-wearing surfaces require a film of oil
between mating parts to prevent rapid wear. dry with metal-ta-metal contact between pins and
plates.
Maintaining an oil film on all chain surfaces will:
At 100 hour intervals, clean chains to remove accumu-
• Minimize joint wear (chain stretch). lation of dirt-and lubricate immediately. (Do not steam
clean chains.)
• Prevent corrosion.
• Reduce the possibility of pin turning.

Lubricant
• Minimize tight joints in roller chain.
• Promote smooth, quiet chain action.
• Lower chain tension by reducing internal friction in

the chain system.
Heavy motor oil is an excellent chain lubricant-even
used motor oil is adequate to lubricate exposed lift
chains.
Laboratory wear tests show SAE 40 oil to have greater
ability to prevent wear than SAE 10 oil. Also, SAE 40
oil is superior to hydraulic fluid or automatic transmis-
sion fluid. Generally, the heaviest (highest viscosity) oil Figure 16850
that will penetrate the joint works best.
Laboratory wear testing shows dry film lubes to be less Lift Chain Replacement
effective in preventing joint wear than fluid petroleum The first step in chain replacement is to find the chain
based products. part number in your service manual parts list.
Some aerosol spray lubes, such as Crown part number An important factor in ordering replacement chain from
063001-009, are effective, more convenient and less the truck manufacturer is that special chains may be
messy than applying motor oils. specified for your truck with certified minimum ultimate
Whatever method is used, the oil must penetrate the strength.
chain joint to prevent wear. Applying oil to external sur- If the unit is equipped with two strands, replace chains
faces will prevent rust, but oil must flow into the live as a pair. It will be virtually impossible to maintain uni-
bearing surfaces for maximum wear life. (Refer to Fig- form loading between the strands if a new chain is put
ure 16850). into service opposite an old chain. The joints in the old
Apply oil to chains with a narrow paint brush. A plastic chain will have worn through the hardest layer of the
liquid detergent bottle makes a handy lube applicator. case-hardened pin. Therefore, the wear rate on the old
Flood the chain with oil over its entire length every chain will be greater than that on the new chain, greatly
lUbe-inspection period. complicating the problem of maintaining equal chain
tension.
Frequency of lubrication will vary with operating condi-
tions and environment. The best estimate of lube pe- The new chain will wear more slowly, causing it to bear
riod is 100 hours actual operating truck time. Trucks the major portion of the load, resulting in premature
parked outdoors, used in freezers or trucks in ex- wear and fatigue failure.
M7.5-18.0-004 Crown 1984 PF58564 Rev. 7/07
08 Rev. 7/07
520
LIFTING MECHANISM
CJ\OWI' Lift Chains
Never steam clean or degrease new chains. The man- 2. A support ring (f1atwasher) with an inside diameter
ufacturer's grease is effective in reducing wear and cor- slightly greater than the pin diameter and a height
rosion. If the original factory lube is dried out or wiped equal to the head height of the pin.
off, soak the new chain in heavy engine oil for at least
3. Grinding wheel.
0.5 hour prior to installing on truck.
4. Pin punch with a diameter slightly less than the pin
After the existing chains have been removed from the
diameter, hammer or pressing equipment.
mast, very carefully inspect chain anchors and
sheaves. Broken, cracked, or worn anchors must be
replaced. Replace worn sheaves, and check sheave Disconnect Procedures:
bearings for wear. Do not paint the replacement chain (Refer to Figure 16851)
before or after it has been installed. Paint will help pre-
vent corrosion, but will prevent oil from reaching the pin 1. Grind the top head of the pin flush with the pin link
surface for good joint lubrication. plate. Be careful not to grind or damage the pin link
plate.
Install the new chains, using new anchor pins. Existing
pins may contain invisible fatigue cracks that could 2. Position the support ring over opening of the work
lead to pin failure. After chains have been connected to surface. The support ring serves to support the
the anchors, adjust chain tension to obtain proper fork bottom pin link plate and avoids damage to chain
or platform height. components while driving the pin through the
chain.
Correct chain installation and mast adjustment will in-
crease chain service life. 3. Stand the chain on its side and seat pin in the sup-
port ring.
Chain Anchors and Pulleys 4. Remove the pin from the chain through the top pin
link plate.
An inspection of the chain system should include a
close examination of chain anchors, anchor tension
devices and pulleys.
Check chain anchors for wear, breakage, and radial (3~
misalignment. Anchors with worn or broken fingers /(4)
should be replaced. Anchors should be adjusted to (2) / ~
eliminate twisting or other misalignment in the chain.
When chain is misaligned, the load is not distributed
uniformly between the plates-prolonged operation will
result in premature fatigue failure.
Pulleys with badly worn flanges and outside diameter
should be replaced. Heavy flange wear indicates chain
misalignment. Investigate cause by checking chain
tension and mast shimming. (1 )
(1) Support Ring
(2) Grind Pin Flush with Link Plate
Leaf Chain Disconnect (3) Grinding Wheel
To minimize the risk of damaging (cracking, etc.) the (4) Pin Link Plate
chain, refer to the following when disconnecting leaf (5) Work Surface Knock Out Aperture
chain.
Tools Required: Figure 16851
1. A sturdy work surface with an opening slightly

greater than the pin diameter, and should be thick
enough to allow the pin to extend beneath the work
surface as it is driven through the bottom pin link
plate.
Crown 1984 PF5856-5 Rev. 7/07 M7.5-18.0-005

08 Rev. 7/07
521
CJ\OWI'
Notes:
522
LIFTING MECHANISM
CJ\owr. Fork Inspection
Fork Inspection
Allowable Wear Thickness Chart 1
& DANGER Standard Fork Allowable 10% Wear
Thickness Fork Thickness
The following causes of fork failure may mean loss of
equipment, damaged materials, bodily injury or loss of mm in mm in
life. Make an inspection and measurement of the forks
31.5 1.25 28.5 1.12
at each planned maintenance interval to check for
wear, overload, fatigue, bends, etc. Refer to "Lubrica- 38.0 1.50 35.0 1.38
tion and Adjustmenf chapter.
44.5 1.75 39.5 1.56
& WARNING 51.0

57.0
2.00
2.25
46.0
51.0
1.81
2.00
Use the proper fork for how it was designed to be
used. 63.5 2.50 57.0 2.25
Avoid using fork extensions.
If using the fork wear calipers, refer to the following:
Do not modify forks.
Only qualified personnel should make repairs. Refer to Figure 16854-01. The fork wear calipers have
Visually inspect forks each work day. two measuring points or jaws. The inside jaws (2) mea-
sure 10% less than the outside jaws (1).
& WARNING
If the fork locking pin is not fully engaged, the fork could
become unintentionally disengaged.
Abrasion 1
Abrasion gradually reduces the thickness of the fork.
Be sure the fork thickness is within specifications. Do
not allow forks to rub the floor during normal operation.
If forks rub floor, check lift chain adjustment. Fork wear
at the heel must not exceed 10 percent of the original
Figure 16854-01
thickness. At this point forks are adequate for approxi-
mately 80 percent of rated capacity. Refer to Chart 2. Outside Jaws 100% (Fork Shank)
Use fork wear calipers, part no. 107330, or a measur-
2 Inside Jaws 90% (Fork Blade)
ing instrument such as a vernier or good 160 mm
(6.0 in) scale. For allowable fork wear thickness, refer Refer to Figure 16855-01. To set the outside jaws,
to Chart 1. measure the thickness of the middle of the shank (this
point receives almost no wear). Set the calipers to the
"feel" of the shank by lightly tapping on them with a
metal object.
NOTE
Care should be taken when using the calipers to hold
them square across the shank or an incorrect reading
will result.
Crown 1988 PF7393-1 Rev. 1110 M7.8-04.2-001

06 Rev. 1/10
523
LIFTING MECHANISM
Fork Inspection CROWl'
Figure 16856-01
Fork Shank Cross Section
Figure 16855-01 Once the outside jaws are set, check to see ifthe inside
jaws of the calipers pass over the flanks of the fork
1 Fork Blade blade at any point between the end of the taper and the
2 Fork Shank heel of the fork blade. After checking the blade, re-
3 Measure Here to Set Outside Jaws check the caliper setting by measuring the shank again
making sure the setting was not inadvertently changed.
Figure 16857-01
Fork Blade Cross Section
M7.8-04.2-002 Crown 1988 PF7393-2 Rev. 1/10
06 Rev. 1110
524
LIFTING MECHANISM
CJ\OW" Fork Inspection
100
I
90 l
80
1\
70 "- ~ "Ill
60
2 50
"" ~
40
30
'" ~
..........
~
20
............... ......
............
10
...............
...............
o
o 10 20 30 40 50 60 70 80 90 100
.. 3
Figure 16858-01
1 Chart 2 - Wear ys. Capacity

2 Percentage Reduction in Fork Blade Thickness
3 Percentage Remaining of Specified Fork Capacity
Overloading 1
Know the capacity of the forks and truck. Fork capacity
and load center is stamped on the fork. Refer to Figure
16859-01. Overloading can cause permanent defor-
mation or serious fatigue conditions.
Figure 16859-01
Location of Capacity and Load Center Rating
Crown 1988 PF7393-3 Rev. 1/10

M7.8-04.2-003
06 Rev. 1/10
525
LIFTING MECHANISM
Fork Inspection CAOWI'
Fatigue
A fatigue crack will normally start in the heel area of the
fork. Cracks can usually be detected in the early stages
by inspection of the heel area. Check for cracks that
transverse the fork in an area up to 130 mm (5.0 in)
either side of the outer heel radius. These cracks are a
sign that the area has weakened and the fork needs to
be replaced. Make a visual inspection for cracks each
work day. If a more accurate inspection is necessary,
use dye penetrants or magnaflux fork.
Figure 16861-01
93° Maximum
Use a carpenter's square to check the fork. Refer to

Figure 16862-01. Hold the square against the shank
staying above the radius of the heel as shown. Mea-
sure the distance closest to the radius of the heel of the
fork blade and square (2). Add 31.8 mm (1.25 in) to this
measurement and record. If the distance between the
end of the square and blade (3) is greater than this cal-
culation, replace blade (fork is deformed more than
93°).
Figure 16860-01 ~C-~ __ 1 ~
1 130 mm (5.0 in)

2 130 mm (5.0 in)
1
Bent or Twisted Forks ~
t
1 I
,
Overloading, glancing blows against solid objects or L 2 T
picking up loads unevenly can bend or twist a fork, 3
making fork replacement necessary. The maximum al-
Figure 16862-01
lowable difference in fork tip elevation from one fork to
another is 3% of the fork length.
1 609 mm (2.0 tt)
The angle between the top of the fork (blade) to the
2 "x"
back surface of the vertical leg (shank) shall be less
3 "x· + 31.8 mm (1.25 in)
than 93°. Any angle greater will require fork replace-
ment. The fork manufacturer or service technician with
the expertise of equal competence are the only parties
that should attempt to make such repairs.
M7.8-04.2-004 Crown 1988 PF73934 Rev. 1/10
06 Rev. 1110
526
LIFTING MECHANISM
CJ\OWf\ Fork Inspection
Hanger
Check for cracks or damage to the fork pins and the
area of fork attachment. Check carriage for excessive
wear or cracks. Repair or replace parts if necessary.
Lt WARNING
If the fork locking pin is not fully engaged, the fork could
become unintentionally disengaged.
Check condition offork locking pin, spring, cam, etc. for
proper operation (if forks are so equipped).
Figure 16863-01
1 Check Locking Pin, Spring, etc.

2 Check for Cracks Under Hanger
Crown 1988 PF7393-0 Rev. 1/10 M7.8-04.2-005

06 Rev. 1/10
527
CJ\OWI'
Notes:
528
- - = - - - - - - - - - - - ------ ----_.-
mowI'
CYLINDERS
529
CJ\OWI'
Notes:
(
530
CYLINDERS
CJ\OW" Lift Cylinders
r Lift Cylinders
Remove Screw
Cylinder Removal
Right & Left Hand Lift

The right or left hand lift cylinder can be removed from
the truck and replaced as described below. DO NOT try
to remove both cylinders at the same time, one cylinder
should be removed and replaced completely before the
second cylinder removal is started.
1. Move the truck to a service area on a level floor
below a hoist, if available, chock the wheels and
remove the forks.
~ WARNING
Wear appropriate safety items, such as safety glasses Figure 22685
and shoes, whenever performing maintenance work.

To avoid injury, do not place fingers, hands, arms or ~ WARNING
feet through mast or position them at pinch points.
Make sure lifting device is sufficiently rated to lift vari- Make sure the platform the maintenance person rides
ous parts of the mast sections either individually or as on is secure and the individual is using an operator har-
a group. Make sure that the blocking material is strong ness.
enough to withstand the weight. Never work under or 5. Connect the battery, key the truck ON, raise the
around a truck that is not properly blocked. mast and remove the blocking.
2. Using two 100 x 100 x 305 mm (4 x 4 x 12 in) hard-
wood blocks, raise and block 2nd stage mast
305 mm (12 in) above the bottom cross brace of
the mainframe. Lower the mast completely.
3. Key the truck OFF and disconnect the battery.
4. Remove the screw holding the ram to the mounting
block at the top of 2nd stage mast. Do not remove
the screw from both cylinders, only the one that is
going to be removed from the truck. Refer to Figure
22685.
Crown 2009 PFl7751-1 M8.0-1457-001
531
CYLINDERS
Lift Cylinders CJ\OWI'
6. Raise the mast sufficiently to block it at 1220 mm 7. Wrap and secure a large chain around the 2nd
(4 ft) if the truck has a collapsed height of 2260 or stage cross brace and the 3rd stage cross brace as
2413 mm (89 or 95 in), or at 1830 mm (6 ft) if the a safety precaution. When removing a lift cylinder,
truck's collapsed height is 2720 mm (107 in) or one of the two mast chains must also be discon-
above. Use hardwood blocks, placing one beneath nected, leaving the remaining mast chain holding
each I-beam of the 2nd stage mast, resting on the the 3rd stage mast in position.
lower mainframe cross brace. Securely clamp both
8. Key the truck OFF and disconnect the battery. Re-
blocks in place. Lower the mast completely. The
move the console and open the Manual Lowering
right and left hand lift cylinders will be defined as
Valve (MVL) on the manifold block to relieve the
viewed from in front of the forks. Refer to Figure
system pressure. Refer to Figure 22075.
22686.
Manual Lowering Valve
Figure 22075
4 & WARNING
under high pressure can penetrate the skin causing se-
rious injury. Relieve pressure before disconnecting hy-
5 draulic lines. Tighten all connections before applying
pressure. Keep hands and body away from pin holes
which could eject fluids under high pressure. Use a
piece of cardboard orpaper to search for leaks. Do not
use your hand.
Figure 22686 is a delayed onset ofpain, and serious tissue damage
1 LH Lift Cylinder diately by a specialist who has had experience with this
2 RH Lift Cylinder type of injury.
3 Mainframe Cross Brace
4 2nd Stage Cross Brace
5 3rd Stage Cross Brace
Crown 2009 PF17751-2

M8.0-1457-002
532
CYLINDERS
CJ\owr. Lift Cylinders
9. Place a shallow pan beneath the mainframe and 11. Remove the hose guide at the top of the lift cylin-
below the cylinder to be removed. Remove the hy- der. Refer to Figure 22688.
draulic line from the bottom of the cylinder. Cap the
cylinder fitting and the line fitting to prevent con-
tamination of the hydraulic fluid, protect the fittings Hose Guide
from damage and to help contain the hydraulic
fluid.
10. Disconnect the height sensor and move the wires
to the side. Remove the chain anchor from main-
frame mount and drape it over the cross brace. Re-
fer to Figure 22687.
Figure 22688
Figure 22687
1 Height Sensor
2 Chain Anchor
Crown 2009 PF17751-3 M8.0-1457-003
533
CYLINDERS
Lift Cylinders l!J\OWI'
12. Remove the hydraulic lines, hoses and spring (if 13. Remove the two screws holding the height sensor
removing the left lift cylinder) from the mounting and move the height sensor to the side. Refer to
bracket approximately 840 mm (33 in) from the Figure 22690.
bottom of the cylinder. Cap all the hydraulic lines
and hoses that were removed. Clean up any
spilled hydraulic oil from the truck.
_---'--t""-3
~-1--4
Figure 22690
1 Remove the Height Sensor

Figure 22689 2 Pin
3 Mounting Bracket
1 LH Lift Cylinder
2 Fittings and Spring
3 RH Lift Cylinder
4 Fittings
Crown 2009 PF17751-4

M8.0-1457-004
534
CYLINDERS
CJ\OWI' Lift Cylinders
14. Remove the pin holding the top of the cylinder to 17. Once the cylinder base is above the 2nd stage
mainframe. cross brace, bring the cylinder out the front, fork
side of the mast.
15. Put the nylon strap around the top of the cylinder
just below the mounting bracket. Refer to Figure
22691.
16. Connect the hoist to the strap and carefully lift the
cylinder above the 2nd stage cross brace. Be very
careful when lifting the cylinder not to catch the hy-
draulic hose mount on 2nd stage cross brace.
2
2
Figure 22692
1 Cylinder
2 2nd Stage Lower Cross Brace
3
Cylinder Replacement
18. Install a cap on the fitting at the bottom of the lift
4 cylinder if one is not already present.
19. Install a nylon strap around the top of the cylinder
just below the mounting bracket and connect it to
the hoist.
it WARNING
Wear appropriate safety items, such as safety glasses
and shoes, whenever performing maintenance work.
To avoid injury, do not place fingers, hands, arms or
Figure 22691 feet through mast or position them at pinch points.
Make sure lifting device is sufficiently rated to lift vari-
1 Mounting Bracket ous parts of the mast sections either individually or as
2 Nylon Strap a group. Make sure that the blocking material is strong
3 Hydraulic Hose Mount enough to withstand the weight. Never work under or
4 2nd Stage Lower Cross Brace around a truck that is not properly blocked.
20. Raise until the bottom of the cylinder is over the top
of 2nd stage lower cross brace and lower the cylin-
der into position.
Crown 2009 PF17751-5 M8.0-1457-005
535
CYLINDERS
Lift Cylinders CJ\OWI'
Lh WARNING Lh WARNING
Make sure the platform the maintenance person rides AVOID HIGH PRESSURE FLUIDS-Escaping fluid
on is secure and the individual is using an operator har- under high pressure can penetrate the skin causing se-
ness. rious injury. Relieve pressure before disconnecting hy-
draulic lines. Tighten all connections before applying
21. Install the pin back through the mainframe and the
pressure. Keep hands and body away from pin holes
cylinder mounting bracket. Install the cotter pin
which could eject fluids under high pressure. Use a
through the bottom of the pin to secure it in place.
piece of cardboard or paper to search for leaks. Do not
Remove the strap from the cylinder. Refer to Fig-
use your hand.
ure 22690.
22. Using the two screws removed during disassem- should be considered as a serious medical emergency
bly, mount the height sensor back into position. despite an initial normal appearance of the skin. There
23. Remove the cap and reattach the hydraulic line to
the bottom of the cylinder.
24. Put the hoses back into position in the hose guide, type of injury.
which is located at the top of the cylinder, and se-
29. Install the screw through the hole in the mast and
cure them using the screw that was previously re-
ram. Refer to Figure 22685.
moved. Refer to Figure 22688.
30. Raise the mast enough to remove the mast block-
25. Connect the hydraulic hoses, lines and spring (if
ing, remove the blocking, then lower the mast com-
the left lift cylinder was removed) to the bracket on
pletely and bleed the right and left stage cylinders
the cylinder. Refer to Figure 22689.
and the free lift cylinder as described at the end of
26. Install the chain anchor back in position and re- this section.
place both of the nuts. Try to put the same amount
31. Raise the mast and check to be sure the mast is
of tension on the chain anchor as before so the
straight when raised. If not, adjust the chain anchor
mast will remain straight.
tension to correct it. Install the cotter pin back into
27. Connect the plugs on the height sensor and the the chain anchor to secure it in position.
harness.
32. Lower the mast completely and key the truck OFF.
28. Close the Manual Lowering Valve (MVL), connect Check the hydraulic fluid level and fill as required.
the battery, key the truck ON and very slowly raise Install the console and forks, and remove the
the mast. Guide the cylinder ram back into position wheel chocks.
in the top of the 2nd stage mast, making sure the
33. Key the truck ON and check the truck's operation.
hole in the ram and the hole in the bracket will line
up. Great care and cleanliness should be exercised in the
disassembly and assembly of any hydraulic cylinders.
Wipe all surfaces clean of dirt and oil before attempting
the disassembly. Care should be taken when removing
the ram from the cylinder to prevent damage to the
packing on the piston end. After the cylinder and wipers
are removed, thoroughly wash all the metallic parts in
solvent and blow them dry with compressed air. Care-
fully inspect the ram assembly and cylinder bore. Re-
place if scored, grooved, pitted or worn. Minor damage
to the cylinder bore can be removed with the use of a
cylindrical honing tool. Place the washed components
in a clean container until assembly. Whenever new
packings are required, new wiper rings should also be
installed.
Crown 2009 PF17751~

M8.0-1457-006
536
CYLINDERS
mowr. Lift Cylinders
Lift Cyli nder Seal Removal

Material covered in this section applies to all n lift cyl- When an excessive amount of hydraulic oil is evident
inders. on the cylinder, where the ram exits from the cap, the
rod packing is probably bad and should be replaced.
The replacement of the packing can be accomplished
without removing the ram assembly from the cylinder
tube or truck.
--2
~-1
3
f}., /
'@, Figure 15963-01
'~
Screwdriver
4
/ 152 mm (6 in) shaft length (min.)
4 mm (0.156 in) shaft diameter (max.)
2 No.8 Metal Screw
Figure 15962-02 Headless (4 mm Self-Tapping)
3 Weld (grind off excess) to a max. dia. of 4 mm (0.156 in)
1 Cylinder Tube
4 Tape
2 Cap
3 Seal If the packing is seated in the cap itself, a hooked tool
4 Bleed Screw
should be used to remove the packing. If the packing is
located below the cap and remains in the cylinder bore
after the cap is removed, a pair of special tools can be
Disassembly
used to facilitate the packing removal. To make these
Tum the cap counterclockwise and unscrew it from the tools, weld or braze a headless 4 mm self-tapping (No.
cylinder tube. Remove the cap and carefully extract the 8 metal) screw to the end of a screwdriver. The screw-
ram assembly from the cylinder bore, never allowing driver must have at least 152 mm (6 in) of shank length
the ram to come in contact with any sharp edges. with no larger than 4 mm (0.156 in) shank diameter. Af-
ter attaching the screw to the screwdriver, grind off the
Seals excess weld to a diameter of 4 mm (0.156 in) Wrap the
shank with electrical tape from the tip of the screw to
The seals used in the cylinders are made of an ex- the screwdriver handle. This will prevent scratching of
tremely durable, hard polyurethane material which can the cylinder bore or the ram. Refer to Figure 15963-01.
be deformed temporarily to allow for installation without
permanent damage.
Crown 2009 PFlnSl-7 M8.0-1457-007
537
CYLINDERS
Lift Cylinders CROWl'
NOTE Seal Installation - General
Extreme care should be taken to prevent damage to Tools used to install the hydraulic seals should be of
the cylinder wall and the ram assembly. soft metal or suitable plastic, free of burrs and sharp
edges. Screwdrivers and other similar tools should not
Insert the tools between the ram and the cylinder walls,
0 be used as they may damage the sealing edges.
180 apart, and screw into the face ofthe packing. After
the threads are sufficiently secured into the packing, The area in contact with the seal should be free of
evenly pull on the screwdriver handle until the packing burrs, sharp edges and nicks.
is removed. Refer to Figure 15964-02.
If necessary to force the seal over sharp edges, slots
or undercuts, protective devices should be used.
Light lubrication should be applied to the seal and in-
stallation groove prior to installation. The same oil as
will be used later in the cylinder should be applied.
Rod U-Cup Installation
Small U-Cup
1. Installation Tools
- A groove alignment plug is needed, which
should be flush with groove edge. Any metal or
plastic material which is smooth and lubricated
may be used. Refer to Figure 16734-01.
Figure 15964-02 2
1 Seal Pulling Tools

2 Ram
3 Cylinder Tube
4 Seal
At this time, the wiper ring should also be removed

since packings and wiper rings should always be re-
placed in pairs. Thoroughly clean the area where the
seals seat. Any burrs, dirt or seal debris must be re-
moved before reinstalling the new seals.
3
it CAUTION
Close inspection of seal seating critical areas should
be made before the new seal is installed. Your seal fail-
Figure 16734-01
ure may not have been caused by a worn seal, but
rather, by bu"s, nicks and dirt located on the seal seat-
1 Critical Seal Seating Area
ing area, causing the seal to deform and lose its seal-
2 Pusher Rod
ing ability.
3 Groove Alignment Plug
- A soft metal or plastic pusher rod is needed.
M8.0-1457-008 Crown 2009 PF1 nS1-8
538
CYLINDERS
l!J\OWr. Lift Cylinders
2. Squeeze the U-cup together and insert the end into

the bore first. When the lower end is engaged in
the installation groove, release the U-cup and force 3
the upper end downward using the pusher rod until
the U-cup snaps into the groove.
Large U-Cup
1. Installation Tool
- An installation tool made of any soft metal or
hard plastic that is smooth and free of burrs
with a fixed steel pin (pin 1) and two movable
pins (pins 2 & 3) is required for this installation
method. Refer to Figure 16735-02. 2
Figure 16736-01
4
1 Pin 1
2 Pin2
3 Pin 3
- Withdraw pin 3 so the U-cup loop snaps into

the installation groove. Refer to Figure
16737-01
Figure 16735-02
1 Pin 1
2 Pin2
3 Pin 3
4 Tool Body
2
2. Installation Procedure
- Slip the U-cup over the fixed pin, refer to pin 1 Figure 16737-01
in Figure 16735-02, and bend it over pin 2 as
shown. 1 Pin 1
2 Pin 2
- Continue bending the U-cup until pin 3 can be
3 Pin 3
pushed through the U-cup loop, which locks
the U-cup in position.
- Insert the installation tool with the mounted
U-cup into the cylinder bore until it is aligned
with the U-cup installation groove. Refer to Fig-
ure 16736-01.
Crown 2009 PF17751·9 M8.0-1457-009
539
CYLINDERS
Lift Cylinders CJ\own
- Withdraw pin 2 and the U-cup will completely
snap into the installation groove. Refer to Fig-
ure 16738-01. 4
Figure 16738-01
1 Pin 1 Figure 15970-01

2 Pin 2
3 Pin 3 1 Critical Seal Seating Area
2 Seal
- Withdraw the installation tool.
3 Forging Tool
4 Sleeve
Cylinder U-Cup Installation
5 Cylinder Tube
For "lip first" installation, a sleeve similar to that shown 6 Collar
in Figure 15970-01 should be used to protect the seal
from damage on the threads and shoulders. Cylinder Assembly
LL CAUTION
Care should be taken when inserting the cylinder cap
to prevent threads and sharp edges from damaging the
new seals and packings.
After the packings and seals are in place and the ram
assembly has been installed, install the cap.
Cylinder - Summary
Occasionally, a slight creep of the fork assembly may
occur. This may be due to internal leakage in the piston
pack but it can also be caused by leakage in the sole-
noid or check valve. To seat these valves properly
when this occurs, raise and lower the forks to flush out
any foreign material from the valve seat. A thorough
check of the system for leaks should be conducted if
abnormal oil losses occur. The hydraulic system is de-
signed to eliminate mechanical damage even if the fit-
tings become loose.
Crown 2009 PF17751-10

M8.0-1457-010
540
CYLINDERS
CJ\OWf\ Lift Cylinders
Cylinder Bleeding and Flushing

Mast hydraulic circuits need to be flushed after repair-
ing lift cylinders and bled of all air. Before the flushing
and bleeding of the system, inspect all hydraulic con-
nections and verify that all filters are installed and the
hydraulic fluid levels are adequate for testing. The hy-
draulic system must be pressurized during the flushing
and bleeding procedures.
it WARNING
under pressure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting hydraulic
hand.
despite an initial nonnal appearance of the skin. There
type of injury.
Bleeding - Free Lift Cylinder

• Slowly elevate the carriage in free lift to approxi-
mately 1220 mm (4 ft).
• Slowly open the free lift cylinder bleed screw and

bleed the air from the cylinder until a solid stream
of hydraulic fluid flows out of the bleed screw.
• lighten the bleed screw.
Bleeding - Stage Lift Cylinders

• Slowly elevate the carriage in free lift to approxi-
mately 1220 mm (4 ft).
• Slowly open the stage lift cylinder bleed screw and

bleed the air from the cylinder until a solid stream
of hydraulic fluid flows out of the bleed screw.
• lighten the bleed screw.
• Repeat the above steps for the other stage lift cyl-
inder.
Crown 2009 PF17751-11 M8.0-1457-011
541
l!J\own
Notes:
542
CYLINDERS
CROWl' Tilt Cylinder
Tilt Cylinder
6
5 \
\
~
""1
" I
" I
" I
I
I
I
,I
"
"""" 15-~ '-17
I
16--~
I
13
\
/
I
I
I
I 9
I
I
I
\
I
I
I
I
I
I
I
I
I
I
'"
Figure 21651
Tilt Cylinder (Optional) ity to tilt the load, the cylinder will have to be removed
from the truck and repaired.
The tilt cylinder is mounted at the base of the carriage
assembly. This tilt cylinder is a double acting piston
type cylinder. Extreme care should be taken when per-
forming any type of repair. In the event of excessive oil
leakage around the cap end of the cylinder or its inabil-
Crown 2001 PF13081·1 Rev. 6109 M8.6-1452-001

01 Rev. 6/09
543
CYLINDERS
Tilt Cylinder CJ\OWI'
Disassembly Rod Disassembly
I
Before proceeding with disassembly. thoroughly clean Clamp the end of the rod containing the ball bushing in
the outside of the cylinder to remove all grease and dirt a vise. Unlock and remove the locknut with the appro-
build-up. Place the cylinder in a vise. Care should be priate size spanner wrench. Slide all components off
taken to avoid over tightening the tube assembly (item the end of the rod. Inspect the rod for scoring or dam-
14) may be easily damaged. The use of an adjustable aged material. If damages or scoring is evident, the rod
spanner wrench, similar to the one shown in Figure, is must be replaced.
required for disassembly. A face spanner wrench with
3/16 inch pins and a spread of at least 67 mm
(2.625 in) is sufficient. Rotate the gland until the wire Seal Replacement
retaining ring (item 13) is completely unwound from the With the use of a small hooked tool. carefully remove
inside of the cylinder. the seals from their mounting grooves.
NOTE
Check the wire retaining ring to determine co"ect turn-
& CAUTION
ing direction for removal. If the cap is turned in the Never use a screwdriver to remove seals, as i"epara-
wrong direction, and the end of the retaining ring is al- ble damage and leakage may occur.
lowed to slip inside the cylinder, removal of the ring is After all the seals have been removed, inspect the con-
very difficult. tact surfaces on both the piston and the gland for scor-
ing. If slight scoring is evident, sand with a fine emery
paper until all high surfaces have been removed. Heav-
ily scored components must be replaced. After all parts
have been disassembled and inspected, wash all cylin-
der components in a good grade solvent and dry with
C> air pressure.
NOTE
When cleaning the piston and gland, be sure to clean
the seal seating areas. Protect eyes and face when us-
ing compressed air.
After all the parts have been thoroughly cleaned, place
in a dirt free area until ready for reassembly.
Figure 19204
Before removing the rod assembly, push the gland.

(Item 3). down into the cylinder, away from the retaining
ring groove area. Using a scraper or similar tool, re-
move any raised material or burrs from the edge of the
groove. If burrs, etc.• are not removed, piston removal
may be difficult.
Carefully remove the rod assembly which includes the
gland (Item 3), the rod (Item 1), the piston (Item 9), the
lockwasher (Item 11), and the locknut (Item 2) out of
the end of the tube assembly. Inspect the tube assem-
bly for any signs of scoring. If scoring is evident, the
tube assembly must be replaced. The tube assembly
should be honed to remove any remaining burrs.
Crown 2001 PF13081-2 Rev. 6/09

M8.6-1452-002
01 Rev. 6/09
544
CYLINDERS
CJ\owr. Tilt Cylinder
Cylinder Reassembly Flushing

Apply a light coating of hydraulic oil (Crown No. • Remove the hoses from the sideshift cylinder and
063001-001) to all seals before they are assembled. connect them together using a male connector.
Install all seals by hand. After the seals have been in-
stalled, slide the gland onto the piston end of the rod. • Energize the SVS sideshift solenoid selector valve,
Install the piston and fasten the locknut; be sure piston actuate manual valve at full speed in order to pump
is seated properly against the rod shoulder. After in- hydraulic oil through carriage hydraulics and then
stalling the rod assembly into the tube assembly, align back through the filter.
the hole in the gland with the slot in the cylinder wall
and carefully press the gland into position. • Flush carriage hydraulics for at least 2 minutes, re-
versing flow frequently.
LL CAUTION • Reconnect hoses to the sideshift cylinder.
Care should be taken when inserting the gland to pre-

vent sharp edges from damaging the new seals and Bleeding
packing's.
• Fully extend the tilt cylinder and tilt the forks up.
Once the gland is in place and the positioning hole is
visible through the cylinder slot, insert the hooked end • Securely block the carriage so it can not tilt down.
of the wire retaining ring into the positioning hole. Turn
Refer to Control Of Hazardous Energy, Lifting
the gland clockwise until the tapered end of the retainer
Blocking, for procedures on blocking the carriage.
is flush with the cylinder tube.
• Loosen the fitting at port T2 on the tilt manifold
Tilt Cylinder Flushing and Bleeding block and remove the hose from the rod side of the
tilt cylinder.
Procedures
• Energize SVT tilt solenoid selector valve, actuate
the manual valve to pressurize the A port to the
pair of tilt cylinder and bled of all air. Before flushing
carriage, and hold until a solid stream of hydraulic
and bleeding of the system inspect all hydraulic con-
fluid flows out through the hose. This is passing hy-
nections and verify that all filters are installed and hy-
draulic fluid through mast hoses, reach manifold
draulic fluid levels are adequate for test. Hydraulic sys-
and through the tilt-sideshift manifold block.
tem must be pressurized during the flushing and
bleeding procedures. • Reconnect the hose at the tilt cylinder and tighten
the fitting in port T2 on the tilt-sideshift manifold
LL WARNING
•
block.
Remove the block under the carriage. Fully retract

AVOID HIGH PRESSURE FLUIDS-Escaping fluid un-
der pressure can penetrate the skin causing serious in- the tilt cylinder and tilt the forks down.
• Loosen the fitting at port T1 on the tilt manifold
block and remove the hose from the piston side of
eject fluids under high pressure. Use a piece of card- the tilt cylinder.
board or paper to search for leaks. Do not use your • Energize the SVT tilt solenoid selector valve, actu-
hand.
ate the manual valve to pressurize the B port to the
carriage, and hold until a solid stream of hydraulic
draulic fluid through the mast hoses, reach mani-
fold and through the tilt-sideshift manifold block.
diately by a specialist who has had experience with this • Connect hose at tilt cylinder and tighten fitting in
type of injury. port T1 on the tilt-sideshift manifold block.
Crown 2001 PFl3081-3 Rev. 8109 M8.6-1452-003

01 Rev. 6/09
545
CYLINDERS
Tilt Cylinder CAOWI'
,,
,
-~
. :@)-----------------------------------------------
R2
I .. ..
--I>
,,: SVR
,:T3
I
A: I
I
,
,,,
I
:T2
I 6'
I
I ,,,T1 6,
,,
: . - - - - -~~y- - --- ,,
,,: R1 R2
, ,
,, .. _--------"
L -_ _----,
I
I
,
I
~
,
J
Figure 20944
1 Secondary Lift Cylinder

2 Primary Lift Cylinder
3 Carriage Hydraulics
4 Velocity Fuse
5 Flow Control
6 Reach Manifold - Contains CBV & SVR
7 TiltlSideshift Manifold - Contains SVS & SVT
M8.6-1452-004 Crown 2001 PF130814 Rev. 6/09
01 Rev. 6/09
546
CROWl'
PLATFORM
547
l!J\OWI'
Notes:
548
PLATFORM
CJ\OWI' Reach Assembly
Reach Assembly Reach Inspection

The reach assembly on your truck is designed to lift,
transport, and deposit materials from racks where out- Poly Stop
riggers cannot enter into or under. After the truck has Located at the bottom and center of the support as-
been positioned in front of the load and the forks ad- sembly is a poly stop. This poly stop prevents metal to
justed to the proper height, the reach carriage can then metal contact when the reach assembly is fUlly re-
be extended. The carriage is extended by rolling the tracted. The poly stop should be shimmed to make
thumbwheel, located on multi-task handle, away from contact with the carriage assembly as the reach cylin-
the operator. Retracting the carriage is accomplished ders are fully retracted.
by rolling the thumbwheel towards the operator. Reach
carriage speed is varied by the amount of thumbwheel The poly stop at the top of the inner arm uses spacers
rotation. After extending to engage the forks under load for correct position. Tighten the socket head screw, do
properly, load is lifted, fully retracted and lowered to a not over tighten. The number of washers can be deter-
safe travel height. mined with the truck operational. The poly stop bumper
should compress 6 - 13 mm (0.25 - 0.50 in) when fully
retracted with a 905 kg (2000 Ib) load. Use thread lock-
Lt WARNING ing adhesive to secure the screw into position. Torque
the screw 32 - 36 Nm (28 - 32 in Ib).
Wear appropriate items, such as safety glasses and
steel-toed shoes whenever performing maintenance
work. Do not place fingers, hands or arms through Reach Cylinder Adjustment
mast or position them at pinch points. Extend the mechanism completely. From the retracted
In this section you may be required to lift and block the position, the distance to the top front edge of the fork
truck and mast or raise and lower different components carriage assembly should be 590 mm (23.3 in). (Mea-
for removal and installation. Make sure lifting device surement must be taken at top of reach mechanism).
and sling are sufficiently rated to withstand the weight With the reach cylinders fully extended, the cylinder rod
being lifted. Never work under or around a truck that is can be turned to obtain the correct dimension. Refer to
not properly secured. Refer to truck Data Plate for truck Figure 17053.
weight information.
It will be necessary to disconnect and remove the bat-
tery from the truck, disconnect tilt cylinders from the r '
I 1
mast, disconnect electrical connections and hydraulic 1 1
lines. "Control of Hazardous Energy" section provides r-i
1
information for performing the above procedures along 590 mm (23.3 in)
I... ~
1
~---ll
dealing with truck maintenance. This section should be I

Figure 17053
Crown 2001 PFl3067-1 Rev. 6/09 M9.0-1452-001

02 Rev. 6/09
549
PLATFORM
Reach Assembly CROW"
52
~53
47
I
I
I
I
I
24':'
25
'i'7 27
28
26
Figure 17054
Disassembly 4. Extend the reach assembly and place a 50 x 100 x

200 mm (2 x 4 x 8 in) hardwood block in either the
(Refer to Figure 17054) left or right channel of support assembly (1).
5. Retract the reach assembly until the column roller
NOTE (28) on the outer arm (34) is resting on the hard-
wood block. The hardwood block will not allow the
Disconnect the battery. If complete disassembly of the
assembly to retract when the reach cylinders are
reach assembly is required, removal of entire reach as-
removed.
sembly from the mast assembly will ease the disas-
sembly procedure. 6. (Disregard if truck is not equipped with tilt). Re-
move the roll pin (48) from the tilt cylinder shaft (49)
1. Remove the four screws holding the load backrest
with a brass punch or other soft material rod.
(not shown) to the fork plate (52) and remove the
load backrest.
NOTE
2. (Disregard if truck is not equipped with tilt). Re-
move screw (53) in the bottom cross member of Ensure hoist has a lifting capacity of at least 905 kg
the fork plate. (2000Ib).
3. Remove the forks (not shown) from the fork plate.
M9.0-1452-002 Crown 2001 PF13067·2 Rev. 6/09
02 Rev. 6/09
550
PLATFORM
CJ\OWf\ Reach Assembly
7. Remove the two roll pins (50) from the pivot shafts Bushing Replacement (Reach Assembly
(51) at top of fork plate. Use a hoist or other suit- Components)
able means to support the fork plate, and remove
the pivot shafts. When removing an old bushing, be sure the seating
area of the bushing is not damaged in any manner. If
8. Remove the hydraulic lines from the tilt cylinder damage has occurred remove all burrs and rough
(43) to manifold block (not shown) on the support edges completely.
assembly. Allow the hydraulic pressure to bleed off
slowly. When installing the replacement bushings in a lubri-
cated area, be sure hole in the bushing is in the proper
9. Remove the four screws holding the tilt cylinder in alignment with the lubrication fitting to allow proper lu-
the carriage assembly (47). brication flow.
10. Remove the tilt cylinder; if further disassembly is Apply a light coat of grease to the bushing seat to ease
required, take to a clean working area. Consult installation and reduce the possibility of damage to the
Cylinder for proper disassembly procedure. replacement bushings.
11. If ball bushing (45) in the tilt cylinder rod end re-
quires replacement, remove the retaining rings NOTE
(46) and use an arbor press to remove and replace
An installation tool can be used effectively to remove
it.
worn or damaged bushings. Various sizes of bushings
12. Attach a hoist to the top cross bar of the carriage will necessitate use of various sizes of installation
assembly. Remove roll pins (40) in the pivot shafts tools.
(39) which connect the outer arms to the carriage
A bushing installation tool, shown in Figure 17055, will
assembly. Remove the pivot shafts and raise the
aid greatly in the correct installation of replacement
carriage assembly to clear the carriage rollers (24)
bushings.
on the inner arm assembly (22).
13. Remove the roll pin (14) from the pivot shaft (13) at
the rod end of the reach cylinders (12). Remove (1 )
the pivot shafts (13) at the rod end.
14. Disconnect the hydraulic lines from the bulkhead
located near the top of the reach cylinders.
15. Remove the roll pin (5) from the upper pivot shafts
(:(\
(6) and remove the pivot shafts. The reach cylin- (2)
ders should be installed in same position on the
support assembly they were removed.
(3)
16. Connect a hoist to the inner arm assembly cross
brace and lift until the column rollers on the outer (1) Bushing Installation Tool
arm assemblies can be rotated out of the support (2) 0.13 mm (0.005 in) Smaller than the Bushing
assembly channel. Outside Diameter
(3) 1.6 mm (0.062 in) Chamfer
17. Remove the column rollers from the outer arms.
(4) 0.13 mm (0.005 in) Smaller than the Bushing
Record the number and the position of all spacers
for reference during reassembly. (5) Equal to the Length of the Bushing
18. Remove the roll pin (33) and retaining ring (32)
from the locknut (31) at the pivot center. Remove Figure 17055
the locknut with a hook type spanner wrench.
19. Remove the outer arm and thrust washers. Record
the location of the thrust washers for reference dur-
ing reassembly.
20. Remove the roll pins (8) in the pivot shafts (7) of
the inner arm assembly.
Crown 2001 PF13067-3 Rev. 6/09 M9.0-1452-003

02 Rev. 6/09
551
PLATFORM·
Reach Assembly Cl\OWI'
NOTE Reassembly
Close inspection of aI/ replacement bushings after in-
stal/ation is necessary to be sure the wear surfaces are NOTE
intact. Before proceeding with reassembly, aI/ parts should be
Ball bushings are removed and installed with greater clean and free of any burrs or rough edges which could
ease when using an installation tool similar to the one damage the replacement bushings or other parts dur-
shown in Figure 17056. ing assembly. Apply a thin coat of grease to aI/ bush-
ings, thrust washers and pivot shafts.
1. Install the inner arm assembly (22) into the support
(1 ) assembly (1).
2. Install the pivot shafts (7) simultaneously, rather
0.5 mm (0.19 in)
!1
than one at a time. Pivot shafts are slotted on the
end to obtain proper alignment for installation of
the roll pin (8).
(2)
NOTE
Refer to Center Pivot Repair and Adjustment (located
in this section) for proper adjustment information of
center pivot.
3.2 mm (0.125 in)
(1) Ball Bushing Installation Tool 3. Install the thrust washer (23) at the center pivot.
(2) 0.13 mm (0.005 in) Smaller than the Bushing
Slide the outer arms (34) onto the center pivot stud.
Outside Diameter Install the thrust washer (30), locknut (31), roll pin
(3) Cut-away View of the Counterbore
(33) and retaining ring (32).
(4) Ball Bushing 4. Use an inside caliper to measure the area of sup-
port assembly where the column roller (28) on the
Figure 17056 outer arm will travel, record the measurement.
5. Install the column rollers to the outer arms. Mea-
Center Pivot Repair and Adjustment sure the distance between the column rollers with
an outside caliper. Subtract this dimension from
NOTE the dimension obtained in step 4 to determine the
number of shims required. Balance out the number
Be sure aI/ areas of contact are thoroughly cleaned and
of shims (Example: 2 shims right, 2 shims left). If
free of any burrs or debris that could damage the re-
an uneven number of shims are required, note to
placement thrust washers.
which side the extra shim was added and install all
When replacing the thrust washers (23, 30) on both other odd shims to that side.
sides of the outer arm assembly, apply a light coat of
grease to all surfaces. NOTE
To properly adjust, tighten the nut on the center pivot Failure of the outer arms to fit into the carriage assem-
assembly snug to eliminate any abnormal drag. bly properly indicates an inner arm assembly, carriage
Loosen the nut and torque to 73 Nm (65 in Ib), then assembly, or outer arm assembly is bent or deformed
continue to tighten to the next nearest groove pin loca- in some way.
tion.
6. Measure the distance between the outer arms at
top. (TT is 335 mm [13.25 in)). Measure the dis-
tance between the pivot blocks welded on the fork
carriage assembly (47). These dimensions should
indicate the outer arms will fit properly in the fork
carriage assembly.
M9.0-1452-004 Crown 2001 PF13067-4 Rev. 6/09
02 Rev. 6/09
552
PLATFORM
CJ\owr. Reach Assembly
7. Attach the carriage rollers (24) to the inner arm as- Reach Cylinders Flushing and
sembly studs.
Bleeding Procedures
8. Raise the inner arm assembly until the column roll-
ers on the outer arms can be fitted into the chan-
Bleeding
nels of the support assembly. Place a 50 x 100 x
200 mm (2 x 4 x 8 in) approximate length, hard-
wood block in either channel beneath the column
roller. Lower the inner arm assembly until the
Lh WARNING
weight of the arm assembly is on the hardwood AVOID HIGH PRESSURE FLUIDS - Escaping fluid un-
block. der pressure can penetrate the skin causing serious in-
9. Guide the fork carriage assembly (47) onto the in-
ner arm carriage rollers.
10. Install the pivot shafts (39) and roll pins (40). eject fluids under high pressure. Use a piece of card-
11. Install the reach cylinders.
hand.
12. Install the pivot shafts (6) and roll pins (5). Any fluid injected into the skin under high pressure
13. Extend the cylinder manually and install the pivot
shafts (13) and roll pins (14).
14. Connect the hydraulic lines from the reach cylin- may occur. Medical attention should be sought imme-
ders to the bulkheads near top of the reach cylin- diately by a specialist who has had experience with this
ders. type of injury.
NOTE pair of reach cylinders and bled of all air. Before flush-
ing and bleeding of system inspect all hydraulic con-
Disregard steps 15, 16, 17 and 18 of reassembly pro- nections and verify that all filters are installed and
cedure if truck is not equipped with the tilt function. hydraulic fluid levels are adequate for test. Hydraulic
15. Place the bushings (44) on the tilt cylinder (43) system must be pressurized during the flushing and
pivot studs and install the tilt cylinder assembly in bleeding procedures.
the carriage assembly. Check the serial number 1. Remove the tilt and side-shift manifold cover.
plate to obtain the capacity of the truck to install the
correct tilt cylinder assembly. This information is 2. Use an absorbent towel or receptacle to collect the
also needed to obtain the proper fork plate assem- hydraulic fluid.
bly (52) and tilt cylinder shaft (49). 3. Loosen the caps from tee fittings, ports (1) and (2)
16. Connect all the hydraulic lines from the tilt cylinder at top of tilt-side-shift manifold. Refer to Figure
to manifold block at top of the support assembly. 17161.
NOTE
Ensure the hoist has a lifting capacity ofat least 905 kg
(2000Ib).
17. Position the fork plate assembly (52) using a hoist
and install the pivot shafts (51) and pins (50).
18. Extend the tilt cylinder piston rod and install the tilt
cylinder shaft (49) and pin (48).
19. Run an operational check. Refer to Reach Cylinder
Adjustment in this section for adjustment proce-
dure.
20. Install the forks and load backrest. Add bolt (53).
Crown 2001 PFl3067-5 Rev. 6/09 M9.0-1452-005

02 Rev. 6/09
553
PLATFORM
Reach Assembly CJ\OWJ\
(2)
(1) Tilt & Sideshift Manifold

(2) Tee Fitting Caps
(3) Bottom of Reach Support
(4) Reach Manifold
(5) Top of Reach Support
(6) Top of Reach Carriage
Figure 17161
4. To bleed air from the mast accessory hoses, ener- 5. Extend reach carriage to maximum extension and
gize retract at maximum speed. Hold retract ener- hold for 15 seconds. Retract reach to home posi-
gized for 30 seconds. This will flush all air out of tion at maximum speed and hold for 15 seconds.
mast accessory circuit.
M9.0-1452-006 Crown 2001 PF13067~ Rev. 6109
02 Rev. 6109
554
PLATFORM
mowr. Reach Assembly
6. Tilt the carriage up to maximum extension and hold

for 15 seconds. Tilt down to home position and ac-
tuate tilt down for 15 seconds.
7. Extend the side-shift cylinder to maximum exten-
sion. Energize side-shift right and hold for 15 sec-
onds. Actuate side-shift left at maximum speed to
home position and hold for 15 seconds.
8. Tighten the caps on the tee fittings, ports (1) and
(2) at top of the tilt and side-shift manifold. Torque
to 15.8 Nm (139.5 in Ib). Refer to Figure 17161.
9. Clean area thoroughly.
Crown 2001 PF13067·7 Rev. 6/09 M9.0-1452-007

02 Rev. 6/09
555
PLATFORM
Reach Assembly CJ\OWI'
R1
T2
Bi T1 Bi
L_ _ . J
i
R1 R2
Carriage ,
Hydraulics
(5)
Trucks with
Tilt Only
(5)
Lift Cylinders
(7)
(1) Reach Manifold Block

A*-----'
(2) Reach Cylinder
B.*-----'
(3) TIIVSideshift Manifold Block
(4) Sideshift Cylinder
C1*------+ (5) Tilt Cylinder
(8)
(6) Tilt Manifold Block
(7) Staged Lift
(8) Flow Control
(9) Free Lift
(7) (10) (10) Velocity Fuse
f--)"'-E--_...J.-~---1
Mast Hydraulics
i
I\.. J!
Figure 17057
M9.0-1452-008 Crown 2001 PF13067-8 Rev. 6/09
02 Rev. 6/09
556
PLATFORM
l!J\OWr. Reach Assembly
Reach Assembly Reach Inspection

The reach assembly on your truck is designed to lift,
transport and deposit materials from racks where out- Poly Stop
riggers cannot enter into or under. After the truck has Located at top of the support assembly on either side
been positioned in front of the load and the forks ad- are poly stops. The poly stop prevents metal to metal
justed to the proper height, the reach carriage can be contact when the reach assembly is fully retracted. The
extended. The carriage is extended by "rolling" the poly stop should be shimmed to make contact with the
thumbwheel, located on the multi-task control handle, carriage assembly as reach cylinders are fully re-
away from the operator. Retracting the carriage is ac- tracted.
complished by "rolling" the thumbwheel towards the
operator. Reach carriage speed is varied by the The poly stop uses spacers for correct position. Tighten
amount of thumbwheel rotation. After extending to en- socket head screw, do not over tighten. The number of
gage forks under the load properly, the load is lifted, washers can be determined with the truck operational.
fully retracted and lowered to a safe travel height. The poly stop bumper should compress 6 mm (0.25 in)
to 13 mm (0.50 in) when fully retracted with a 905 kg
Lh WARNING (2000 Ib) load. Use thread locking adhesive to secure

the screw into position. Torque screw 3.2 - 3.6 Nm (28
- 32 in Ib).
Wear appropriate items, such as safety glasses, steel-
toed shoes, whenever performing maintenance work.
Do not place fingers, hands or arms through mast or Reach Cylinder Adjustment
position them at pinch points. Extend mechanism completely. From retracted posi-
In this section you may be required to lift and block the tion, the distance to the top front edge of fork carriage
truck and mast or raise and lower different components assembly should be 1080 mm (42.50 in) or 1030 mm
for removal and installation. Make sure lifting device (40.50 in) if equipped with side shift. (The measure-
and sling are sufficiently rated to withstand the weight ment must be taken at the top of the reach mecha-
being lifted. Never work under or around a truck that is nism). With reach cylinders fully extended, the cylinder
not properly secured. Refer to truck Data Plate for truck rod can be turned to obtain the correct dimension. Re-
weight information. fer to Figure 17067.
It will be necessary to disconnect and remove the bat-
lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
(1) Reach 1080 mm (42.50 in)

(2) w/Side Shift 1030 mm (40.50 in)
lL...lJ \!;{-""'--_~
Figure 17067
Crown 2001 PF13068-1 Rev. 7/07 M9.0-1652-001

01 Rev. 7/07
557
PLATFORM
52
I>5
61
Figure 17068
Disassembly 4. Raise mast and put two 50 x 100 x 690 mm (2 x 4

x 27 in) hardwood blocks under second stage of
(See Figure 17068) n mast. Extend reach assembly and place 50 x
100 x 200 mm (2 x 4 x 8 in) hardwood block in ei-
1. Remove four screws holding load backrest (not ther left or right channel of reach support assembly
shown) to fork plate (70) and remove load back- (1 ).
rest.
5. Retract reach assembly until column roller (32) on
2. Remove screw (5) in bottom cross member of fork outer arm (25) is resting on hardwood block. The
plate. hardwood block will not allow assembly to retract
3. Remove forks (not shown) from fork plate. when the reach cylinders are removed.
6. Disconnect battery, chock wheels.
M9.0-1652-002 Crown 2001 PFl3068-2 Rev. 7/07
01 Rev. 7/07
558
PLATFORM
7. Remove roll pin (66) from tilt cylinder shaft (67) 16. Remove roll pins (29) and retaining rings (45) from
with brass punch or other soft material rod. locknut (46) at upper end of primary outer arm (25).
Remove two roll pins (68) from pivot shafts (69) at Remove locknut with a hook type spanner wrench.
top of fork plate. Use lifting device or other suitable
17. Remove roll pin (29) and retaining ring (30) from
means to support fork plate, and remove pivot
locknut (28) at pivot center of primary outer arm
shafts.
(25) only.
Remove hydraulic lines from tilt cylinder (62) to
manifold block (not shown) on support assembly. 18. Carefully remove primary outer arm (25) and thrust
(Allow hydraulic pressure to bleed off slowly). Re- washers. Record the location of thrust washers.
move four screws holding tilt cylinder in carriage Use for reference during reassembly.
assembly (61). Remove tilt cylinder, if further dis-
19. Carefully remove secondary inner arm assembly
assembly is required take to a clean working area.
(50). Record the location of thrust washers on pri-
Consult cylinder section of this manual for proper
mary outer arm (25). Use for reference during re-
disassembly procedure.
assembly.
If ball bushing (64) in tilt cylinder rod end requires
replacement, remove retaining rings (65) and use 20. Remove roll pin (29) and retaining ring (30) from
an arbor press to remove and replace it. locknut (28) at pivot center of primary outer arm
(25).
8. Attach lifting device to top cross bar of carriage as-
sembly (61). Remove roll pins (55) in pivot shafts 21. Remove primary outer arm (25). Record the loca-
(54) which connect outer arms to carriage assem- tion of thrust washers. Use for reference during re-
bly. Remove pivot shafts and raise carriage as- assembly.
sembly to clear carriage rollers (40) on inner arm
22. Remove lifting device from primary inner arm (23)
assembly (50).
and attach to reach support (1).
9. Remove roll pin (20) from pivot shaft (21) at rod
23. Disconnect chains and hydraulic lines from reach
end of reach cylinders (33). Remove pivot shafts
support (1). Remove rest of reach assembly from
(21) at rod end. Disconnect hydraulic lines from
truck and set on floor.
bulkhead located near top of reach cylinders. Re-
move roll pin (6) from upper pivot shafts (7) and 24. Remove roll pins (9) in pivot shafts (8) of primary
remove pivot shafts. Reach cylinders should be re- inner arm. Use lifting device or other suitable
placed on support assembly in same position as means to support primary inner arm and remove
they were removed. pivot shafts.
10. Using two lifts connect hoists to primary inner arm
assembly cross brace (23) and to secondary inner
arm assembly cross brace (50). Lift until column
rollers on outer arm assemblies can be rotated out
of support assembly channel.
11. Remove column rollers (40) from secondary inner
arm assembly (50).
12. Remove column rollers (32) from outer arms (25).
Record the number and position of all spacers.
Use for reference during reassembly.
13. Remove roll pins (35) and retaining rings (34) from
locknuts (36) at lower end of secondary outer arms
(52). Remove locknut with a hook type spanner
wrench.
14. Remove roll pins and retaining rings from locknuts
(28) at pivot center of secondary outer arms.
15. Remove secondary outer arms (52) and thrust
washers. Record the location of thrust washers.
Use for reference during reassembly.
Crown 2001 PF13068-3 Rev. 7/07 M9.0-1652-003

01 Rev. 7/07
559
PLATFORM
Reach Assembly CJ\OW"
Bushing Replacement (Reach Assembly NOTE
Components)
The installation tool can also be used effectively to re-
When removing old bushing be sure seating area of move worn or damaged bushings. Various sizes of
bushing is not damaged in any manner. If damage bushings will necessitate use of various sizes of instal-
does occur remove all burrs and rough edges com- lation tools.
pletely.
Ball bushings are removed and installed with greater
When installing new bushings in a lubricated area ease when using an installation tool, refer to Figure
make sure hole in bushing is in proper alignment with 17056
the lubrication fitting to allow proper lubrication flow.
Apply a light coat of grease to bushing seat to ease
NOTE
installation and reduce possibility of damage to new Close inspection ofall new bushings after installation is
bushings. necessary to be sure wear surfaces are intact.
A bushing installation tool, refer to Figure 17055, will
aid greatly in proper installation of new bushings.
(1 )
(1 )
0.5 mm (0.19 in)
/:(\ J1
(2)
(2)
(3)
(3) 3.2 mm (0.125 in)
(1) Bushing Installation Tool (1) Ball Bushing Installation Tool
(2) 0.13 mm (0.005 in) Smaller than (2) 0.13 mm (0.005 in) Smaller than
the Bushing Outside Diameter the Ball Bushing Outside Diameter
(3) 1.6 mm (0.062 in) Chamfer (3) Cut-away View of the Counterbore
(4) 0.13 mm (0.005 in) Smaller than (4) Ball Bushing

the Bushing
Figure 17056
(5) Equal to the Length of the Bushing
Figure 17055
Center Pivot Repair and Adjustment
When replacing thrust washers items 24, 27 and 51 on
both sides of the outer arm assembly, apply a light coat
of grease to all surfaces.
NOTE
Be sure all areas of contact are thoroughly cleaned and
free of any burrs or debris that could damage new
thrust washers.
To property adjust, tighten the nut on the center pivot
assembly snug to eliminate any abnormal drag.
Loosen nut and retighten to 460 Nm (65 in Ib), then
continue to tighten to next nearest groove pin location.
M9.0-1652-004 Crown 2001 PF130684 Rev. 7/07
01 Rev. 7/07
560
PLATFORM
Reassembly 4. Install thrust washer (48) on upper pivot of primary

outer arm (25). Using second lifting device, install
it WARNING the secondary inner arm (50) on outer stud of pri-

mary outer arm (25). Install thrust washer (47),
locknut (46), roll pin (29) and retaining ring (45).
Wear appropriate items, such as safety glasses, steel-
toed shoes, whenever performing maintenance work. 5. Place thrust washer (24) on center pivot of primary
Do not place fingers, hands or arms through mast or inner arm (23) and thrust washer (16) on primary
position them at pinch points. outer arm (25).
6. Install primary outer arm (25) on secondary inner
truck and mast or raise and lower different components
arm (50) and on primary inner arm (23). Install
for removal and installation. Make sure lifting device
thrust washer (27), locknut (28), roll pin (29) and
retaining ring (30) on center pivot, and thrust
washer (47), locknut (46), roll pin (29) and retaining
not properly secured. Refer to truck Data Plate for truck
ring (45) on outer pivot.
weight information.
It will be necessary to disconnect and remove the bat- 7. Place thrust washer (39) on lower pivot of second-
tery from the truck, disconnect tilt cylinders from the ary outer arms (52) and thrust washer (51) on cen-
mast, disconnect electrical connections and hydraulic ter pivots of secondary inner arm (50).
lines. "Control of Hazardous Energy" section provides
8. Slide both secondary outer arms over center pivot
information for performing the above procedures along
of secondary inner arm (50) as well as into lower
hole on primary inner arm (23). Install thrust
washer (27), locknut (28), roll pin (29) and retaining
ring (30) on center pivots of inner arm (50), and
thrust washer (37), locknut (36), roll pin (35) and
retaining ring (34) on lower pivots.
NOTE
9. Use an inside caliper to measure area of support
Before proceeding with reassembly, all parts should be assembly where column roller (32) on outer arm
clean and free of any burrs or rough edges which could will travel, record measurement.
damage new bushings or other parts during assembly.
Apply a thin coat of grease to all bushings, thrust wash- 10. Install column rollers (32) to outer arms (25). Mea-
ers and pivot shafts. sure distance between column rollers with an out-
side caliper. Subtract this dimension from dimen-
1. Refer to Figure 17068. Install inner arm assembly sion obtained in step 9 to determine the amount of
(23) into reach support (1). shims required. Balance out the number of shims
Install pivot shafts (8) simultaneously, rather than (Example: 2 shims right, 2 shims left). If an uneven
one at a time. Pivot shafts are slotted on the end to number of shims are required, note to which side
obtain proper alignment for installation of roll pin the extra shim was added and install all other odd
(9). shims to that side.
2. Install reach support assembly and primary inner 11. Lift unit and install column rollers back into support
arm back into mast and reconnect chain. Remove assembly channel. Place 50 x 100 x 200 mm (2 x
lifting device from reach support and connect to 4 x 8 in) hardwood block in right or left channel of
primary inner arm (23). reach support assembly. Lower reach assembly
3. Install thrust washer (24) at center pivot. Slide one until column roller (32) is resting on hardwood
outer arm (25) onto center pivot stud. Install thrust block.
washer (27), locknut (28), roll pin (29) and retaining 12. Remove hoist from cross brace of secondary inner
ring (30). arm (50).
13. Measure distance between outer arms at top. 335
NOTE
mm (13.25 in). Measure distance between pivot
Refer to Center Pivot Repair and Adjustment, (located blocks welded on fork carriage assembly (61).
in this section) for proper adjustment information of These dimensions should indicate that the outer
center pivot. arms will fit properly in the fork carriage assembly.
Crown 2001 PF13068-5 Rev. 7/07 M9.0-1652-005

01 Rev. 7/07
561
PLATFORM
Reach Assembly Cl\OW"
NOTE
Failure of the outer arms to fit into carriage assembly
it WARNING
AVOID HIGH PRESSURE FLUIDS - Escaping fluid un-
properly indicates inner arm assembly, carriage as-
der pressure can penetrate the skin causing serious in-
sembly, or outer arm assembly is bent or deformed in
some way.
14. Attach carriage rollers (40) to inner arm assembly sure. Keep hands and body away from pin holes which
studs. eject fluids under high pressure. Use a piece of card-
15. Guide fork carriage assembly onto inner arm car-
hand.
riage rollers.
16. Install pivot shafts (54) and roll pins (55). should be considered as a serious medical emergency
17. Install reach cylinders.
- Install pivot shafts (7) and roll pins (6). may occur. Medical attention should be sought imme-
- Extend cylinder manually and install pivot
type of injury.
shafts (21) and roll pins (20).
- Connect hydraulic lines from reach cylinders to
pair of reach cylinders and bled of all air. Before flush-
bulkheads near top of reach cylinders.
ing and bleeding of system inspect all hydraulic con-
18. Place bushings (63) on tilt cylinder (62) pivot studs nections and verify that all filters are installed and
and install tilt cylinder assembly in carriage assem- hydraulic fluid levels are adequate for test. Hydraulic
bly. (Check serial number plate to obtain capacity system must be pressurized during the flushing and
of truck to obtain proper tilt cylinder assembly. This bleeding procedures.
information is also needed to obtain proper fork
plate assembly (70) and tilt cylinder shaft (67). Flushing
19. Connect all hydraulic lines from tilt cylinder to man- 1. Remove hoses from side-shift cylinder and con-
ifold block at top of support assembly. nect them together using a male connector.
20. Position fork plate assembly (70) with a lifting de- 2. Energize SVS side-shift solenoid selector valve,
vice and install pivot shafts (69) and pins (68). actuate manual valve at full speed in order to pump
21. Extend tilt cylinder piston rod and install tilt cylinder hydraulic oil through carriage hydraulics and then
shaft (67) and pin (66). Remove hardwood block back through the filter.
from reach support channel and two hardwood 3. Flush carriage hydraulics for at least 2 minutes, re-
blocks from mast second stage. Remove lifting de- versing flow frequently.
vice from primary inner arm (23) cross brace.
4. Reconnect hoses to side-shift cylinder.
22. Run an operational check on reach assembly. Re-
fer to "Reach Cylinder Adjustment" for adjustment
procedure.
23. Install forks and load backrest. Install bolt (5).
Crown 2001 PF13Ofl8.a Rev. 7/07

M9.0-1652-006
01 Rev. 7/07
562
PLATFORM
Bleeding
1. Fully extend reach cylinders.
2. Block carriage so it can not retract.
3. Remove hose from rod side of left reach cylinder.
4. Energize SVR reach solenoid selector valve, actu-
ate the manual valve to pressurize "A" port to the
carriage. and hold until a solid stream of hydraulic
draulic fluid through mast hoses, reach manifold
and through the tilt-side-shift manifold.
5. Connect hose on left reach cylinder.
6. Repeat above steps for the right reach cylinder.
7. Remove blocks from carriage.
8. Fully retract the reach cylinders.
9. Remove hose from piston side of left reach cylin-
der.
10. Block carriage so it cannot extend.
11. Energize SVR reach solenoid selector valve, actu-
ate manual valve to pressurize "B" port to the car-
riage, and hold until a solid stream of hydraulic fluid
flows out through hose. This is passing hydraulic
fluid through mast hoses, reach manifold and
through the tilt-side-shift manifold.
12. Connect hose on left reach cylinder.
13. Repeat above steps for the right reach cylinder.
14. Remove blocks from carriage.
Crown 2001 PF13068-7 Rev. 7/07 M9.0-1652-007

01 Rev. 7/07
563
PLATFORM
R1
(1) R2
i;·=·~-=·=·=·=·=·=·=·=·~ : ~ -f3- - - i21- -- --r:::·:::·)~L:::.:::.~ - - - - - - - - - 1

i: CBV SV! ! SVS !
:1 ! i !
Ai I . Iss2
I T2
, A !iSS1
BL ~.~.~ J T1 B SVT i
!T2
(4)
R1 R2
Carriage (2)
Hydraulics iT1
L••••••••••••••••••••••••••••• : ~ ~
/
/
HSS/LS~
DCV
(5)
Trucks with
Tilt Only
(5)
Lift Cylinders
(7)
(1) Reach Manifold Block

(2) Reach Cylinder
(3) TiltlSideshift manifold Block
A*-------' (4) Sideshift Cylinder
B*------' (5) Tilt Cylinder
(6) Tilt Manifold Block
C1X-----4 (7) Staged Lift
(8)
r----------- (8) Flow Control
!
!, '-" (9) Free Lift
L_...~ ..,---_-, (10) Velocity Fuse
(9)
(7) (10)
Mast Hydraulics )(- - ·~···1
~...----'
!
L ... J
Figure 17057
Crown 2001 PFl3068-8 Rev. 7/07

M9.0-1652-008
01 Rev. 7/07
564
mown
GLOSSARY
565
CROW"
Notes:
566
GLOSSARY
CJ\owr. Glossary
on the truck such as on platform or in power unit. The

Glossary 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-1457-002 (B-1) 01.2-1457-100
Compartment DIA-1457-Q09 (C-3)
DIA-1457-011 (A-4)
DIA-1457-018 (C-1)
DIA-1457-Q19 (C-1)
DIA-1457-Q20 (C-1)
DIA-1457-Q21 (C-1)
CONNECTIONS
CA201 Distribution Panel +BV Key Switch & Module DIA-1457-002 (C-3) 04.3-1457-001 (1)
Power DIA-1457-005 (A-1)
CA202 Distribution Panel Options Power DIA-1457-002 (C-3) 04.3-1457-001 (1)
DIA-1457-005 (B-1)
CA203 Distribution Panel Lights, Alarms & Precharge DIA-1457-002 (C-3) 04.3-1457-001 (1)
Power DIA-1457-005 (B-2)
CA204 Distribution Panel CAN Connections - Options DIA-1457-002 (C-3) 04.3-1457-001 (1)
DIA-1457-005 (B-2)
CA205 Distribution Panel CAN Connections - Standard DIA-1457-002 (C-3) 04.3-1457-001 (1)
DIA-1457-Q05 (B-3)
CA220 Multi-Task Control Han- HNS, POT1, POT2 & POT3 DIA-1457-Q02 (B-3) 04.6-1457-003 (37,
die DIA-1457-Q06 (B-1) 40,44 & 52)
CA221 Multi-Task Control Han- EDS, FS, RS, SSS, TBS & DIA-1457-002 (B-2) 04.6-1457-003 (42
die TDS DIA-1457-Q06 (B-2) &44)
CA225 KYS Truck ON & OFF DIA-1457-002 (A-4) 04.0-1457-001 (19
DIA-1457-Q06 (B-3) &24)
04.0-1457-100 (18
& 23)
Crown 2009 PF17436-1 M10-1457-001
567
GLOSSARY
Glossary CJ\OWI'
CONNECTIONS (Continued)
Location Function Diagram Paris Breakdown
CA401 ACCESS 3 ACCESS 3 DIA-1457-003 (B-3) 04.0-1457-003 (43)
DIA-1457-004 (B-2) 04.0-1457-102 (43)
DIA-1457-007 (B-1)
DIA-1457-018 (B-3)
DIA-1457-019 (B-3)
DIA-1457-020 (B-3)
DIA-1457-021 (B-3)
CA402 ACCESS 2 (AC) ACCESS 2 (AC) DIA-1457-003 (B-2) 04.0-1457-001 (1)
DIA-1457-008 (B-1)
DIA-1457-018 (A-1)
DIA-1457-020 (A-1)
CA404 Contactor Board Control Fuse Block DIA-1457-009 (B-1) 04.1-1457-350
04.1-1457-400
CA405 ACCESS 1 ACCESS 1 DIA-1457-Q02 (B-1) 04.8-1457-001 (1)
DIA-1457-010 (B-1)
CA406 Capacity Display Moni- Capacity Display Monitor DIA-1457-002 (C-2) 04.8-1457-001 (1)
tor (COM), near (COM) DIA-1457-010 (B-2)
ACCESS 1
CA407 Power Unit Input to Freezer/Corrosion DIA-1457-011 (A-2) 04.9-1457-001
Distribution Panel
CA408 Steer Tiller ECR7 DIA-1457-002 (A-3) 06.0-1457-005 (68)
DIA-1457-007 (B-3)
CA41 0 ACCESS 4 BNEG, BRK1, +BV, In/Out & DIA-1457-002 (B-2) 04.0-1457-003 (40)
Module Power DIA-1457-013 (A-1) 04.0-1457-102 (40)
CA411 ACCESS 4 BRES1, BRES2, ED1, Sole- DIA-1457-002 (B-2) 04.0-1457-003 (40)
noid Valve Negative & Switch DIA-1457-013 (A-1) 04.0-1457-102 (40)
Inputs
CA412 ACCESS 4 BDI, CAN, ECR V-Comm & DIA-1457-002 (B-2) 04.0-1457-003 (40)
CHs, FS, LS & RS DIA-1457-013 (C-2) 04.0-1457-102 (40)
CA413 Beneath ACCESS 1 D-Comm Supply DIA-1457-010 (A-1)

CA414 Beneath ACCESS 1 Specials Switch Input DIA-1457-010 (A-1)
CA417 Near Mast Cable HGTRS2 DIA-1457-002 (B-2) 07.2-1452-001 (27)
DIA-1457-010 (B-2) 07.2-1452-003 (27)
DIA-1457-029 (B-2) 07.2-1452-005 (27)
07.2-1452-100 (27)
07.2-1452-200 (58)
CA418 Right Side of Power Unit Mast Cable Connection DIA-1457-014 (A-2)
Crown 2009 PF17436-2

M10-1457-Q02
568
GLOSSARY
CJ\OWr. Glossary
CA425 ACCESS 2 (DC) ACCESS 2 (DC) DIA-1457-004 (B-1) 04.0-1457-100 (1)
DIA-1457-008 (B-3)
DIA-1457-019 (A-1)
DIA-1457-021 (A-1)
CA426 Motor Compartment ECR3 DIA-1457-004 (C-1) 02.2-1457-050 (15)

(DC) DIA-1457-008 (A-3)
CA438 Thermo Assist PHS DIA-1457-026 (B-3)
CA439 Thermo Assist Heated Pad Controller Power DIA-1457-026 (B-4)
CA440 Top of Motor Compart- CAN Service Connection DIA-1457-010 (B-3)

ment DIA-1457-Q26 (B-2)
DIA-1457-028 (C-1)
CA441 Thermo Assist Inside Back Pad DIA-1457-026 (B-4)

CA443 Thermo Assist PHS DIA-1457-026 (B-2)
CA444 Thermo Assist 12 V Power Supply DIA-1457-026 (B-1)
CA445 Thermo Assist Heated Pad Controller Power DIA-1457-026 (B-3)
CA490 Thermo Assist Thermo Assist Power Supply DIA-1457-026 (B-2)
CA607 Floorboard Floorboard, BRS1, DMS1 & DIA-1457-015 (B-1) 01.0-1457-052 (50)
ENS
CA609 Near M3 BRK1 DIA-1457-002 (A-3) 05.3-1452-100
DIA-1457-015 (B-3)
CA612 Manifold Block Load Sense DIA-1457-002 (B-4) 02.4-1457-003 (40)
DIA-1457-016 (B-1)
CA613 M2 (AC) ECR6 DIA-1457-003 (C-2) 02.2-1457-001 (14)
DIA-1457-008 (A-1) 02.2-1457-100 (14)
DIA-1457-016 (B-3)
CA614 M2 (AC) TS2 DIA-1457-003 (C-2) 02.2-1457-001
DIA-1457-008 (A-1) 02.2-1457-100
DIA-1457-016 (B-3)
CA615 Beneath ACCESS 1 Power Options - FNS DIA-1457-014 (B-1) 04.8-1457-001 (4)
CA622 Mast Cable SVR Positive DIA-1457-002 (A-2) 02.4-1457-200 (2)
DIA-1457-014 (C-2)
CA623 Mast Cable SVR Negative DIA-1457-Q02 (A-2) 02.4-1457-200 (2)
DIA-1457-014 (C-2)
CA624 Mast Cable SVT Positive & SVS Positive DIA-1457-002 (A-2) 02.4-1457-200 (11,
DIA-1457-014 (C-2) 15 & 20)
CA625 Mast Cable SVS Negative DIA-1457-Q02 (A-2) 02.4-1457-200 (20)
DIA-1457-Q14 (C-2)
CA626 Mast Cable SVT Negative DIA-1457-002 (A-2) 02.4-1457-200 (11
DIA-1457-014 (C-2) & 15)
Crown 2009 PF17436-3 M10-1457-003
569
GLOSSARY
Glossary Cl\OWI'
CA630 M1 ECR1 DIA-1457-003 (C-3) 03.1-1457-001 (14)
DIA-1457-004 (C-3)
DIA-1457-007 (C-3)
CA631 M1 TS1 DIA-1457-003 (C-3) 03.1-1457-001
DIA-1457-004 (C-3)
DIA-1457-007 (B-3)
CA645 Near Mast Cable ECR2 DIA-1457-002 (A-4) 07.2-1452-001 (24)
DIA-1457-014 (B-3) 07.2-1452-003 (24)
07.2-1452-005 (24)
07.2-1452-100 (24)
07.2-1452-200 (78)
CA647 POT4 on Outer Reach POT4 V-Comm DIA-1457-003 (C-3) 09.0-1452-003 (72)
Carriage DIA-1457-004 (C-2) 09.0-1452-102 (72)
DIA-1457-014 (C-2) 09.0-1652-001 (76)
CA648 POT4 on Outer Reach POT4 12 V Power Supply DIA-1457-003 (C-3) 09.0-1452-003 (72)
Carriage DIA-1457-004 (C-2) 09.0-1452-102 (72)
DIA-1457-014 (C-3) 09.0-1652-001 (76)
CA649 POT4 on Outer Reach POT4 DIA-1457-003 (C-3) 09.0-1452-003 (72)
Carriage DIA-1457-004 (C-2) 09.0-1452-102 (72)
DIA-1457-014 (C-3) 09.0-1652-001 (76)
CA650 Left of Steer Tiller CAN Connection DIA-1457-017 (A-1)
CA651 ACCESS 5 ACCESS 5 Electronic Power DIA-1457-003 (B-1) 04.0-1457-005 (89)
Steering DIA-1457-017 (B-1)
DIA-1457-018 (C-3)
DIA-1457-020 (C-3)
CA652 Steer Tiller RPS2 DIA-1457-003 (B-1) 06.0-1457-104 (83)
DIA-1457-017 (A-1)
CA653 M4 ECR4 DIA-1457-003 (C-1) 06.2-1452-001
DIA-1457-017 (A-2)
CA654 Undercarriage RPS1 DIA-1457-002 (B-4) 06.0-1457-200 (5)
DIA-1457-003 (B-1)
DIA-1457-013 (C-4)
DIA-1457-017 (A-2)
CA661 Near Mast Cable Power Options - LGT2 & LGT3 DIA-1457-014 (B-2) 04.9-1452-052 (35,
Work Lights 46 &47)
CA662 Near Mast Cable FAN5 & LGT4 DIA-1457-014 (B-1) 04.9-1452-050 (9)
CA663 Between ACCESS 2 & RES26 CHS +BV DIA-1457-002 (B-2)
Mast DIA-1457-011 (B-1)
CA664 Between ACCESS 2 & RES26 CHS BNEG DIA-1457-002 (B-2)
Mast DIA-1457-011 (B-1)
CA665 Near Battery Compart- BRES1 & BRES2 BNEG DIA-1457-002 (B-2) 01.2-1457-100 (13)
ment DIA-1457-014 (B-4)
M10-1457-Q04 Crown 2009 PF17436-4
570
GLOSSARY
CJ\OWI' Glossary
CA667 Near Battery Compart- BRES1 & BRES2 Input DIA-1457-002 (B-2) 01.2-1457-100 (13)
ment DIA-1457-014 (B-4)
CA668 Between ACCESS 2 & CHS V-Comm DIA-1457-002 (B-2)

Mast DIA-1457-014 (B-3)
CA669 Between ACCESS 2 & CHS Input DIA-1457-002 (B-2)

Mast DIA-1457-Q14 (B-3)
CA671 Right Side of Power Unit POT4 with Room for Freezer/ DIA-1457-003 (C-3) 09.0-1452-003 (72)
Corrosion Heater DIA-1457-004 (C-2) 09.0-1452-102 (72)
DIA-1457-014 (B-3) 09.0-1652-001 (76)
CA672 K3 Positive & Negative Accessory DIA-1457-Q02 (A-1)

+BV DIA-1457-009 (B-3)
CA673 K3 Positive & Negative Accessory DIA-1457-002 (A-1)

BNEG DIA-1457-009 (B-3)
CA803 Power Unit RES6 BRES2 +BV DIA-1457-002 (B-2) 01.2-1457-100 (13)
DIA-1457-011 (C-1)
CA804 Power Unit RES6 BRES2 BNEG DIA-1457-002 (B-2) 01.2-1457-100 (13)
DIA-1457-011 (C-1)
CA805 Power Unit RES5 BRES1 +BV DIA-1457-002 (B-2) 01.2-1457-100 (13)
DIA-1457-011 (C-1)
CA806 Multi-Task Control Han- RES10 (POT3), RES11 DIA-1457-002 (B-3) 04.6-1457-001
die (POT1) & RES22 (POT2) DIA-1457-011 (C-2)
CA807 Distribution Panel 12 Pin Freezer/Corrosion Dis- DIA-1457-002 (C-3) 04.9-1457-001

tribution Panel DIA-1457-011 (B-1)
CA808 Distribution Panel 5 Pin Freezer/Corrosion Distri- DIA-1457-002 (C-3) 04.9-1457-001

bution Panel DIA-1457-011 (A-2)
CA81 0 Power Unit RES5 BRES1 BNEG DIA-1457-002 (B-2) 01.2-1457-100 (13)
DIA-1457-011 (C-1)
CA812 CHS CHS +BV DIA-1457-002 (B-2)

DIA-1457-011 (A-1)
CA814 Power Unit +BV Jumper C49 & C26 DIA-1457-Q11 (B-1)
CA815 Power Unit BNEG Jumper C49 & C26 DIA-1457-011 (B-1)
CA816 Floorboard RES13 (BRS1), RES14 DIA-1457-002 (B-2) 01.0-1457-050 (55)
(DMS1) & RES15 (ENS) DIA-1457-011 (B-3)
CA817 Multi-Task Control Han- RES8 EDS BNEG DIA-1457-011 (B-2) 04.6-1457-001 (7)
die
CA818 Multi-Task Control Han- RES8 EDS +BV DIA-1457-011 (B-2) 04.6-1457-001 (7)
die
Crown 2009 PF1743M M1D-1457-005
571
GLOSSARY
Glossary CJ\OWI'
CONNECTIONS (Cont/nued)
CA819 ECR2 RES19 ECR2 +BV DIA-1457-002 (A-4) 07.2-1452-001 (24)
DIA-1457-011 (B-1) 07.2-1452-003 (24)
07.2-1452-005 (24)
07.2-1452-100 (24)
07.2-1452-200 (78)
CA820 ECR2 RES19 ECR2 BNEG DIA-1457-002 (A-4) 07.2-1452-001 (24)
DIA-1457-011 (B-1) 07.2-1452-003 (24)
07.2-1452-005 (24)
07.2-1452-100 (24)
07.2-1452-200 (78)
CA824 Motor Compartment FAN 1 DIA-1457-002 (A-3) 04.0-1457-005 (79)
DIA-1457-007 (C-4) 04.0-1457-104 (70)
CA840 CHS CHS BNEG DIA-1457-002 (B-2)
DIA-1457-011 (A-1)
CA899 Between ACCESS 2 & Camera DIA-1457-029 (B-2) 10.0-1457-100
Mast
Crown 2009 PF17436-6

M10-1457-006
572
mowr.
WIRING DIAGRAMS
573
CJ\OWI'
Notes:
574
WIRING DIAGRAMS
CJ\OW" Introduction to Diagram Usage
Introduction to Diagram Usage • The truck has been sectioned with one page cov-
ering each section. When options affect the wiring
in a section, an additional page is added which du-
Schematic plicates wiring that is identical and adds the option
wiring. In this way only one page of the truck sec-
• Power up diagram. Illustrates the circuitry involved tion is required for the applicable truck configura-
in getting the truck system to an operating mode tion.
(Can Interface, Access 1,2,3, Controller, Contac-
tor, ect.). • Wiring that is identified by color rather than number
will typically be a cable or wires with vendor com-
• Circuitry which stands alone and is separate from ponentry.
truck operation is shown in block form with the pic-
torials detailing the circuitry (e.g. light package, dis- • Page titles, listed at the beginning of the electrical
plays, wire guidance, freezer condition). diagrams, indicate the subsystem or section of
truck wiring that is covered by each page.
Pictorials
• Terminal board and connector numbering on the
pictorials are in two classes; power unit and plat-
form. Power unit TB's and CA's are even 100's
(200,400,600 etc.) and platform TB's and CA's are
odd 100's (100,300,500 etc.). On manup trucks
(SP, TS, TSP etc.), odd and even 100's will be
present on the wiring diagrams. Man-down trucks,
which don't have a platform (stand-up rider, pallet
etc.), only even 100's will be present.
• Wiring starts at a central location (e.g. distribution

board) and wiring connection points are numbered
with the lowest number odd or even. The next wir-
ing connection point from the distribution board are
then numbered with the next group of 1OO's and so
on for each connection point removed from the
central location.
• Terminal board and connector numbering is se-

quential on each consecutive page. In this way a
wiring address giving a connector number or termi-
nal board number will indicate which direction to
look in the diagrams for the other end of the wire.
When wiring goes to a component and not a termi-
nal board or connector, a reference terminal board
is used and is shown with a dashed line box with
the reference terminal board number in parenthe-
sis. This terminal board will not appear on the truck
and only present as a wiring directory.
• Input/Output arrows may appear at terminal

boards and connectors. These indicate whether
what the wire is carrying is incoming or outgoing.
This is helpful when tracing the origin of the signal
or voltage.
Crown 1991 PF8974-1 Rev. 6/08 DIA-ITD-001

02 Rev. 6/08
575
CROWl'
Notes:
576
WIRING DIAGRAMS
CJ\owr. 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.
Chart 1 - Electrical Diagrams Index
Title Page Number Revision
Electrical Schematic - All Trucks DIA-1457-002
Electrical Schematic - AC Traction/Hydraulics DIA-1457-003

Electrical Schematic - DC Hydraulics DIA-1457-Q04
Distribution Panel DIA-1457-005

Multi-Task Control Handle DIA-1457-006
ACCESS 3 - TCM & Motors DIA-1457-007
ACCESS 2 - HCM DIA-1457-008
Fuse Panel DIA-1457-Q09
ACCESS 1 - OM & Key Switch DIA-1457-Q10
42 inch Freezer/Corrosion Package DIA-1457-Q11 01 - 7/09
48 inch Freezer/Corrosion Package DIA-1457-012 01 - 7/09
ACCESS 4 - VCM DIA-1457-013
Mast Cable & Options DIA-1457-014 01 - 9/09
Brakes & Floorboard DIA-1457-015
Power Unit Hydraulics DIA-1457-016
Electronic Power Steering Control DIA-1457-017
42 inch Power Cables - AC Hydraulics DIA-1457-018 01 - 7/09
42 inch Power Cables - DC Hydraulics DIA-1457-019 01 - 7/09
42 inch Power Cables - AC Hydraulics European DIA-1457-020 01 - 7/09
48 inch Power Cables - AC Hydraulics DIA-1457-021 01 - 7/09
48 inch Power Cables - DC Hydraulics DIA-1457-022 01 - 7/09
48 inch Power Cables - AC Hydraulics European DIA-1457-Q23 01 - 7/09
Thermo Assist DIA-1457-024 01 - 7/09
Thermo Assist DIA-1457-025 01 - 7/09
Infolink DIA-1457-026 01 - 7/09
Mast Camera DIA-1457-027 01 - 7/09
Wire Harnesses DIA-1457-028 02 - 9/09
Crown 2009 PF17437-1 Rev. 9/09 DIA-1457-001

02 Rev. 9/09
577
WIRING DIAGRAMS
Electrical Schematic - All Trucks CJ\OWI'
A B c
~. K2.
~. TI'9 K3A. TPl0
UGHTIFAN·
OPTIONS:
~. K3B •
F/C
.00 w0
1 '" "be
~ w
f'
0
I "zw
c
ACCESS 1
OM &l"8~ HTS1/lMS1/ZSs-AlRMT RAS
~S5-llIRMT LWR
•
REMOTE RAISE!
LOWER
~
'"
III
~
., ~
III
1
~~ I
III ...J
CMOS-1
0 OR
t;~
g:fll,g ~5 w
0 PRIMARY RAISE
c CM05-13
I-
ILMS3IZ~~S CUTOUTS '"
~ T ~ STATUS ALARM TPl2
CM05-14 r-<""
OR
ZONE SELECT SWITCH
~C-
III
CZN~t
CM05-2 2
ALM1
B ~~ L!
~~S) C"It~~
LGS1.- DOME LIGHT
<>--;:g)i.GT1
~
SVT ~.~.
CM11.JO CM11-33
V~OMM
;=e- SVS.
IDESHI
CM11-29 CM1l-3
oLMS.
n HGTRS
CAPACITY DATA
'1~~R.
SVR
~
REACH
CM11-28
CM11-24
CM1l-4
oBRES2
CM11-14 r--
• oBRES1.
BRS30
~~fi~
+ cZN~
D-
-e ·r
CM11-18
CM11-9
~ CAN_L
CM1l-17 ~ B R S 2
2
---e ~
~
CM11-13
HOIST CM11-25
CM11-15 H BRS1
« ~DMS2 II
2
~ ~
CM11-19
-e
CM11-28
CM11·12 f.-.<LENS
CM11-27 • -oFLSo-
SV POWER OUT CM10-4 .., CM11-20
.~ORS
~ EDCOILPOS CM11-1 I
I
CM11-21
oCHS.
.~
CM11-22 f-" SS~
I
CM11-23
FAN1~
I
I
CM11-32 TDii'-,; ~
CM11-31 CM11-16
HN~",----
COMPAR~~'e"
I
I CM11-5
TP6
~ CM1~
I
I
DVCC
OUT
LE~b
LED-
GND
RS
CMl2-15
W I
8:'~
CR5
FU3
CA411-3b
CM11-34 ~'
I
CM12-14 I - -
CM12.JO
t1: LED+gJ
LED-
GND
FS
3
1/ FU2
l5A
l5A
CM10-3 J
CA41o-9-, I
II
CMl2-32
CMl2-24
CMl2-l3
CM12-8
CM12-7
B ~~T1ON
3
ED1 I <> 1.
sXb CMlO-S.J I CM12-5
CMl2-l9
CMlO-S - I <~~ElLOWER
_.-..... CM1o-7 CMl2-18
I <0 1.9
..L 0- CM1o-l2 CM12-l6
~®T[SSORY
ED2
'" •
~
_._....!
~Wd
~Q
CM12-31 DISTRIBUTlON BOARD
L---.S1.
T1LLER
8t>tl~ RPSl .. CAN H TP7 2
~17 +5V
ND
~ /
~~LE
CMl2-35 TP6
COPi ANALOG
~~tlt-21 CM12-34
V~MM CAN_L
CM12-33
-Q
SIGNAL
~~ CM12-25
4-20 MA ANALOG
LS
SECONDARY 8t>tlMLK +12V
MAST HEIGHT ~11 CMl2-26
CM12·2 CAN...-tl 2
~MU-l0
BOI+BV
CM12-1
~ 4
4 MODULE POWER
CM12-3 CM1o-2 hV~MM
CMlo-10
- KYS
~ TR1 CR3j
CM1O-l
EO IN CM11-2
CM1O-11
fa51 BNEG
.I .~
START CM12-4
~ Lr.
oACC "'.:r-
CR4 TP11 K1
15A IGN ~ K1 EDS
I ~ TP1
OFF l!: CR2
IlQ I
-v- 36V
A
+llil
B c
146670 B 1 of 3
Crown 2009 PF17437-2

DIA-1457-002
578
WIRING DIAGRAMS
CJ\OW" Electrical Schematic· AC Traction & Hydraulics
A B c
ELECTRONIC POWER STEERING
ACCESS 5 BRN TS4

THERM CA653-4
<p
:e
SCII(AC) CA651-16
RPS1 ~
COMM CA653-6 COMMIBlK
~~~gLE If;, CA651·9 r -CA651-4
+5V CA65~1
POSITION +5VIREO
1 RPS2-A II+5V CA651-3- - - _I
- r
I
-CA651-3 CHI.
CA651-5
~2 MVHT l'CR 1
RPS2 :r/" ~~l:l1 _ ___ ...J CA65~
CHB CA653-3
U
BlBLU
I
~
STEERTlUER COMM
RPS2-B I
POSITION +/" V M4
CA651-10 ;;:
::: w
FU4
@
V-COMM
51. FU12
~:Wfk CA65Hl
CA651-15 CANL""""
501.
-<B "A65'·'3
CAN H /
ACCESS 2
HCII(AC)
THERM CA614-1 BRN TS2

CA402-16
CA614-2 BRNlBLK <+r" I 2
2 COMMI CA61~2 COMMIBlK
CA402-4
CA402-3
CA402-5
CA402~
+12V
CHA
CHB
CA61~1
CA61~
CA613-4
U
+VIREO
MVHT
BlBLU 8
;;.,..
~
V
W ~~ M2
@
~~~k CA402-15
CAN L
FU9
6001.
~- CA402-23
CAN H /"
ACCESS!
TCII (AC)
3 CA401-9 ~ TILT ~~¥!"ON 3

~ FAN3 ACCESS 3
CA401-8 L...S K
~~ FAN4
ACCESS2e
1 CA401-3
CA401-4
COMM
+12 V I CA63G-1 +12V/RED
I CA63G-2 COMMIBlK~
CHA C ~ MVHT CR1
CA401-5
TRAVEL AlARM CHB CA63O-4 BlBLU
CA401-16 CA401-8
ALM2
O B CA401-2 THERM CA631·1 BRN TSl
CA401-16
CA631-2 BRNlBLK<+r" I
~
U
V
~M1
-
:::
'U'
w
CA401-1 +BV KYS

@
FU10
-
~
CA401-23
CA401-15
~
500 A CAN L
4 w II: '"::> 4
'"::> C)
III
~
II:
~
III
~
C)
w
!~
~
g:
~
~
§
Z
-J
0
t>
Q
'"::>
III
~
0
Q.
C)
w
Z
+
<
+
III
~
t>
w
Q w
III
..
A B c
146670 B 2 of 3
Crown 2009 PF17437·3 DIA-1457-003
579
WIRING DIAGRAMS
Electrical Schematic - DC Hydraulics CJ\OWI'
A B c
ACCESS 2
HCM(OC)
1 ~ONTACTOR 1
COMM CA42&-2 COMMlBLK
~RNEG CM25-2
CM25-1
+11.3V CA426-1
+VIREO~ M2
~~~oURCE CHA CA42&-3 IWMT '-"C
CM25-13
CHB CA426-4 BlBLU
CM25-14
FU4 MODULE POWER @

5A ~~~3
I-"~'-'-'---
;
..
, _._.- ........._._......=FU90
...._._.__..._.__.......__._._....................._._.. . . . . -_ ..~
300 A FU9
800 A
e p-
CM25-18 ~
CM25-19 CAN_L
0 /
...... _._._.. ......_._ .._. .._....._._._.- . .=FUll0

........__.-.. ._-_......_._... _..... _......
300 A
~
L-@-
FUll0 ...... P2
M3
300 A
2 2
ACCESS 3
TCM(AC)
~TILT~~mON
CM01~
U 4
~~'I
CM01~
PK
~ FAN40 CMOl-3
+12 v IrCA63G-l +12 VIREO
ACCESS 2
CMOl-4
COMM I CA63G-2 COMMlBLK$
~FAN60
CHA CA630-3 AlWHT "CR
CMOl-5
DC HYD MOTORS CHB CA63O-4 BlBLU
CM01~
THERIA CA631·1 BRN TS1

CM01·16
• TRAVEL~
CM01-18
CA631-2 BRNlBLK<+r'" I
~ U
® ~
v V Ml M1
CMOl-2
-~
W
3 @ 3
CMOl-l +BV KYS
FU10 I~
I~
CM01·23
CMOl-15
~
SOOA CAN L
w « '":::>
'":::> C)
'"
«
'"« ~ ~ C)
w ~
~
Q. Z 0
'":::>'"
(J
w W -J Q.
«
Q.
-J
:::> 0(J C)
w
~ 4
0 z
4 ~ ~ 0
fil
+ ::l;
w
'" u.
0
'"
< (J
A B c
146670 B 3 of 3
Crown 2009 PF17437-4

DIA-1457-004
580
WIRING DIAGRAMS
CJ\OWrl Distribution Panel
A B c
Ir-;=========================-290~2902
1 CA225-3 +BVK1
CA22S-2 KYSKYS
+BV Kl START
IGN
rr~~~~~~~~~~~~~~~~~~~~~~~~~290~~Afc.illn~6~~~~
2905 CA411-2 VCM ED IN
2906 CA405-3 ACCESS 1
2907 CA402-1 ACCESS 2 (AC ONLY)
2908 CA401-1 ACCESS 3
1 Ir-;==================~iQ!2909CA41~1 +BVACCESS4
2910 CA404-16 FU4 ACCESS 5 (AC~
1
2910 CA404-16 FU4 ACCESS 2 (DC
-+1"UJ.~~,+:f======================22911 CA407-2
2912 (CA401) Ff
FAN3
r
__ ~C~A2~2rOllU(:§(G~RA~rJ)ll~2~3~4~5~8M7~8~9~1~1~
U -,
~
CA202 (BROWN)
~ ~r.;,:;TP2 TP3 ....,1----11----..,.,~

r 5 b I - - + - - - - - - - - - - - 2 9 5 5 CA662-3 +BV LGT4 STROBE
~ ~ TKl ~r-t_+;~
-iK2Hf-TP-41.... 2956 (CA662) +BV FNS & LGT2Jl.GT3
+TP4 "'--f--+-i8
9 b 1 - - + - - - - - - - - - - - - - 2 9 7 5 CM04-14 FU8 CAMERA
TP5
TP9 i==E~t~:======;~~~~~ CA8~2
11 51345105
(CA4<14) THERMO ASSIST
CAMERA BNEG
MONITOR
543 (CA661) SPLlCE19 BNEG LGT2Jl.GT3II.GT4IFAN5
CR2 CA203 (GREEN)
TPl1 - 1 509 (CA401) SPLlCE04 BATT NEG
6A2OO
2 2913 CA824-1 COMPARTMENT FANS
3 2914 (CA440)ALM2-1
4 2919 CA406-1 COM +BV
5 1 H - - - - - - - - - - - - - - 2 1 2 (CA404) SPLlCE10 +BV
2 VR1 5601 TP12 6
7
29251<3-10 KllK2 TO K3 COIL
5951 CA405-2 Al.Ml
2
8 209 (CA404) SPLlCE10 +BV
Rl 9 2916 (CA41T) LGS1-l
560 Ili 2917 (CA440) ALM2-2
-11 510 (CA404) SPLICE04
1 2987 (ACCESS 2) BUS PRECHARGE (DC)
TR2 CR5 TP61 TR3 CR6 29n (ACCESS 2) BUS PRECHARGE (AC)
:r
39
6A2OO ':r
5.6
6A200
,.--1
CA204 (BLACK)
2
t--3
1---4
~5
.t----;:::{I6gj:tt======:Jl~2t_======017
I - 7 018 CA406-3
CA406-4 COM
COM HIGH
LOW
.... 8
Jl R2 .... 9
121 :=~
TP7 CA205 (GRAY)
1
2
..
1
3
8. 001 CA405-8 ACCESS 1 CAN_H
002 CA402-23 ACCESS 2 CAN HI1all~
028 CA42S-18 ACCESS 2 CAN HIGH DC
003CA401-23 ACCESS 3 _
3 3
4
4
_CA412-2 ACCESS 4 CAN H 3
5 oo5CA44 ~1 SERVICE PLUG
TP8 6 006 CA85O-4 ACCESS 5 CAN_H
6
7 OO7CA650-3 ACCESS 5 CAN_H
8
9
5
3 .
4
2, 8
008C ~2 SERVICE PLUG
009CA412-1 ACCESS 4 CAN_L
010CA401-1 5 ACCESS 3 CAN_L
011 CA402-15ACCESS 2 CAN 'lCI
11 027 CA42S-19 ACCESS 2 CAN:L DC
1
012 CA405-9 ACCESS 1 C _L
BOARD LAyour
TEST POINT OESCRJPTIONS:
TPI - BNEG KllK2 COIL
PIN 1~8 CA201 TP2 - KEY SWITCH START
12't..:...:...:...h (GRAY) TP3 - KEY SWITCH IGN (BEFORE Kl TIPS)
A A
A TP4 • +BV KEY SWITCH INPUT AFTER Kl
v TP5 - EO SWITCH INPUT
V V V
l TP6 - HCMlTCM +BV PRECHARGE
~ ~ J PIN1~6 CA202
(BROWN)
TP7 - CAN HIGH
A;j 12 't..:...:.:.:.: 7 TP8-CANLOW
V'" TP9 - FU8 SUPPLY TO K2 CONTACT
PIN1~6 CA203
4 I Kl RELAY I ~~ 12 't..:...:.:.:.: 7 (GREEN)
TP10 - K2 CONTACTS TO FAN/LIGHTS
TP11 - K11K2 COIL POSITtVE
4
I K2RELAY I PIN1~8 CA204
TP12 - Al.Ml BNEG FROM DRIVER
A A A A;j 12 't..:...:.:.:.: 7 (BLACK)
V
v ....
V V
P1Nl~6 CA205 NOTES:
~ ~ ~ ~~ 12 't..:...:.:.:.: 7 (GRAY) • SHUNT/JUMPER ON Jl MUST BE PRESENT FOR CAN NETWORK OPERATION
A;j
v~
A B c
146671 B
Crown 2009 PF17437-5 DIA-1457-005
581
WIRING DIAGRAMS
Multi-Task Control Handle l!J\OWI'
A B c
1 1
MULTI-TASK CONTROL
~3~<.i~~. 5.2 V
CA220
(GRAY)
PUF FULL "TRACTION 4.4 V
701 CM12-ll POn +5 v "- 1 ~ HANDlE CENTERED:2.6 V
102 CM12·7 POTl WIPE R
550 CM12-5 POTl VoCOM M
2
3
::: <--s FF FULL "TRACTION· 0 .9V
401 CM12·19 POT2 & 3 +5V 1\ V SPLICE06
"'1
402
4
~ ~3~~tt~~!bv
~ FULL
103 CM12·18 POT2 WIPE R 5 LOWER • 4.0 V
551 CMl2-16 POT2 & 3 V.coMM
/
SPLICE07
l
552
403 6
7
BU<
RED
WHT <?
....s
HANDlE CENTERED. 2.4 V
FULL RAISE =0.9 V
104 CM12~1 POT3 WlP ER 8 POT3 (ACCESSORY)
v
~
553 SUPPLY VOLTAGE -S.2V
9 FULL RElRACT = 4.7V
/2Y562 (CMll)SPUCE03 V.cOMM
V10 ]...JTH\JMB-8AI..1.CENTERED· 2.8 V
5910CMll-5 HNS INPUT 1 -L.. FULL REACH = 0.9 V
HNS
FS
r FORWAAo-'
1 OPTlCAI. I
OPTICAl. SWITCH BOARD L SWITCH I
2 2
;l
CA221 r------~
(BLACK) I RED
O 021 CM12·14 FS INPUT

022 CM12-15 RS INPUT
703 (CM12) SPUCE02 +5 V FSIRS
" 1
2
3
BLK
WHT
V10
I BU<
GRN
555 (CM12) SPUCEOl VoCOMM FSIRS 4 GRN
~I
V ORG
5911 CMll-16TOS INPUT 5
5912CA411~2TBS INPUT
WHT WHT
6
5913 CA411·23 SSS INPUT 7
~S; TBS ~I
561 (CM11) SPUCE03 VCM.cOMM 8 I ______ 1
GRN '- BLU
I LI
I I r REVERSE-I
I, , I
OPTICAl.
L~C~_I
I 0---.0..:.
2903CA201~+BVEDSCOMM- - - - - - - - - - - - - 7 - - " - : - - -:. . . . . . : . 1 EDSv 2 _ _---, RS
2904CA201-4 +BV EDS INPUT ----------~~----'.-.-. ------------'
'-I
KEY SWITCH
3 203~ +BV F U 1 - - - - - - - - - - - - - - - - - - - - + - f C [ 1 J C h
2902 CA201-2 +BV KYS IGN ----------------~-_tr:l
3
2901 CA201·1 +BV KYS START---------------+---j4~Jq--....J
NOTES:
• WHEN IN NEUTRAL, FSIRS WILL MEASURE +5 V.
WHEN FS OR RS IS ACTIVATED. THEY WILL MEASURE BNEG.
4 4
A B c
146672 B
DIA-1457-006 Crown 2009 PF17437~
582
WIRING DIAGRAMS
CJ\OWrl ACCESS 3 • rCM & Motors
A B c
ACCESS 3
TCM
CMOI
2908CA20 1-8 +BV (Kl) 1 +BV KEY INPUT
1 5950 (CMO 1) ED CONTACTOR NEG 2 ED CONTACTOR NEG DRIVER U
1
" SPlICEll 304
302CA63G- , ECRI +'2 V TRAC 3 +12VSUPPLY
588 CAB»-2 ECRI GND TRAC
1 SPUCE08 587
4 T-eOMM SUPPlY NEG ~ 1.11
023 CAB»-3 ECRI CH.A
024 CA63Q-4 ECRI CH.B
;:7
5
6
ECRI CHANNEL A INPUT
ECRI CHANNEL B INPllT
W
V~
'"
3
5924 (CMO ') FAN3 & 4 NEG

" 7
8 FAN3 & 4 NEG DRIVER
9 TPA WIPER INPUT
"-
I
,~
345CA671- , TPA+12V
145CAS71-4 TPAWIPER
573 CA671-5 TPAT-eOMM
" ,
" ,,
Wi
0) • • •
589CA631-2 TSI NEGATIVE
~: ~
lOSCA631-1 TSI SIGNAL CAN_L
" 1.11 MOTOR THERMAL INPllT
2953CA407-3 FIC STATUS SW
5932 (CA44 0)ALM2NEG , F/C STATUS SWITCH INPllT
TRAVEL~MNEGDRWER
w.,.."
N·":"·
2
010 CA205- 10CAN_L
003 CA205-3 CAN_H
v
" CAN_H
I
0
8+.r-"\. +
I 0/ 10
2 I 2
TO FUSE 9
I I I
TOB-BAR
1 1 FAN3 ACCESS 3
f - - r r - - - - - - - - -,
2924(CA425)FAN5+BV(Kl)- -
2949(CM02)FAN4+BV(Kl)- -
2912 CA201-12FAN3I4/6 +BV (Kl)
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
- f - - - - -
: ::
-1' @
~0
'\
I") - - - - - I
I 1 I
5924 CMOl-8 FAN3I4/6 DRIVER NEG I 1 1 1
5925 (CM02) FAN4 DRIVER NEG - -
5941(CM25)FAN6DRlVERNEG - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-<- ---------------- 1
-<- - -L.+ - - - - - - - - - - - - - - '
ECR7 TILLER COMMAND

CM08 +5 VIREO
705
030 CM12·21 +5VB -----------,II------~---I
CM12-23 ECR7 CH.
029 CM12·17 ECR7 CH. A
-f_r -E,-_~---IIS:l ---'' -' !!!..-\$
~T I
~
ECR7
597 CM12-20 ECR7 V-eOMM -------...,:+1-------+-1 COMMlBLK
"
3 3
ECRI TRACTION FEEDBACK (1.11)
:
302 (eMO') SPlICEll ECR
=~~~~~~. ~CRI
024 CA401-6 ECR' CH.
__l_+_'2_V -+I_!'
T-<:DMM --------,If-------J>--i
B--------~fl-----E_--~
~--_iIS~~
_
CA830 +12 VIREO
-'C~OM=MIB"_L_lK$
AlWI'iT
BlBLU
I ECRI
"
CA831 TSI TRACTION MOTOR TlEMP (1.11)
'OS CA401-16 TSI THERMAL INPllT - - - - - - - - t :'-'----+---(ifi1q2' BROWN ~
589 (CA40') SPlICE08 T-eOMM '1_
/ lSll9 ...: B"'R"'O"'WN=IB"'LA"'C"'K"-_ _-'-+'-_-'
CA824 FANI MOTOR COMPARTMENT

+BV(Kl)----------------:~-(ifi1q21
2913 CA203-2 FANI :::299=2 ~~J------_
5922 eMll-31 FAN' DRIVER NEG --------------7--l!;illgI 5973 \?t3J
4 4
NOTES:
o FAN3 IS COOLING FAN FOR ACCESS 3 ON 42" TRUCK. ON 48" TRUCK, FAN 31S COOLING FAN FOR ACCESS 2 AND ACCESS 3
A B c
146680 B
Crown 2009 PF17437-7 DIA-1457-007
583
WIRING DIAGRAMS
ACCESS 2 • HCM CJ\OW"
A B c
AC HYDRAUUCS
ACCESS 2
HCM
CM02
2907 CA201·7 +BV ( K 1 ) - - - - - - - - - - - - - - - - - + - f c 1 l 1 J 1 +BV KEY INPUT
2
1 ~~ ~:~~ ~~~: ~~~V 570 ~ ;~P~~:~~ 1
U
025 CA613-3 ECR6 CH. A 5 ENCODER CHANNEL A INPUT
026 CA613-4 ECR6 CH. B 6 ENCODER CHANNEL B INPUT
7
8
9
w
572 CA814-2 TS2 NEG - - - - - - - - f - ' - - - - - - - '

106 CA814-1 TS2 S I G N A l . - - - - - - d - - - ,
002 CA205-2 CAN H ---------jl..O....---t---+-7--l4!3jCAN_H

011 CA205-11 c A i t L - - - - - - - - - - - ; + - - - - - - - '
e-
O
2 29n CA203-12 BUS PRECHARGE +BV(AI<) -------------,~--;-+--------------' 2

FAN4HCM
2949 (CA401) FAN3 +BV(Kl)---------------7----..J----------'1~
1~
5925 (eM01) FAN3 DRIVER NEG - - - - - - - - - - - - - - - J > - - . 1 . - , - - - - - - - - -
DC HYDRAUUCS
ACCESS 2
HCM CAA25
CAA25 121
F:~~~~~:{IP1_-_+~:____--i~ffi_7-----_fC::Iml ECR3 POS (12 V)
1113···········
:' 23
ECR3 24·········· '35
M2MOTOR Pl--+--<i---,-...,0"'35;------i<l:l2 ECR3 NEG
FEEDBACK TO
ACCESS 2 (DC)
036 ~
5
6
7
8
9
3 3
028 CA205-2 CAN_H----------+-~--+----

027 CA205-11 CAN_L ----------<:----+-f------
+ P2 l-'5"'92o=3'- ~-------- P CONTACTOR NEG

2923 P CONTACTOR POS (36 V)
4
2918 eM04-15 FU4-2 +BV (AI<) ---------~------ +BV KEY INPUT
Be 4
2967 CA203-12 BUS PRECHARGE +BV (AI<) ------7-------.;-~------__=_===:-'
I I FANe M2IM3
2924(CA401)FAN6+BV(Kl)- - - - - - - - - - -)- - - - - - - L 1_ - - - - - - - -@. - -.,
5941 (CM01)FAN6DRlVERNEG- ~ ...,I I - - •- - - J
_I NOTES:
• FAN8 IS ON 48" DC HYDRAUUCS TRUCKS ONLY
A B c
146674 B
DIA-1457-008 Crown 2009 PF17437-8
584
-------------------- ---- ---
WIRING DIAGRAMS
CJ\OWrl Fuse Panel
A B c
CM04
8 FUSE PANEl
CONTROL FUSING (FRONT FUSE VIEW)
201(CM04)+BVBUSBAR---------------+--CM04~43 - ~~ ~~~ =~
202 CM4().4 +BY FUI
- -
- - -
FU2-15A
- - - -- - --
- _ISEY1!V'1!fClj -
- - - -.J
=
FU2-15 A =FU6-15A
L1GHTIFAN
1
2927 (CM04) +BV (ED)
2943CM1Q-9+BV(ED)FU27
~8 -
-
-
-
- ~- - - - - - - - ,
- - _B.!Y<1J~RL - - - -
FU3-15A
BRKIOUTER
=
FU3-15A
BRKllNNER
=
FU7-15 A
FREEZER 1
==:~:I)FU3 ~ ~ II = = =~~UIN]E~Y~J =
FlJ4.6A =
~ ~~;::TBi--=-""--= ~Tc"D'u~;;;"u,,;:;: _'
ELECTRONIC
2910CA201-IO+BV(AK) - - POWER
2918 CMZ5-33 +BV (KYS) ACCESS Z (DC) ~ PWC~ ~"""".L> .... STEERING! FU8-ZA
2954 CASSo-I +BV (KYS) ACCESS 5 (AC)
=~l~~~---------------(4~-qJ-
111
===~'~cfYQPLIOEs= FU5 -15 A
= = J
OCHYO
= 8 FUSE PANa
CAMERA
=
===~LjQ@FKN=
FU6-15A
==~~VL~~~T~AN :J Z1S~- (REAR WIRE VIEW)
SPLlCE10 = = = = J
i
KEYSwrrCH
+BV---------------~::r
OPTIONS
204CM1Z-3 BDI P1 FUS-Z FUS-I FUl-Z FUl-1
Z1Z CA203-5 K2 L1GHTSIFAN I I DO DO
207 (CM04) +BV BUS BAR
Z17 K3-9 Ftc AND THERMO ASSIST ------------+--f-'!r
~
FU7 -15 A
~9-- _- _- _- =
__
F-_REEZE_-_RJO_PT-_ION_S -_ -_ '_
L1GHTIFAN
FU8-Z FUll-I
DO
BRKIOUTER
FUZ-2 FU2-1
DO
FREEZER BRKI INNER
~~:=~~:~-SU-P-P-L-Y-------------~-~ =~c~]RK
I I
== FU8-ZA
= = = = = J
FU7-Z FU7-1
DO
FU3-Z FU3-1
DO
ELECTRONIC
POWER
STEERING!
I I CAMERA OCHYO
I I FU6-2 FUS-l FU4-Z FU4-1
DO DO
K3&EO I I
29Z5 ~ +BV AFTER KEY
511 (CM04)SPLlCE04 BNEG
"
: :
. .j.._---:>-
1-
a
A ~~B::",-
-=:::::O::"
--,
---l AD 0 04
K3
7
0
1
2 RELAY 2
MOUrrrNG
BRACKET
Z17~ +BVFU7~~iY_===============IJ~~'~79~KJ.a~S~---------,
Z19 CM07-1 +BV BEFORE KEY : : ( ) y II
nilS SIDE BO 09 05 03
291114 niERMO ASSIST POWER SUPPLY------------...,jC"Tj~(-------------
(BOTTOM OF RELAY SHOWN)
~
206 CM04-1 +BV FU5 '--':~--'h..:,7~K3-At-1-:4'-- --'-'- WHT ACCY CABLE +BV (10)
I Z15 CAm. ---!-L. _

I 1 - RED ACCY CABLE +BV ALWAYS ON
I 51Z CAS73
•
1 BlK ACCY CABLE BNEG
I I U
I I
2946r@ 15946
I I
I I
I I I Z
2950 CMll-1 ED COIL POSITlVE DRIVER
I ~;; l
5950 CM01-Z ED COIL DRIVER ACCESS 3
3
201 CM04-4 +BV FU I
205 CM04-Z +BV FU5
206 CM04-6 +BV FU6
207 CA404-10 +BV FU7
-,~ 3
TO POWER FUSES
I I 1 ,EDI Z ~ +:
BATT
I1II f-
~~~~z~~J ~6f~3
I I /
•
2967 CA203-1Z BUS PRECHARGE +BV (KYS)
I I
I I
I I 0- I--
ACCESS 3 BNEG TERMINAl.
I I
50Z CM1Q-Z BNEG ACCESS 4
503 CM1Q-10 BNEGACCESS4
S04CM1Q-ll BNEGACCESS4
50S CM1Z.. BNEG BDI 501
50S (CMI7) BNEG LGTI SPUCEOoI
507 CASSo-Z BNEG ACCESS 5 (AC ONLY)
.-: '--- f---
50S CM4o-3 BNEG SERVICE CONNEcnON /.
S09 CA203-1 BNEG START CIRCUIT
510 CA203-11 BNEG DISTBRO
511 KJ.a BNEG TO K3COIL
lZ
4 4
513 CM07.. BNEG
514 CMOS4 BNEG ACCESS 1
0/
515 CM06-Z BNEG COM
ACCESS Z BNEG TE RMINAl.

u NOTES:
• 2967 IS ON EDI ONLY ON 48" TRUCKS
• EUROPEAN TRUCKS ONLY
A B c
146673 B
Crown 2009 PF17437-9 D1A-1457-009
585
WIRING DIAGRAMS
ACCESS 1 • OM & Key Switch cnoWI'
A B c
1 DISPLAY
CM05
1
5955
eM14 1 1 SPECIALS SWITCH INPUT ACCESS 1
5951 CA203-7 ALM1 D1ST BRD -------------~-__ltd2l2
2906 CA20HI +BY (K1) 3
AlM1 NEG DRIVER
+BV
OM
~
514 (CM01) SPLICE04 BNEG - - - - - - - - - - - - - - - + - l d 4
eM13 1 5
BNEG
D-eOMM SUPPLY
~
595
6
7
-==========t====t=tt~89 CAN::L
001 CA205-1 DIST BRD
012CA205-12DISTBRD). CAN H
5956
eM15 1 SPECIALS SW INPllT
eM16 1 SPECIALS SW INPllT
5957
CDMOP11ON
CM06
2919 CA2OJ..4 +BV (K1) 1 l d - - - - - - - + - - o +BV
CAPACITY
515 (CA401) SPLlCE04 BNEG 12 2 BNEG DATA
017 CA204-6 CAN_H 3 CAN_H MONITOR
018 CA204-7 CAN_L 4 CAN_L
2 2
C1.417 WIRED NORMALl.Y OPEN; WHEN
------------4~~t=j:[~K[D===8~~=:H-?-TRS2----.J
5930 C1.411.. HGTRS2INPllT MAST IS BELOW STAGING. SWITCH
583 (eM11) SPLlCE03 SW V-eOMM IS HELD CLOSED
I I (HEIGHT RESET)
I I
I I
LGS1 I I
RES1 C1.410 2951
2916 CA203-9+BV(K1)-----------------~-11-1:.-------<O:-:--O-..:294=1--".N ...\ , - . . : 2 9 4 = 2 ' - -1- "RED
::::::h
I I DOME LIGHT
I I LGT1
506 (CM04)SPLlCE04 BNEG ---------------~-...,_f--TI------------- _ .J
SERVICE CONNECTION
CA440 (CAN DOWNLOAD AND INFOUNK)
005 CA2Os-5 CAN_H 5" 1 CAN_H
008 CA205-8 CAN_L 2 CAN L
508 (CA401) SPLICE04BNEG 3 BNEG 210
202 CA404-3 +BV (FU1) 4
I
•
5 +BV(AK) +BV KEY INPllT
3 203 CAll&-1 +BV TO KYS 6 3
I
2920 I I
I I 2
5931 C1.41G-5 HORN DRIVER
~ HORN
I
I
2914 CA203-3 +BV HORN
'/1
5932CA401-18TRAVELALARMDRJVER-------------'~;_:...------------~\_T1
2917 CA203-10+BV (K1) TRAVEL ALARM - - - - - - - - - - - + - L + - - - - - - - - - - . - Jt'J+ ALM2.(TRAVEL)
1
565 SPLlCE03V-eoMM BNEG------------------'~~'------~>-----
5954 C1.411-21 ORS INPllT ACCESS 4 -----------~'--__i-'-------------
4 4
NOTES:
• POST FURTHEST FROM MOUNTING PLATE IS +
• WIRE 210 JUMPER IS REMOVED FOR INFOLINK OPTION
A B c
146676 B
DIA-1457-010 Crown 2009 PF17437-10
586
WIRING DIAGRAMS
42 inch Freezer/Corrosion Package
A B C
HEATER FOR HEIGHT

ENCODER ASSEMBLY
r---------l CAl14
I WHT C~1g C2&-WHTr.
::m 29104 29131
CA803
"";:;;
1
RJW
!
I
~RES19
PATCH
I
I
I I
I I ~o C~ GRN
RES8
"BRES2
1 I HEATER WHT I CAl20 C26-8LK I I CAl1a
..L 1
1 ...L 29105 CA80a
L - - - - - - - C~..J r. C4~ CAIe3_ 1
RJW
1I e ' - RES5
~ RES26 C~12 I I C4!l-GRN
CAll64 522 524
2
CAl10
1
GRN 'BRES1
I ..---_~_1 ...L
:;- 'CHS
FIC DISTRIBUTION BOARD
CA807
___'>L_
J 29103
~"~fi~B..fl!..!J!:!....---~
Kli:Bl r.....f22l-~52~1=----...J
i~ ~ 1==~CHTfe1~~ij';O~001E=iJl r~4~Al08 .-F«U=1)-4_, .... -<H'--1]~}-"-r~ ~2~3";~!2: :': :': :': :': :': :': :': :': :': :'=I -t _ _-h
"'5~=3", ~,. .C::dl

- -+ ~. L~hl K_12_-A_~L~~~'~[I~~;~:~~~1~]f=n e
RES23
RES11
POn WHT
~;~
WHT
COPIED FROM
MAST CABLE
1.+'--iK11 •
, ',Rf'
T
9
I
'-1", 29111
~ I ED
SPlIC""
PUCE1 528 2
7'"R~~ REt 24 RES22
POT2
L. :~.:.:1.:. .1--D_J-l 3
~3
SHEET
NIW-12 -Iill 1 ~
29128 ~ 29111 ~,
WHT
2 RES8 RES10 2
till 541 5416lWl:!I..-
II R S9
WHT
POT3
WHT
=-.=- I
~ =::=:
r
:::. :::.. :::.. :::.'
Cl.WIB
C1-RIB
~
8
C23-WHT
C23-BLK
Y.Y:I
~-.J
29109
29110 '?!1~
(THS4. TOP OF POWER UNIT DECK)
L--29-1-08-C-'~-1-~'-~58-~=-:-=:::J 12969 I P~13 5S8

559 '7'"''lYy-<:.
L:=====:J~29~1ii11~~ L, • 112910 ~ 551
I R;~~5
IL..:r---cTH=S5::J'I
42" flOORBOARD
(THSS, OMS1, BRS1 & ENS)
3 3
RR 5100 FREEZER CONOmON SCHEMATIC
C1· 8 CONDUCTOR 18 AWG CABLE
~ K12-B eJ· 3 CONDUCTOR 18AWG CABlE STANDARD

FU13 5 CONDUCTOR 18 AWG CABlE LOAD SENSE 1 OR 2
FU1
15A
15A
I 8 CONDUCTOR 18 AWG CABLE LOAD SENSE WIFC
10 CONDUCTOR 18 AWG CABlE TPA
FU14 K12·A (DROPPING) (POT3) C22. 3 CONDUCTOR 18 AWG CABLE LOAD SENSE WIFC
15A RES23 RES14 5 CONDUCTOR 18 AWG CABlE TPA
(BRES2)
C23, C24, C26. 2 CONDUCTOR 18 AWG CABLE
~a
RES4 C25. 2 CONDUCTOR 18 AWG CABLE LOAD SENSE
FU1 KYS K1 EDS (DROPPING) (POn)
15A RES24 RES10 5 CONDUCTOR 18 AWG CABlE LOAD SENSE WIFC
(BRES1) C49 - 5 CONDUCTOR 18 AWG CABlE CHS WIFC
RESS
(DROPPING) (POT2)
RES9 RES12
K11 THS4 '(ECR2)
RES19 NOTES:
.!
-=36V L (EDS)
RES8
'(CHS)
RES26
•
•
DASHED BOXES AND ASTERISK INDICATE OPTIONAl FEATURES
THS4 SHOWN AT AMBIENT OF 21' C (10" F)
(DMS1) < 4' C (40' F). CLOSED
RES13
4 THS5 > 16' C (50' F). OPEN 4
(BRS1) ~ (FLS) ~ • THS5 SHOWN AT AMBIENT OF 21' C (10' F)
~
RES14 U RES8
, U < 50' C (140' F) • ClOSED
> 71' C (160' F). OPEN
K111~ ~:;> K12 (ENS)
RES15 • 36 V BOARDS HAVE RESISTOR
e VOLTAGE DROPPING RESISTORS: 36 V RESISTOR VAlUE 140 OHM, 10 WATT
A B c
146682 C
Crown 2009 PF17437·11 Rev. 7/09 DIA-1457-011

01 Rev. 7/09
587
WIRING DIAGRAMS
48 inch Freezer/Corrosion Package CJ\OW"
A B c
HEATER FOR HEIGHT
ENCODER ASSEMBLY
1 1
~.L.._
1Ft..
: :
!l
: :
jj COPIED FROM
ii
: ; MAST CABLE
SHEET
2
1
2 K12
CA418
iij j TII406
29109
8
it....... 7 ..............•.T·C1.WIB 71-"""".lUJ.L-.JVV'v--, 29110 THS4
(THS4 • TOP OF POWER UNIT DECK)
L.......... 8 ················-·-C:':?1-=.RIBQ:----{Il-""""''''''-----' CA819

532
2911
CA816
3 RR5700S 48 INCH
3
FREEZER CONDITION SCHEMATIC LOWER flOORBOARD
(THS5, DMS1, BRS1 & ENS)
FU13 K12-ll RES15 557

(DMS2)
15A ENS
RES18
FU7
15A
FU14 C1· 8 CONDUCTOR 18 AWG CABLE
K12·A (DROPPING) (POT1) (BRS2)
.
15A RES11 RES18
C3. 3 CONDUCTOR 18 AWG CABLE STANDARD
RES23
8 CONDUCTOR 18 AWG CABLE TPA
0---< C22· 3 CONDUCTOR 18 AWG CABLE LOAD SENSE WIFC
FUl KYS K1 EDS (DROPPING)(POT2) (BRS3) 5 CONDUCTOR 18 AWG CABLE TPA
15A RES24 RES22 RES17 C23. C24. C26 • 2 CONDUCTOR 18 AWG CABLE
C25· 2 CONDUCTOR 18 AWG CABLE LOAD SENSE
(DROPPING) (POT3) 5 CONDUCTOR 18 AWG CABLE LOAD SENSE WIFC
RES9 RES10 (BRES1) C49 - 5 CONOUCTOR 18 AWG CABLE CHS WIFC
K11 RES5
- Weo:J
(DMS1)
RES13
(ECR2)
RES19
"(CHS)
RES26
NOTES:
4) DASHED BOXES AND ASTERISK INDICATE OPTIONAl FEATURES
• THS4 SHOWN AT AMBIENT TEMP OF 21"C (70"F)
< 4"C (40"F)· CLOSED
> 16"C (80"F) • OPEN 4
4 ~S1) • THS5 SHOWN AT AMBIENT TEMP OF 21"C (70"F)
S14 < 8O"C (14O"F). CLOSED
~
> 71"C (180"F). OPEN
K11 (ENS) ~ (FlS) 036 V BOARDS HAVE RESISTOR
RES15 <; RES8 <; 411 VOlTAGE DROPPING RESISTORS; 36 V RESISTOR VAlUE 140 OHM.
10 WATT
A B c
146681 C
Crown 2009 PF17437-12 Rev. 7/09

DIA-1457-012
01 Rev. 7/09
588
WIRING DIAGRAMS
l!J\OWr. ACCESS 4 - VCM
A B c
CM10,...-----------------=-CM-:-:-:l":"1------,
~ ~
2909 CA201-9 +BV (1<1) 1 MOOUlE PWR
502 (CM04) SPUCE04 BATT NEG 2 MOOUlE BATT NEG 3 ·23 .121
2944 CA404-11 +BV (ED) FU3 3 FU3IN(+BV) BRKl-INNERIIlRK2ISV 4 •· .. ·· .. 35
2930 (CA612) rNA +BV POWER 4 SV POWER OUT (+BV)
WHITE CONNECTOR
5931 (CM40)HORN BATTNEG---,,-+---tll:l5 HORN DRJVER(BlW3A)
(TIN PINS)
2945 CA.609-3 +BV (ED) BRKl~ 6 BRKI INNER +BV
1 5918 ~2 BRKl~ BATT NEG 7 BRKllNNER NEGATIVE 1
I~ ~o·::;
:~'"
rl;--iCI8 BRKI OUTER +BV
2943 CA404-7 +BV (ED) FU2---+-+--jc:~ 19 FU2 INPUT (+BV) TO BRKl OUTER
503 (CM04) SPUCE04 BATT NEG 10 MODULE BATT NEG
504 (CM04) SPUCE04 BATT NEG A 11 MOOULE BATT NEG ~~
5917~IBRK1'()BATTN:G I [gBRK10UTERNEGATIVE 3~ 0 ::
2946 CA609-4 +BV (ED) BRKl-O-;r-
CM11 -~ ......
2950 (CM04) EDI COIL POSmvE 1 ED COIL POSITIVE DRVR
2905 CA201-5 EDS OUT 2 ED SWITCH IN (+BV=NORM, 0 V-EDS ACTIVATED)
3 SPARE INPUT (PRIMARY cn
INDEX· OV WITH FORKS DOWN)
5930 CM17.1 HGTRS21NPUT 4 HGTRS2INPUT (+BV-ABOVE STAGING, 0 V-MAST BELOW STAGING)
5910 CA22G-ll HNS INPUT-----~_1~5 HNS INPUT (+5 V-NORM, 0 V-HNS PRESSED)
6
7
8 ACCESS 4
5906 (CA612) PVA NEG ------.+---jc ~ PVA NEG
VCM
11
5918 CA607-5 ENS INPUT ~ENS (ENTRY BARKO V-NORM, +5 V=ACTIVATEDKOPEN)
5903 (CA612) PVL NEG ------+----11 ~ PVL NEG
5952 BRES INPUT 14 BRES (BATT RESKO V-NORM, +5 V-ACTIVATEDKOPEN)
5914 CA607-1 BRSllNPUT 5 BRSI (BRAKEK+5 V=NORM, 0 V-ACTIVATEDKATTENDED)
5911 CA221-5 TDS INPUT 6iTOS (TILT OOWNK+5 V=NORM, 0 V=ACTIVATEDKTQS PRESSED)
2 5920 CAS08-1 BRS2 INPUT
5921 CAS08-2 BRS3INPUT
7 BRS2 (BRAKEK+5 V=NORM, 0 V=ACTIVATEDKATTENDED)
8~RS3 (BRAKEK+5 V-NORM. 0 V-ACTIVATEDKCTR PEDAL PRESSED)
2
5915 CA607~ DMSII2INPUT 9PMS112 (OP PRESENCEK+5 V-NORM, 0 V=ACTlVATEDKATTENDED)
5929 CMI8-6 FLS INPUT (FREE UFTKO V=BELOW FREE UFT, +5 V--ABOVE FREE UFT)
5954 (CM40) ORS ~S (0VER-RJ0E}(+5 V-NORM, +5 V-ACTIVATEDKOP SELECTED)
5953 (CA645) CA669-1 CHS (CHAIN SLACK}(O V=CHAJN llGHT, +5 v-ACTIVATEDKCHAlN SLACK)
5913 CA221-7 SSS INPUT ~. INPUT (SIDESHIFTK+5 V-NORM, 0 V=ACTlVATEDKSSS PRESSED)
5902 (CA612) SVBY NEG ~SVBY NEG CM12
5905 (CA612) SCV NEG SCV NEG CAN L 11:Jl~-7----f'-----009 CA2QS.9 DIST BRD
5904 (CA612) SVL NEG -WSVt. NEG CAN -H 2 004 CA205-4 DIST BRD
=~~~~~~~ i$?jsvANEG BDl+BVINM 3 204 (CA404)SPUCEl0+BVBDI
5927 CMI8-3 SVS NEG I~:~ BDI BATT NEG INPUT 4 505 (CM04) SPLICE04 BNEG BDI
5928CM1~SVTNEG VTNEG POT1V-COMM 5 ~,
5922 CA824-2 FANl NEG 31 MOTOR COMPo FAN DRVR POTl WIPER ~ -r---- ~o:.~~~~~~
5912CA221~TBSINPUT TBS(TILTBACK}(+5V=NORM,OV=ACTIVATED} POT1 +5V 8 ../" 701 CA22G-l POT1 +5V
WITCH V-<:<>MM OUT ECR2 (SECONDARY HT) V-COMM 9 598 CA845-2 ECR2 COMM
2947 CA61().1 BRK2 C+ ------+~: EE;l~41:BRK2RK2 Cc-+ ECR2 (SECONDARY HT) CH. Bill 034 CA845-4 ECR2 CH. B
5947 CA61()'2 BRK2 C- = ECR2 (SECONDARY HT) CH. A 11 033 CA645-3 ECR2 CH. A
:~~~~~~~~~~MM~ 582
V-C:~R~;~:~~6~~~~
FS OPTO IN (+5 V=NEUTRAL, 0 V=ACTlVATEDISELECTED) 4
554 SPLICEOI " "555~=:~~~
021 CA221-1 FWD SW
560 CA607~ FLRBRD SWITCH V-COMM -I , RS OPTO IN (+5 V=NEUTRAL, 0 V=ACTIVATEDISELECTED) 5 022 CA221-2 REV SW
581 CA221-a MTC SWITCH V-CDMM ----" SPLICE03 r-----:<I---703 CA221~ FSIRS +5 V
3 j"L-- 551 (CA220) SPLICE07 POT2 & 3 3
V
582 CA22G-l0 HORN SWITCH V-COMM .... POT2 & 3 V-COMM I &l:lj---+I+--j
583 CA665 BRESl-2 V-COMM---/ ECR7 (STR) CH. A 17 V-COMM
584 CA688-1 CHS V-COMM
58S OR5-2 (CA440) ORS NEG ----l,
POT2 WlPER.~~8:~:=;!tt~~~~103
104 CA22O-5
CA22().8 POT2
POT3 WIPER
POT2 & 3 +5 V SUPPLY 1 401 (CA220) SPLICE06 POT2 & 3 +5 V
585 CA608-4 UPPER FLOORBOARD---l, ECR7 (STR) V-<:<>MM 597 CA408-4 ECR7 BNEG
586 CA608-6 UPPER FLOORBOARD - - l ECR7 (STR) CH. B 2 030 CM08-2 ECR7 CH. B
4--+--- 029 CM08-3 ECR7 CH. A
ECR7 (STR) +5 vl23I:JI---;*-H-+--705 CM08-1 ECR7 +5 V
+5 V REF INPUT & OPTO SUPPL

702 l~
+---++-+---F-
I
LS SIGNAL (4-20 MA "-101 CA612-1 LS ()'20 MA
LS +12 V SUPPLY 301 CA612-2 LS +12 V
SPARE V-<:<>MM REFERENCE

SPARE ANALOG IN (~V)
SP~~~= 558
POT3ANALOG N~~1 ~
4
FSIRS +5 V SUPPLy
RPSl SENSOR V-COMM
RPSl ANALOG INE£!
704 ,,579 CAI54 V-COMM (BLK)
--+---r';'155~q3
755 ~
ANALOG (WHT]
+5 we (RED) ~
~ I4
1
~.::.~.~~.:::~~RPS1SENSOR+5VSUPPLYp= -........ S:G
12.... ·;.;· .... ~ ~

BLACK CONNECTOR
(GOLD PINS}
A B c
146675 B
Crown 2009 PF17437-13 DIA-1457-013
589
WIRING DIAGRAMS
Mast Cable & Options CJ\OW"
A B c
JUMPER
083019--++---v
1 1
OHGOPTIONS
~~:~t=:=~~:§~~~~C~A6~1~5~~~C!A~6~6~2=~tL~:==::J
2956 CA202~ +BV FNS
2955 CA202-5 +BV LGH STROBE
543 CA202-12 BNEG LGT2ILGT3ILGT4IFAN5,----------=~~ ~~§E~~~~~~~L~G~ OHG OR MAST-MOUNT

WORKUGHTS
CA622
MASTCABUBCOMPONENTS CA623
2 2
CM18
5926CA411-28 SVR NEG
5927 CA411-29 SVS NEG
5928 (CA612l
2922 CMll-30+BV SVNEG
SVT por~R~i~~~II~~1
5929 CA411-20 FLS INPUT
~l<t~n~~bC::n~%XsCfOMM
561 CM07~ F/C B- UP MAST ~~=~~~~lm~II~~~~~=
!.'L=:;----ttl_.J;J~W!.l.e!Q.!S.-_'.lV-eOMM
573 (CMOll
FHS SPECIAL ~-e~O~M~M~===j~f==~~~~~:g
SWITCHSPLlCE08
CA671
I'"i:n:t::j:~
I
~3=±:===±l=~~:~~:~~, POT4
TPA
FHS SWITCH SPECIAL
145 CMOl-9 TPS SIGNAL--;-:=====~~=::j~
345 (eM01) SPUCEll +12V 0-
"OPTIONAL"
' - - - - - - - - - - - ' INDICATES REACH
IN HOME POSITION
SECONDARY HEIGHT ENCODER
3 593 CM12-9 ECR2 BNEG

~: ~g:~~ ~g~ ~~B
033eM12-11
, f
v
~
ECR2CHA:~~~~~~~~~~~1~~~~~]
Lf\ ~OM;~ED
S~~~NDARY
wi HEIGHT ENCODER
a 3
CHAIN SLACK SWITCH
564 (CMll) SPLICE03 V_eOMM--------------+---1m§ BLK

5953 CMll-22 CHS INPUT ACCESS 4,----------+------1~ WHT
CA689
42" BATTERY RESTRAINT
C~A8657
5939
563 (CA411) SPLlCE03 V_eOMM BNEG------------+-----1- BRE::=:-J
_ _ _ _ _ _ _ _ _+ BRES1 0
_
5952 eMll-14 BRES INPUT ACCESS 4
4 4
48" BATTERY RESTRAINT
_ _ _ _ _ _ _ _ _ _ _---'~Ci/!.A66_5yBRESl ~,.,C"'A6"""67'-------,
563 (eMll) SPUCE03 V_eOMM BNEG I§II~
5952 eMll-14 BRES INPUT ACCESS 4 - - - - - - - - - - - - . f - - - - - - - - - - - - - - - - - - "
A B c
1466790
DIA-1457-014 Crown 2009 PF17437-14 Rev. 9109
01 Rev. 9/09
590
WIRING DIAGRAMS
CJ\OWrl Brakes & Floorboard
A B c
42" TRUCK FLOORBOARD CAS07 LOWER FLOORBOARD
591. CMII-15 V-COMM B R s I - - - - - - - - - - ' j C - - + - - - j q ItfR""E"'D'- ~:BR:S:<I>---.!!B'!:!LK~,
~ °DMSI BLK
~~~I"lj~~~~~H~~;;=====~t===~~=i.~~~iD~r======;
5915 CMII-19 V-COMM OMSII· V-GOMM ~1:.f<ij;~~DI------:I~EN~SO-....!!BLK~-/ 0
1
1
... TRUCK FLOORBOARD LOWER FLOORBOARD

CAS07
,.. RED BRSI BLK
591. CMII-15 V-GOMM BRS I I
2
?
/SPUCEI6 o DMSI
3 BLK
5934
5933 CMII-19 V-GOMM OMS I
5916 CMII-12 V-GOMM ENS
•
~
5 RED
o ENS
6
BLK
560 (CMII) SPUCEOJ V-<;OM M 6
CAIOI UPPER FLOORBOARD

2 5920 CMII-17 V-COMM BRS2 t I 5935 I BRS22 CAIlMI 2
5936 5919
5921 CMII-18 V-<;OMM BRSJ
5938
2
5937 ~ I BRSJ
3 2 589
2 590 6 -<>21
585 (CMII)SPUCEOJ V-<;OM M
598 (CMII) SPUCEOJ V.(;QM M
./
5
•597
598
I
TRAcnON BRAKE CAIOI TRACTION BRAKE

) I~I ~~ ~ o--OUTERCOlL NEGATIVE
~~g~~~ ~~~~====~V~(~== ~=============~)~= . I-~~::;ELL"'=O:"'E""--~ ~:~~~~~~~~i:
~~~:~2~~~~~~ J f-------+- 0+ O+-OUTERCOILPOSITIVE
(BETWEEN CA609-1 &. 0 V'BRAKES APPUED,

18 V'BRAKES RELEASED, 5.5 V=FOLDBACK)
3 (BETWEEN CA~2 & 3, 0 V'BRAKES APPLIED,
3
8 V=BRAKES RELEASED, • V'FOLDBACKj
... CASTER BRAKE
2947 CMII44 BRK2 FV3 RED

BLK
SUP
RING CASTER BRAKE
CAPSULE
RED
BLK
5947 CMII-35 BRK2 NEG
4 4
NOTES:
• BRSI, BRS2, OMSI & DMS2 ARE ALL WIRED NORMALlY CLOSED - HELD OPEN
• BRSJ & ENS ARE WIRED NORMAl.lY CLOSED AND ARE NOT ACTUATED UNTlL THE CORRESPONDING PEDALS ARE DEPRESSED
• ALL SWITCHES SHOWN WITH NO OPERATOR ON PEDAlS
• A LOGIC ZERO (V-GOMM) RELEASES BRAKES
A B c
146678 B
Crown 2009 PF17437·15 DIA-1457-015
591
WIRING DIAGRAMS
Power Unit Hydraulics
A B c
1 1
101 CA412-25 4-20 MA SIGNAL ------+fi:nT
301CA412-26+12VSUPPlY------~
2930 CA410-4+BV(FU3)-------+--;--i-----------------,
OV=OFF 1 2
5901 CMll-27 SVA NEG
2OV=RETRACT. TILT. SVA
DOWN •OR SS RIGHT
2931
5902 CMll-24 SVBY NEG ~_H-----.,"'O:;:V;::=~O~FF~=_-...!.{s
20V'RAISE.
2932
5904CMll-26SVLNEG-------+--i-i-----,,7.°~V7.-oF~F~;_;;;.___4
2-10 V-LOWER.
MANIFOLD BLOCK ASSEMBLY
2933
OV'OFF 1 2 (MAIN HYD BLOCK· SIDE VIEW)
5903 CM11-13 PVLNEG
20 V' FULL SPD LWR • PVL
2964
OV=OFF 1 2
2 5905 CM11-25 SCV NEG 2
20 V=LOWER. SCV
p I LS ()
5906 CM11·9 PVA NEG ---;~--!...--_..';O;;V-~-0'f!FFh=-~ LOAD SENSOR
2-10 V=ACCY.
2922CM18-1 +BV (Kl) M A S T - - - - - + - - l - L - - - - - - - - - - - - . J
I I
LI (MAIN HYD BLOCK - TOP VIEW)
CAI13 I
I-----------~
•
INTERNAL TO M2 MOTOR
I
303 CA402-3 ECR6 +12 V -----IL..._---;~___fCl11lQ~+~12~V~RE5!D~ ECR6 I
3 571 (CM02-4) SPlICE09 ECR6 NEG 2 NEG BLACK M2 MOTOR I 3
025 CA402-5 ECR6 CH. A 3 CH. A WHITE FEEDBACK TO I
026 CA402~ ECR6 CH. B 4 CH. B BLUE ACCESS 2 (AC),
I
I I
I I
106CM02.16TS2SIGNAL-------1-,,:>.....~--_I;C; I BROWN ~:
572 (CM02-4) SPlICE09 TS2 NEGL V ~: BROWNIBLACK jyJ I
~----- I
NOTES:
• THIS VOLTAGE OBTAINED FROM DVOM CONNECTED ACROSS COIL
• AC HYDRAULICS 0P110N TRUCKS ONLY
4 4
A B c
146677 B
DIA-1457-016 Crown 2009 PF17437-16
592
WIRING DIAGRAMS
CJ\owr. Electronic Power Steering Control
A B c
CA650
29 54CM04-15+BVKl FU4~
2980
580
50
00
~ =~~C~04 BNEG "
2
3
080
081
006 CA205-6 CAN::H v 4
~ CA652
1 OUT A 152 1
~f5~
BlU
1
BlK GNDA 575
RPS2 2 751
RED +5VA
STEER 3 +5VB~ 752
WHT
:0
TILLER 4
GRN GNDB 576
POSInON --, BRN
5
OUTB 151
6
ACCESSS
~ SCII
SPLICEI
I"
I
-------,
w
CI>",
:: i!j
M<4
GNDlBlK >--
I
CA853
7)(1 -
750
CMSI
1
2
3
+BV KEY INPUT
SENSORSUPPlY+5V
I~ Q.. a +VIRED I 1
+5V 753 574
4 SENSOR S-CDMM
I~ re 0 IVWIff 2
CHA 082
083
082 5 ECR4CH.A
~ ill
CHB 083
BlGRN 3 6 ECR4CH. B
I THERM 1I 153
4 7
I
7 ~
K A YEl
I
5 8 CAN NEG
'TS4 BLK GND 577
l _ ------- 6 9 RPSllNPUT
151
RPS2 INPUT B
RPSI
RED 1§
+5V . 754
I
152
RPS2 INPUT A
S~EEL I~
RP WHITE ANALOG 154
STEERING
ANGLEPD SinON -
BLACK i GND 576
080
153 :J'.'!l~-6'R TEMP INPUT
2 8
2
2
081
CAN_H
=
B-
U V CA651 W
e [3] g •.... ··1

16...... 2
c :;:
<
OJ " " "
~
~
;;
"2l
0
;;l
;;
~
Q
~ ~
Q
U
FU12 V M<4
29XX (CM02) +BV (ED) TERMINAL
50A
3 5XX (CM02) BNEG TERMINAL 3
PHYSICAL LAYOUT
NOTES:
• THIS FEATURE IS OPTIONAL
4 4
(0:;:
A B c
143977 B
Crown 2009 PF17437·17 DIA-1457-017
593
WIRING DIAGRAMS
42 inch Power Cables - AC Hydraulics CJ\OW"
A B C
(Q)~
It
,.0
1
] rrEM2
o:t;
~~
~~
0
1
ACCESS 2
HCM
'I'
L- --{ ITEM 5
2 2
EMERGENCY
DISCONNECT
CONTACTOR
(ED1)
( rrEM 10 )
ACCESSS ~
TCM
c&n
ACCESSS
B-
w(Q) SCM
3 3
v(Q)
[
ITEM 15
B-
ITEM PART'
1. 137636-010
2. 137636-009
3. 143961 BUS BAR
CABLE SIZE PART NO.
4. 137636-007
PC.l0 090963
5. 137636-008
084568
6. 084573-254
PC 14 084569
7. 084573-255
PC 12 084570
8. 084573-256
PC.1 084571
9. 084572.J61
PC 110 084572
10. 084572-344
PC 210 084573
11. 084572-341
4 PC 310 088479
12. 084572-342 4
PC 410 137636 NOTES:
13. 084572-343
14. 137634 BUS BAR • us TRUCKS ONLY
15.
16. 090963-061
17. 090963-062
A B c
146683 C 1 of 3
DIA-1457-018 Crown 2009 PF17437·18 Rev. 7/09
01 Rev. 7/09
594
WIRING DIAGRAMS
CJ\owr. 42 inch Power Cables· DC Hydraulics
A B C
ACCESS 2
HCII
rr:
~~
Ww
~~
p.
1
(J
+B ITEM 2
EMERGENCV
DISCONNECT
CONTACTOR
2 (ED1) 2
NOTES:
• US TRUCKS ONLV
ACCESS 3
TCII
3 3
ITEM PART#
1. 08457~
2. 084573-259
3. 143961 BUS BAR
4. 137~11
5. 084572-313
6. 084572-314
CABLE SIZE PART NO. 7. 137634 BUS BAR
-
PClt10 090963 8. 084572-311
MO
.-_-=P2/M=3:--.:.,TORTr O_P_-=-Pl'"'IM"'2:----, PC #6 084568 9. 084572-312
PC"" 10. 084572-310
4 A
© A
© PC 112
PC#1
084570
084571
11.
12.
137~12
084572-381 4
(NEGATIVE) (NEGATIVE) 084572 084572-344
PC 110 13.
PC 210 084573 14. 084572-341
o t6'
(POSITIVE) ~
0 t6'
(POSITIVE) ~
PCW
PC 410
086479
137638
15.
18.
084572-342
084572-343
MOTOR BOTTOM
A B c
146683 C 2 of 3
Crown 2009 PF17437·19 Rev. 7/09 DIA-1457-019

01 Rev. 7/09
595
WIRING DIAGRAMS
42 inch Power Cables· AC Hydraulics European cnOWI'
A B C
(Q)J>
>~
]
1 "'",
~~ 1
aI~
'"
ACCESS 2
HCIl
'I'
ITEM 5
2 2
( ITEM 10 )
ACCESS'3 ~
TCIl
+8 8-
w(Q) ACCESS'
SCIl
3
(Q)n 3
[
ITEM 15
v(Q)
8-
ITEM PART'"
1.
2.
3.
137~
137636-034
143961 BUS BAR
8
CABlE SIZE PART NO. 4. 137636-007
PC I"! 0 090963 5. 137636-008
PCi16 6. 084573-254
PC iN 084569 7. 084573-255
PC 12 084570 8. 084573-256
PC I"! 084571 9. 084572~1
PC 110 10. 084572-344

PC 210 084573 II. 084572-341
4 PC 310 086479 12. 084572-342

4
PCW 137636 13. 084572-343 NOTES:
14. 137634 BUS BAR
• EU TRUCKS ONLY
15. 09ll963-060
18. _I
17. _2
18. 137836-033
A B c
146683 C 3 of 3
DIA-1457-020 Crown 2009 PF17437-20 Rev. 7/09
01 Rev. 7/09
596
WIRING DIAGRAMS
CROWl' 48 inch Power Cables· AC Hydraulics
A B c
IlEM 1
~
EMERGENCY
BATIERY
CONNECTOR ~
JaV
~
1 DISCONNECT
CONTACTOR
(ED1)
I TRUCK BATIERY
I 1
10 0 ITEM 8 -w
112
ITEM 7 V HYD
MOTOR
tID
0<
::ID :ID w $ U
ITEM 6 .JI
a ...~<~
~<
~~
f-- I-- f--
u~ UPL u~
ACCESS 2
HYDRAUUCS
NOTES:
. . US TRUCKS OM.Y
• DIN BATTERY CONNECTOR OPTION
1lEM4
2 2
I I~ ~
+B
©I
I
/1
IlEMll yy
111
IlEM 10 V TRAC
MOTOR
W
©
V U
1lEM9 U
ACCESS $
sell
w©
ACCESS 3
TRACTION ITEM $
3
+B
©I I~~
B-
v©
[ 3
B+
I I
I IlEM 12 U©
~
IlEM e-aoX lHlOX E-BOX
•
1. 137~19 137636-020 137~1
CABlE SIZE PART NO. 1. 137636426 137636-027 137~

PC,.,O 090963
•
2. 137~18 137~18 137~18
PC 116 084568 2. 137~25 137~ 137~
PC'"' 084569
3. 137~15 137~18 137~17
PC~ 084570
4. 08457~273 08457~274 08457~275
PC,., 084571
5. 08457~278 08457~278 08457~278
PC 110 084572
8. 08457~261 08457~261 08457~261
PC 210 084573
4 PC 310 086479
7. 08457~262 08457~262 08457~262 4
6. 08457~263 ~263 08457~263
PC 410 137636
9. 084572-371 084572-371 084572-371
10. 084572-3n 084572-3n 084572-3n
11. 084572-373 084572-373 084572-373
12. ~ ~ ~
13. 090!lll3-057 090!lll3-057 090!lll3-057
A B c
146684 C 1 of 3
Crown 2009 PF17437-21 Rev. 7/09 DIA-1457-021

01 Rev. 7/09
597
WIRING DIAGRAMS
48 inch Power Cables· DC Hydraulics CAOWI'
A B c
ITEM 1
~
~
BATTERY
CONNECTOR iNEG"]
1 1
~
EMERGENCY MV
DISCONNECT
CON'TACTOR
(EDl)
I TRUCK BATTERY
I IIOTOR
(P2)
C) 0 + P2
~
ITEM 6
PUMP
ITEM 12 A 1I0TOR 0
(Pl)
!ID ;:ID ]V
ITEM 13
0« ~« .,« /
~~ ~~ ~~
~
f-- - f--
lJIil. j~ lJIil.
B+
p.
@)
+BF B- NOTES:
2 2
ACCESS 2
DC HCII
© •
•
US TRUCKS ONLY
DIN BATTERY CONNECTOR 0PT10N
ITEM 4
~
ITEM 11 VY
111
ITEM 10 V TRAC
~
IIOTOR
ITEM 9 ~u_
W U
ACCESS 3
TCII ITEM 5
3 +B B- 3
©I 1$I ~
(
ITEM c-aoX ~OX E-lIOX
•
1. 137~ 137636-023 137636-024
1. 137636-029 137~ 137636-031
•
2. 137636-018 137636-018 137636-018
2. 137636-025 137636-025 137636-025
3. 0&I57~26S 08457H66 08457~267
4. 0&157~273 0&157~274 ~275

CABLE SIZE PART NO.
5. ~270 ~270 08457~270
PC 110 0909B3
TOR TOP 8. 0&157~268 0&157~268 ~268
PCilI6 0&1588
P2IM3 7. ~264 ~264 08457~264
PC . . 0&1589
4 CQ) 4
A
© A
PCt12
PC 11
0&1570
0&1571
8.
9.
~272
0&I572~71
0&157~272
0&I572~71
08457~272
084572~71
(NEGATTVE) (NEGATTVE) 0&1572 10. 0&1572~72 0&I572~72 084572~72

PC 1/0
PC 210 0&1573 11. 0&1572~73 0&I572~73 084572~73
0'6'
~
(POSIT1VE)
oCQ)
(POSIT1VE)
PCW
PC 410
086479
137838
12.
13.
0&157~289
0&I57~271
0&157~269
0&I57~271
08457~289
08457~271
MOTOR BOTTOM
A B c
146684 C 2 of 3
DIA-1457-022 Crown 2009 PF17437-22 Rev. 7/09
01 Rev. 7/09
598
WIRING DIAGRAMS
CJ\OWI' 48 inch Power Cables· AC Hydraulics European
A B c
ITEM 1
~ BATTERY
CONNECTOR ~
:ltV
1
1
EMERGENCY
0 C!) (ED2).
I TRUCK BATTERY
I 1
DISCONNECT
CONTACTORS
0 0 (E01) ITEM 8 'W
112
ITEM 7 V KYO
MOTOR
tID ;::ID tID w ®V U

ITEM 6 .u
0<
~§
~<
~iil 2i
- I-- I--
JPt lJ~ U~
ACCESS 2
HCM
NOTES:
• EU TRUCKS ONLY
• DIN BATTERY CONNECTOR OPTION
ITEM 4
2 2
I
+8 B-
©/ I~ ~ I
/1
ITEM 11 -w
M1
ITEM 10 V TRAC
MOTOR
W
®
v U
ITEM 9 U
ACCESS 5
ACCESS 3
TCM ITEM 5
w© SCM
3
©I
+8
I~ ~
I I
B-
v© [ 3
ITEM 12
\. ITEM 13--1
"©,~
[}.BOX
••
ITEM e-BOX E·BOX
1. 137~ 137636-ll37 137636-038
••
1. 137638-026 137636-027 137636-028
CABLE SIZE PART NO. 2. 137636-035 137636-035 137636-035
PC #10 090963 2. 137636-025 137636-025 137636-025
PCl\l6 084568 3. 137636-015 137636-016 137636-017
PC*' 0&4569 4. 064573-273 084573-274 084573-275
PC #2 084570 5. 084573-276 084573-276 064573-276
PC.l 084571 6. 084573-261 084573-261 084573-261
PC 1/0 084572
4 PC 210 084573
7. 064573-262 084573-262 084573-262 4
8. 084573-263 084573-263 084573-263
PC 310 086479
9. 084572-371 064572-371 084572-371
PC 410 137638
10. 064572-372 064572-372 064572-372
11. 084572-373 084572-373 084572-373
12. ~ ~ ~
13. 090963-057 090963-057 090963-057
A B c
146684 C 3 of 3
Crown 2009 PF17437-23 Rev. 7/09 DIA-1457-023

01 Rev. 7/09
599
WIRING DIAGRAMS
Thermo Assist CJ\OWI'
A B c
5134 CA202-11 BNEG-
1 CA444 1
~320-+-
-5138 ,..137-+--:-
(
12V POWER SUPPLY
(CA404) K3-6 29165
29164
CA490
---+-+-310+-
L-5135- ~ - f-s-136~ 12V POWER SUPPLY
2 2
HEATED PAD ~N_S~~ ~A~~P!~ _-,

CONTROLLER r- TR1 I
CA443 CA44~f------r~LU~~ ~
J<LUI~
RES40 TI I
I
,-------====::t=t:+=t=314-+-
r- 315-+ l' _
""RN_C = _
= = = - ·_--.-J I
- l - - + - - - - - - H t t316-+ ~ f-+--=--GRY L _ _ _ _ _ _ _ _ J
A445
3 L5137T J 3
'-320
HEATED PAD
CONTROLLER
~
----+-------H-=~U=+ I~~II?-E-S!?!: ~A~
• / CA438
I ~~H.:::::!.--:L----H~
~ CA~~BLU,-:==::D==SBULUJ=======~:~ ~Wv- - - -,~= = -~ ~
313-+ I RES42 I _
PHS LOWl ~ r---t- BLU ----;::r

(PAD H~TER
SWITCHI
CA439 ~ ~GRY
I'J ~N L062007-051
BARREL INS~~ ~~~~
CONNECTOR r - - - TR2
__ .,
:~ES41 J ~ 4
4
~====~-~-
A B c
147260 A 1 of 2
Crown 2009 PF17437-24 Rev. 7/09

DIA-1457-024
01 Rev. 7/09
600
WIRING DIAGRAMS
CJ\OWrl Thermo Assist
A B c
1 1
HEATED PAD
CONTROLLER INSIDE SEAT
PHS r--------------,
(PAD HEATER CA440 I RES47 TR1 I
SWITCH) CA438
"':"""---311 1
1 §~~-----.::---J¥Ic=J ~:
5 HI~312
~313
LOW
GRY ~
L _ _ _ _ _ _ _ _ _ _ _ _ _ 1I
BLU-------I?lL...--BLU :
INSIDE ARM PAD
r---------,
RES48
g~~ BLU-------~I--'¥Ic=J
I -
1 :
4 GRY CA420 L - - - - - - - - J
INSIDE BACK PAD

r-------------
I
I RES46 TR2
I
I
2
~=-------+---==-------lJ: I
_ _ _ _ _ _ _ _ _ _ ...J
2
12V POWER SUPPLY
O _____-0
FU20
FU21
+ +
3 3
CA442
~;~~5-----«'-----J~138
314~--+---+----.J
'::-
5135 CA202-10 BNEG,-----(:........:,....J
29164 (CA404) K3-6------~)-J3 7 4 5137---+------.J
29187-----'
4 4
A B c
147260 A 2 of 2
Crown 2009 PF17437-25 Rev. 7/09 DIA-1457-025

01 Rev. 7/09
601
WIRING DIAGRAMS
InfoLink CJ\OWI'
A B c
067 CA440-1 CAN_H
,.
069 CA440-2 CAN_l
/
.J
5108 CA440-3 BNEG
232 CA440-4 +BV (FU 1) INFOLINK
1 2999 CA440-5 +BV (K 1)
@ 1
-
233 CA440-6 +BV (FU 1)KYS - -
1 PROX+5V
2 PROX DATA 0 INPUT
CAN2PROGRAMMING
-
-
3 PROX DATA 1 INPUT CD
1~
2 ~
068
070
063- 4 CAN_H
-
064- ~ CAN_l 8@G
3
4
~ IMPACT+5V
5107 7 IMPACT BNEG
-
CD
5
6
-98 IMPACT X-AXIS INPUT
IMPACT Y-AXIS INPUT
-
-1 065 -10
-2 Q66 .!! RS232 TX
12 RS232RX
-
-~11
2 2 I, ~ MODUlEBNEG 2
RS232 .---- 14 PROXNEG
-
~ +BV (KYS) INPUT DETECT
16
-
.!?
-18
SHOCK ~
-
V10 72& ~
...!..- "'
IMPACT__ r--_,G RN 5110 ~
ENSO ~ 22
BRN --,
~ 30- -
~
W HT ~ 131-
~ -233 ~ +BV TO KYS (AFTER lOGIN)
ALARM -232 ~ MODULE +BV (BEFORE KEY)
tB==:=;231 ~ ALARM POSITIVE 3
3 2 5999 !l ALARM NEGATIVE
~
~
~13...........
••••• ~ .... ~21
PROX
~
410
~ 2~
J... ~ 24........ • ..35
, 5109
~
J- 61
32
-33
2
-~ , :;62- -34
-
35
NOTES: -
o OPTIONAL PROXIMITY READER.
8 TRUCK SHOWN WITH OPTIONAL INFOLINK.
4 ED- 0 4
BlK
PROXIMITY READER
GRN-
WHT-
A B c
147258 A
Crown 2009 PF17437-26 Rev. 7/09

DIA-1457-026
01 Rev. 7/09
602
WIRING DIAGRAMS
CJ\owra Mast Camera
A B c
-
1 .-o-o---jH---l 1 COAX 1 1
-
-o-o--I-+---i 2 COAX SHIELD 2 LCD
- DISPLAY
ED
-3
,-<>-<J>----t-lH 3
--<>-<J>---+--1f----l 4 BLK 4
c::::::l~c::::::lc::::J
CAMERA
CAS 99
-
,-------2:983 1 f----RED 1
-
5105 CA202-10 BNEG S U P P L Y - - - - - - - + - - - - - - - - - - j 2 f--WHT 2
-
989 3 f----BLU 3
-
4 4
-
5 5
-
2976 CA404-13 FU8 +BV (K1}-------...:::::",.-"I""9-.;:------J 6 6
2 R9 - 2
7 7
-
8
5988
315
(HEIGHT RESET)
316 PC417 JC417 HGTRS2
5930 CA411-4 HGTRS2 INPUT------------------(-----------------iGIJOt-5986 5987 -RED-A------oJI--o----,
583 (CA411) SPLICE 03 SW V-COMM--------------)---------~51 04 -BLK--tj--------------------J
WIRED NORMALLY OPEN HELD CLOSED

WHEN MAST IS BELOW STAGING,
SWITCH IS HELD CLOSED.
NOTE:
1) CAMERA HARNESS CONNECTION IS IN-LINE WITH HGTRS2 STANDARD WIRING.
2) VIEW OF NORMAL HGTRS2 WIRING IS REPEATED HERE FOR ILLUSTRATION PURPOSES ONLY.
3 3
4 4
A B c
147259 A
Crown 2009 PF17437-27 Rev. 7/09 DIA-1457-027

01 Rev. 7/09
603
WIRING DIAGRAMS
Wire Harnesses CJ\OW"
Chart 2 - Wire Harnesses
Harness
Truck Compatibility Components Connected By:
Part Number
122176-001 42 & 48 inch RR Trucks Tilt/Sideshift Harness - CA624. CA625, CA626, SVS, SVT
122176-002 42 & 48 inch RD Trucks Tilt/Sideshift Harness - CA624. CA625, CA626. SVS. SVT
123314-002 42 inch RRiRD Trucks ORS Harness - PC202, ORS
123314-003 48 inch RRiRD Trucks ORS Harness - PC202. ORS
123343 42 & 48 inch RRiRD Trucks Keyless Key Switch Harness - JC401, KYS
125793 48 inch RRiRD Trucks Upper Floorboard Harness - JC606. BRS3
48 inch Freezer/Corrosion Upper Floorboard (Freezer/Corrosion) Harness - JC606,
125815
RRiRD Trucks JC818. RES8
127690 42 & 48 inch RRiRD Trucks Internal Fans Harness - JC824
127716 42 inch RRiRD Trucks Floorboard Harness - JC607, BRS1. DMS1, ENS
42 inch Freezer/Corrosion Floorboard (Freezer/Corrosion) Harness - JC816. BRS1,
127749-001
RRiRD Trucks DMS1,ENS, RES13. RES14,RES15,THS5
42 inch Electronic Power Electronic Power Steering Harness - JC650. PC651,
143978
Steering RRiRD Trucks PC652, PC653
Main Harness - PC201, PC202, PC203. PC204. PC205,
PC220. PC221 , PC225, PC401, PC403. JC404. PC405,
PC406,PC407,PC408,PC410.PC411,PC412,JC414,
143979 42 inch DC RRiRD Trucks PC415,PC417,PC418,PC425.PC426,JC440,PC440.
PC490, PC607, PC609, PC612, PC630, PC631 , PC645,
PC650. PC654, PC661 , PC662, PC671 , PC672. PC673,
PC824. PC845
Main Harness - PC201, PC202, PC203, PC204, PC205,
PC220, PC221, PC225, PC401, PC402,PC403, JC404,
PC405,PC406,PC407.PC408,PC410,PC411,PC412,
143980 42 inch AC RRiRD Trucks JC414,PC415,PC417,PC418,JC440.PC440.PC490.
PC607, PC609, PC612, PC613. PC614, PC630, PC631,
PC645. PC650, PC654, PC661. PC662, PC671 , PC672.
PC673.PC824,PC845
143981 42 inch RRiRD Trucks Battery Restraint Harness - JC665. JC667, BRES1, BRES2
Overhead Guard Options Harness - PC202, JC615, PC661,
143983 42 & 48 inch RRiRD Trucks
PC662,FNS,LGS2,RES2,RES3
143986 42 & 48 inch RRiRD Trucks Fan and Strobe Light Harness - JC662, SB80, SB81
143987 42 & 48 inch RRiRD Trucks Work Lights Harness (Mast Mounted) - JC661. LGT2, LGT3
143987-002 42 & 48 inch RRiRD Trucks Work Lights Harness (OHG Mounted) - JC661, LGT2. LGT3
DIA-1457-028 Crown 2009 PF17437·28 Rev. 9/09
02 Rev. 9/09
604
WIRING DIAGRAMS
CJ\owr. Wire Harnesses
Chart 2 - Wire Harnesses
Harness
Truck Compatibility Components Connected By:
Part Number
PC220, PC221, PC225, PC401, PC402, PC403, JC404,
PC405,PC406,PC407,PC408,PC410,PC411,PC412,
JC414,PC415,PC417,PC418,JC440,PC440,PC490,
143990 48 inch AC RRIRD Trucks
PC606, PC607, PC608, PC609, PC610, PC612, PC613,
PC614, PC630, PC631, PC643, PC644, PC645, PC650,
PC654, PC661 , PC662, PC671, PC672, PC673, PC824,
PC845
PC220, PC221 , PC225, PC401, PC403, JC404, PC405,
PC406,PC407, PC408, PC410,PC411,PC412,JC414,
143991 48 inch DC RRIRD Trucks PC415,PC417,PC418,PC425,PC426,JC440,PC440,
PC490, PC606, PC607, PC608, PC609, PC610, PC612,
PC630, PC631 , PC643, PC644, PC645, PC650, PC654,
PC661,PC662,PC671,PC672,PC673,PC824,PC845
Freezer/Corrosion Harness - JC407, JC663, JC664,
48 inch Freezer/Corrosion
143993 PC80S, PC806, PC807, PC808, PC810, PC812, PC813,
RRIRD Trucks
PC814,PC815,PC816,PC819
Camera PAL Harness - PC202, PC417, JC417, PC899,
143999 42 inch RRIRD Trucks
HGTRS2
Camera PAL Harness - PC202, PC417, JC417, PC899,
144000 48 inch RRIRD Trucks
HGTRS2
42 inch Freezer/Corrosion Harness - JC407, PC806, PC807,
145191 Freezer/Corrosion PC808, PC809, PC810, PC811, PC812, PC813, PC814,
RRIRD Trucks PC817,PC818,PC819,PC823
42 & 48 inch Thermoassist Harness - PC438, PC443
146426 Freezer/Corrosion
RRIRD Trucks
146725 42 inch EU RRIRD Trucks ED2 Option Harness - ED1, ED2
146843 42 & 48 inch RRIRD Trucks Infolink Harness - Alarm, CAN2, Module, Prox, Shock
147327-001 RRTrucks Tilt, Sideshift, TPA Harness - SVS, SVT, TPA
147327-002 RD Trucks Tilt, Sideshift, TPA Harness - SVS, SVT, TPA
Crown 2009 PF17437-29 Rev. 9/09 D1A-1457-029

02 Rev. 9/09
605
CJ\OWI'
Notes:
606
mow"
HYDRAULIC SCHEMATIC
607
CJ\OWI'
Notes:
608
HYDRAULIC SCHEMATIC
cnOWrl Hydraulic Schematic
1067 mm (42 in) AC Hydraulics
, ~ 4
I
I
: P2 CV2
C1'
PVL MVL
CV1
ORF4X
SVBy ,
I
SVL
,,
,, SVA
I
I
I
.,
--: *ORF3
I
,
I
'Gp
RV1
CV3
,,
.. __ J
. ~ ~~ 1t .
P1
RH Reservoir
2 LH Reservoir
3 Diffuser
4 Return Filter
5 Lift Pump and Lift Pump Motor
6 Manifold Assembly
7 Quick Disconnect Test Point
8 Strainer
9 Breather
10 Pressure Transducer
Figure 20941
Crown 2008 PF17438-1 HYD-1457-001
609
HYDRAULIC SCHEMATIC
Hydraulic Schematic CJ\OW"
,,
,
-~
.
:ij----------------------------------------------------,
•_, Fi1 R2
I
: :
..
SVR
..
--,:T3
,, ,,
I, ,,
,
AI' ,,, ''
'
I
I , '
I 'T2 A'
B'
,T1 B',
,,
-- ,,
R2 ,,

4 Velocity Fuse
5 Flow Control
7 liltlSideshift Manifold Contains SVS & SVT
Figure 20942
HYD-1457-002 Crown 2008 PF17438-2
610
------------------
HYDRAULIC SCHEMATIC
CJ\OWI) Hydraulic Schematic
1067 mm (42 in) 24 Vdc Hydraulics
.----------------------------~-------------
,,
,
'P2 CV2
C1'I
PVL
'~~,F/
ORF4X,
,
SVL
,
~'P
,
1 "
~ I
LS:
,,
,,
,, ,
,,, .- - --.
,,, , RV1 ----,CV3
,, 'P1
,,
,,,
I
------------------~~~~-----~ T2 1:1. _
,,
,,
,,
EF'
P, '¢ ,
_______ : '" ic
._~~-J
LS~
I P1 :I
!-~£'fP~
1 RH Reservoir 7 Hydraulic Steer Motor

2 LH Reservoir 8 Manifold Assembly
3 Diffuser 9 Quick Disconnect Test Point
4 Return Filter 10 Strainer
5 Primary Lift Pump and Lift Pump Motor 11 Breather
6 Steer Control Unit 12 Pressure Transducer
Figure 20943
Crown 2008 PF17438-3 HYD-1457-003
611
HYDRAULIC SCHEMATIC
Hydraulic Schematic CJ\OWI'
.. :~-----------------------------------------------'
. , ~1 'R2------'
I .. "
--e
: :
0,
SVR :T3
o .---------~
I,
I
A' ,
I
I
,
I ,,: SVS,
,
,, ,
I ,
, ,'T2 A''
S'
oT1 S,
o ,
. - - - - g~'{ - - ---
o
,,
,
,, R1 R2
,,
,
,,, .. _--------~
,,
,,
--------------------------------------------------

4 Velocity Fuse
5 Flow Control
7 TiIUSideshift Manifold - Contains SVS & SVT
Figure 20944
Crown 2008 PF17438-4

HYD-1457-004
612
--------------------------
HYDRAULIC SCHEMATIC
Hydraulic Schematic
.
I
I
1 _
:P2 CV2
F~-------...._----+_--~--- • .:.,
PVL
. 1__ SVL
SVA
I
I
I
I
I RV1
'p1
I
. I
~~~~ ? ~~ T1 ,
I
I
I
I
I
EF '
P, ;~
I : .. jc I I
.. -------.-~~-~ I
LS~ .!-?f'fP~
1 RH Reservoir 8 Manifold Assembly

2 LH Reservoir 9 Quick Disconnect Test Point
3 Diffuser 10 Strainer
4 Retum Filter 11 Secondary Lift Pump and Lift Pump Motor
5 Primary Lift Pump and Lift Pump Motor 12 Breather
6 Steer Control Unit 13 Pressure Transducer
7 Hydraulic Steer Motor
Figure 21489
Crown 2008 PF17438-5 HYD-1457-005
613
HYDRAULIC SCHEMATIC
Hydraulic Schematic CJ\own
. :~----------------------------------------------- .
: :
..
SVR
..
--,:T3
,,
, I
, ,,
,
AI'
I
,,
,, ,
, , '
'T2 A'
8'
,T1 8,
,, ,,,
,,
R2 '
""---------"

2 Primary lift Cylinder
4 Velocity Fuse
5 Flow Control
7 liltlSideshift Manifold - Contains SVS & SVT
Figure 20944
HYD-1457-006 Crown 2008 PF1743U
614
----------------------------------
HYDRAULIC SCHEMATIC
CJ\owr. Hydraulic Schematic
1220 mm (48 in) AC Hydraulics
._--------------------------~----------------- -----~--, Gc
P2 CV2
PVL MVL
SVL
SVA
--: *ORF3
, ,,
RV2',
,
Gp
RV1
CV3
,,
.. __ J
" ~ ~~ 1~ ,
1
1 Reservoir
2 Diffuser
3 Return Filter
4 Lift Pump and Lift Pump Motor P1
5 Manifold Assembly
6 Quick Disconnect Test Point
7 Strainer
8 Breather
9 Pressure Transducer
Figure 20945
Crown 2008 PF17438-7 HYD-1457-007
615
HYDRAULIC SCHEMATIC
Hydraulic Schematic CJ\OWI'
..
:ij----------------------------------------------------,
._,
I
-'~1 R2
'-t,T3
r J
,,: ,,: SVR ,,

,, ,
A' ,
,, ,,, '
'
''
, ,
'T2 A:
B'
,T1 B'
,, :'
R2- :
I
I

2 Primary Lift Cylinder .
4 Velocity Fuse
5 Flow Control
7 TiltlSideshift Manifold - Contains SVS & SVT
Figure 20942
HYD-1457-008 Crown 2008 PF17438-8
616
HYDRAULIC SCHEMATIC
CJ\OWI' Hydraulic Schematic
-----------------------------,-------------
I
I
I
,p2 CV2
C1:
I
,,
I
,
I
I
I
I
I
_----1-_ I
I
I
:r
I SVA
~IP
I I I
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,
LS' I
I
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I RV1 ----.CV3
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~----------------_:~~~-----§ --- ~~----------- ~!_----_.
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EF '
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: P, I¢
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. -------.-~~-I
LS~ .!-§!'fP~
I
1 Reservoir 7 Manifold Assembly

2 -Diffuser 8 Quick Disconnect Test Point
3 Retum Filter 9 Strainer
4 Primary Lift Pump and Lift Pump Motor 10 Secondary Lift Pump and Lift Pump Motor
5 Steer Control Unit 11 Breather
6 Hydraulic Steer Motor 12 Pressure Transducer
Figure 20946
Crown 2008 PF17438-9 HYD-1457-009
617
HYDRAU~IC SCHEMATIC
Hydraulic Schematic CROWl'
I
I
I
-~
.. :@)-----------------------------------------------'
• , ~1 R2
:, :-------iVR
, -- --6
:T3 • ~
,I,,
,, : svs,
A' , ,
, I
,,
,
, ,,
'T2 A'
B'
,T1 B,
,,,
,,,
I
I
I
R2
I
I
,,
I
,,
, I
t J

4 Velocity Fuse
5 Flow Control
6 Reach Manifold - Contains CBV & SVT
7 TiIUSideshift Manifold - Contains SVS & SVT
Figure 20944
HYD-1457-010 Crown 2008 PF17438-10
618
mown
POWER UNIT PARTS
619
POWER UNIT PARTS
Power Unit CJ\OW"
1r8~, ,,
" t
, .:
"~
,"""
I
16-''@. I
I
../ ' I
17 I
13-, "- , l,
'@.. 12
1~ .
2- 0,
(a) Part of Overhead Guard
Figure 21556
Crown 2010 PF25158-1

01.0-1457-007
620
POWER UNIT PARTS
l!J\own Power Unit
INDEX PART NUMBER PART NAME NUMBER REQUIRED
1 . . . .. . Power Unit Contact Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

2 145073 Door Panel 1
3 060019-067 Screw 2
4 060009-136 Retaining Ring 2
5 144525 Hinge 1
6 060017-024 Screw 3
7 060030-335 Flatwasher. 3
8 129273 Fastener Plate 1
9 123890 Shim Plate 1.5 mm (0.06 in) Thick AR
10 122930 Guard Inside RH (Not Shown) 1
122936 Guard Inside LH 1
11 060016-030 Screw 4
12 128627-002* Outside Guard RH B Battery Compartment (Not Shown) 1
128627-003* Outside Guard RH C Battery Compartment (Not Shown) 1
128627-004* Outside Guard RH D Battery Compartment (Not Shown) 1
128627-005* Outside Guard RH E Battery Compartment (Not Shown) 1
128625-002* Outside Guard LH B Battery Compartment. . . . . . . . . . . . . . . . . . . . . . . . .. 1
128625-003* Outside Guard LH C Battery Compartment .,. . . . . . . . . . . . . . . . . . . . . .. 1
128625-004* Outside Guard LH D Battery Compartment 1
128625-005* Outside Guard LH E Battery Compartment. . . . . . . . . . . . . . . . . . . . . . . . .. 1
13. . . . . 060032-066 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14 122998 Tapped Block 2
15 060089-012 Wedge Washer 4
16 060078-026 Screw , 2
17 060030-012 Flatwasher 2
18 123333 Tank Cover RH (Not Shown) 1
123334 Tank Cover LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19. . . . . 145676 Fan Shroud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20. . . . . 060030-378. . . . . . . . Flatwasher. AR
* To select appropriate part number, use the data number

to determine truck features. Refer to Introduction.
Always Specify Model, Data & Serial Number

Crown 2010 PF25158-2 01.0-1457-008
621
POWER UNIT PARTS
Power Unit CJ\OWI'
,.
I
f
+-.. .~
I
t
<Ii
¢
ll~"
t;tr~-(a)
..... (a) Part of Ovemead Guard
Iq)i
r~!
!.
Figure 21557
01.0-1457-009 Crown 2010 PF25158-3
622
POWER UNIT PARTS
CROWl' Power Unit
30 123644* Bracket RH B Battery Compartment (Not Shown) 1

123645* . . . . . . . . . . Bracket RH C Battery Compartment (Not Shown) . . . . . . . . . . . . . . . . . . .. 1
123646* Bracket RH D Battery Compartment (Not Shown) 1
123647* Bracket RH E Battery Compartment (Not Shown) 1
123667* . . . . . . . . . . Bracket LH B Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123668* . . . . . . . . . . Bracket LH C Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123669* . . . . . . . . . . Bracket LH D Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123670* Bracket LH E Battery Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
31 060015-082 Screw 4
32. . . . . 060078-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
33 060030-012 Flatwasher. 4
34. . . . . 123743-012-01 * Console B Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123743-012-02* Console B Battery Compartment and InfoLink 1
123743-013-01* Console C Battery Compartment 1
123743-013-02* Console C Battery Compartment and InfoLink 1
123743-113-01* Console C Battery Compartment and Comfort Package 1
123743-113-02* Console C Battery Compartment, InfoLink and Comfort Package 1
123744-011-01 * Console D Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123744-011-02* Console D Battery Compartment and InfoLink 1
123744-111-01* Console D Battery Compartment and Comfort Package 1
123744-111-02* Console D Battery Compartment. InfoLink and Comfort Package 1
123744-012-01 * Console E Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123744-012-02* Console E Battery Compartment and InfoLink . . . . . . . . . . . . . . . . . . . . . .. 1
123744-112-03* Console E Battery Compartment and Comfort Package 1
123744-112-04* Console E Battery Compartment. InfoLink and Comfort Package 1
35 061073 Spring Clip 5
36 060012-074 Screw 10
37. . . . . N01203 Fire Extinguisher Assembly Includes Index 37 - 40 . . . . . . . . . . . . . . . . . .. 1
079528 Fire Extinguisher & Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
38 060014-022 Screw 2
39 060005-005 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40 060021-005 Nut 2
41 123632 Arm Pad 1
139655 Heated Arm Pad Assembly FIC 1
42 060015-082 Screw 8
• To select appropriate part number, use the data number

Crown 2010 PF25158-4 01.0-1457-010
623
POWER UNIT
Power Unit PARTS CROWl'
F':r,-" I
I
I
I
" I
""
"" "
" "
58--j
60 _ ~ - 59
il~
61 - ~
'"'~. i - a
I
$"" ()
~-57
62
Q
~ __ --0
~;~~F,
65 - ~~
I ~ "'-64
63
Figure 21558-01
01.0-1457-011 Crown 2010 PF25158-5
624
POWER UNIT PARTS
CJ\OWI' Power Unit
50. . . . . 130257 . . . . . . . . . . . Back Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

139654 . . . . . . . . . . . Heated Back Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
51 060016-004 Screw 2
52 060030-017 Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
53. . . . . 130486 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
54 060015-108 Screw , 4
55. . . . . 146753 . . . . . . . . . . . Knee Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
56 060080-004 Flange Nut. 3
57 125891-001* 3rd Post 2415 mm (95 in) Collapsed Height or Greater 1
125891-002* 3rd Post 2260 mm (89 in) Collapsed Lift Height 1
58 060023-014 Screw 1
59 060005-023 Lockwasher 1
60 060030-292 Flatwasher 1
61 132248-003 Upper Grommet 1
62 132179-003 Lower Grommet 1
63. . . . . 142434 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
64 123890 Shim Plate 1.5 mm (0.06 in) Thick AR
65 060017-014 Screw 4
66 060080-001 Nut. 4
67 109127-001 Arrow Clip Green 1
109127-002 Arrow Clip Yellow 1
109127-003 Arrow Clip Red 1
68. . . . . 123594 Clipboard Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
69 060013-030 Screw 2
70 060005-053 Lockwasher 2
71 060031-011 Speed Nut 2

Crown 2010 PF25158-6 01.0-1457-012
625
POWER UNIT PARTS
Floorboard CROW"
. . ~-5
/33
/ 34
~
16~ o oll /~1
<
.. ~'tJ;/
,~ 29
30
I
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7 .. , ~/~
~
25/~<26
-18: ;-.. " 28
I
23 '.
~'"
-18 24
Pf""~
rl-14 r~1 I'
~
15/ 32 27
31
(a) Components part of floorboard hamess
(b) Parts shown rotated 90° up from mounted position
Figure 21031
01.0-1457-050 Crown 2008 PF17588-1
626
POWER UNIT PARTS
CJ\owra Floorboard
1 . . . .. 130923 Operator Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

133858* Operator Mat FIC 1
2 131715 Presence Pedal. 1
3. . . . . 065038-009. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 131155 Brake Pedal. 1
5 076048-001 Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 123724 Poly Slide 4
7 132118 Floorboard 1
8 060016-018 Screw 6
9. . . . . 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
10 122807 Pivot Pin 1
11 060038-017 Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 122834 Compression Spring 2
13 123482 Poly Stop 2
14 123037 Pivot Pin 1
15 060038-017 Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
16 127648 Entry Bar 1
17. . . . . 127699 . . . . . . . . . . . Entry Bar Assembly " 1
18 065038-017 Bearing 4
19 076048-001 Lubrication Fitting 2
20. . . . . 123852 Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 060015-006 Screw 2
22. . . . . 060005-022. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
24. . . . . 126435 Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
25 127642 Harness Mount Bracket. 1
26. . . . . 060016-004 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
27. . . . . 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
28 060030-017 Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
29 062749-001* Attachment Clip FIC 1
30. . . . . 060014-087* Screw FIC : . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
31 127575 Harness Mount Cover 1
32 060014-088 Screw 2
33. . . . . 123965 Compression Spring 2
34. . . . . 123871 Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2008 PF17588-2 01.0-1457-051
627
POWER UNIT PARTS
Floorboard mow"
57~
11 ,,""<.
DMS1
50~
& "
53 52
I ~":s,," ~ 56
; " RE"~14
r-.lJ""~~
54
I
I 73
J
J
.
I
,,~
" 71
I
, ml~ , "9" / I
1I
70
72
I
I "I " X 74 75
I "
" "
/~/
/""
-;:::;,.
,/
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.....
/.
..... ,......
//,.,
."
".
....:-;~ . . . / // 64
""
""" "
73
68
I "
}3'
72
55
RES15
Figure 21063
01.0-1457-052 Crown 2008 PF17588-3
628
POWER UNIT PARTS
l!J\OWrl Floorboard
50. . . . . 127695 Switch Assembly 2

51 060064-012 Screw 2
060064-013* Screw F/C 2
52 060059-014 Nut. 2
53 123891 * Spacer FIC 3
54 123895* Heater Plate FIC (1) , 2
55 062033-026* Resistor 36 V Trucks FIC (1) 3
062033-051* Resistor 24 V Trucks FIC (1) 3
56 060010-004* Screw FIC (1) 6
57 060005-001* Lockwasher FIC (1) 6
58 123789* Heater Plate FIC (1) 1
59. . . . . 060011-003. . ...... Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
060011-013* Screw F/C 2
60. . . . . 060005-049. . ...... Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
61 062695* Thermostat FIC (1) 1
62 060011-001* Screw FIC (1) 2
63 060005-036* Lockwasher FIC (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . 2
64. . . .. 123859 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
65 060030-161 Flatwasher 2
66 065007-084 Bushing 4
67 060030-037 Flatwasher 2
68. . . .. 123986 . . . . . ...... LH Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
69. . . . . 123872-001 LH Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
70 060030-010 Flatwasher 2
71 060005-007 Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
72 060015-003 Screw 2
74. . . . . 131694 . . . . . ...... RH Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
75 123872-002 RH Cover 1
76 060000-075 Roll Pin 3
(1) Part of 127749-001/-002 Floorboard Harness

Crown 2008 PF17588-4 01.0-1457-053
629
POWER UNIT PARTS
Undercarriage Articulation CROWl'
---17
1
2'---ll--
91 (b)
3-~
4--
20--rIl/
(a) Installing incorrect dash number will affect

truck stability, number of grooves indicates
I
dash number
(b)
(c)
Torque 375 - 405 Nm (275 - 300 ft Ib)
Torque 305 - 340 Nm (225 - 250 ft Ib)
5-~
(d) Torque 136 - 163 Nm (100- 120 ft Ib) t-7
91
6-1
(c) I
Figure 21099
Crown 2008 PF17442·1

01.0-1457-100
630
POWER UNIT PARTS
CJ\OW" Undercarriage Articulation
1. . . . . 060041-002 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 060021-034 Nut. 1
3. . . . . 127792 Wear Plug , 1
4. . . . . 143116 Carrier (Electronic Power Steering). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
143115 Carrier (Hydraulic Steering) 1
5. . . . . 125679 Rear Mounting Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
086991 Front Mounting Block , 1
6 060023-028 Screw 4
7 060005-046 Lockwasher 4
8 134177 Shaft , 1
34178* Shaft F/C 1
9 065007-092 Bushing , 2
10 060030-311 Flatwasher 1.5 mm (0.06 in) Thick 8
060030-324 Flatwasher 0.75 mm (0.03 in) Thick AR
11 126781 Spacer , 4
12 060019-072 Screw 4
13. . . .. 126780-001 * Spacer Cap, Trucks without Sideshift 2
126780-002* Spacer Cap, Trucks with Sideshift (1) 2
126780-004* Spacer Cap, Trucks with Sideshift (2) 2
14 122457* ., Spring, Red (3) . • . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . • . • • . . . 2
122456* Spring, Blue (4) 2
15 126784 Stop Bolt 2
16 ,. 060021-034 Nut. , , 2
17 126787 Stop 1
18. . . . . 060019-029 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19 060005-012 Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20. . . . . 080573 . . . . . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) Trucks with Lift Heights 5335 mm (210 in) or Less

(2) Trucks with Lift Heights Greater Than 5335 mm (210 in)
(3) Trucks with Lift Heights 6850 mm (270 in) or Less
(4) Trucks with Lift Heights Greater Than 6850 mm (270 in)

Crown 2008 PF17442-2 01.0-1457-101
631
POWER UNI
Mast Guard T PARTS CJ\OWI'
21&0 ~O~~~).
. C)OIl~psed Height
2260,2415
5030,5335 & 2720
& 6095 mm (89,
(198,95
In Lift Height
5"
, "
-"
(a)
(a) Drive-Thru Option

(b) To Main Frame
Figure 21124
Crown 2008 PF17443-1 Rev.8I10

01.2-1457-001
01 Rev. 8/10
632
POWER UNIT PARTS
l!J\owra Mast Guard
1 060032-066 Screw 14
2 060089-012 Wedge Washer 14
3 128895-001 Shim 16 Gauge, 1.5 mm (0.06 in) Thick AR
128895-002 Shim 13 Gauge, 2.3 mm (0.09 in) Thick AR
128895-003 Shim 12 Gauge, 2.8 mm (0.11 in) Thick AR
4. . . .. 127987-003* LH Mast Guard (1) Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127987-001* LH Mast Guard (1) Glass Shield 1
127987-004* LH Mast Guard (2) Screen 1
127987-002* LH Mast Guard (2) Glass Shield 1
129625-003* LH Mast Guard (1) Screen & Drive-Thru Rack Mast 1
129625-001* LH Mast Guard (1) Glass Shield & Drive-Thru Rack Mast. 1
129625-004* LH Mast Guard (2) Screen & Drive-Thru Rack Mast 1
129625-002* LH Mast Guard (2) Glass Shield & Drive-Thru Rack Mast. 1
5. . . . . 123459-003* Rubber Molding (1) 2
123459-004* Rubber Molding (2) . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . 2
6. . . .. 123459-002. . . . . . . . Rubber Molding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 074745-017* Glass Shield (1) 1
074745-018* Glass Shield (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • 1
8. . . . . 127980-003* RH Mast Guard (1) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127980-001 * RH Mast Guard (1) Glass Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
138911 Clamp Cover (Installed on Tabs) 2
127980-004* RH Mast Guard (2) Screen 1
127980-002* RH Mast Guard (2) Glass Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
138911 Clamp Cover (Installed on Tabs) 2
129626-003* RH Mast Guard (1) Screen & Drive-Thru Rack Mast 1
129626-001* RH Mast Guard (1) Glass Shield & Drive-Thru Rack Mast 1
129626-004* RH Mast Guard (2) Screen & Drive-Thru Rack Mast 1
129626-002* RH Mast Guard (2) Glass Shield & orive-Thru Rack Mast . . . . . . . . . . . . .. 1
131425-003* RH Mast Guard (1) Screen & RH Work Assist Tube 1
131425-001 * RH Mast Guard (1) Glass Shield & RH Work Assist Tube 1
131425-004* . . . . . . . RH Mast Guard (2) Screen & RH Work Assist Tube . . . . . . . . . . . . . . . . . .. 1
131425-002* RH Mast Guard (2) Glass & RH Work Assist Tube 1
132160-003* RH Mast Guard (1) Screen, Drive-Thru Rack Mast & RH Work Assist Tube. 1
132160-001 * RH Mast Guard (1) Glass Shield, Drive-Thru Mast & RH Work Assist Tube. 1
132160-004* RH Mast Guard (2) Screen, Drive-Thru Rack Mast & RH Work Assist Tube. 1
132160-002* RH Mast Guard (2) Glass Shield, Drive-Thru Mast & RH Work Assist Tube. 1
(1) 2260 mm (89 in) Overhead Guard
(2) 2415 mm (95 in) Overhead Guard - Not available on 2260 mm (89 in) collapsed height truck as a stan-
dard option.

Crown 2008 PF17443-2 Rev. 8110 01.2-1457-002

01 Rev. 8/10
633
POWER UNIT PARTS
Mast Guard
2260,2415 & 2720 mm (89, 95 & 107 in) Collapsed Height

5030,5335 & 6095 mm (198, 210 & 240 in) Lift Height
- !!
f1I
j!
1
;I I -I
II,
II ..... 1
I
.....
«I
II,!, \
"-
H
!i ") I
(a)
IIiI I
I
!!
I
I
I

(b) To Main Frame
Figure 21125
01.2-1457-003 Crown 2008 PF1744~ Rev. 8110
01 Rev. 8/10
634
POWER UNIT PARTS
CJ\owr. Mast Guard
20 145730 Shield Support D & E Battery Compartment(1)(3) 1

145731 Shield Support C Battery Compartment(1)(3) 1
145732 Shield Support D & E Battery Compartment, Drive-Thru Rack Mast(1)(3) .. 1
145733 Shield Support C Battery Compartment, Drive-Thru Rack Mast(1)(3) 1
145734 Shield Support B, D, & E Battery Compartment(2)(3) 1
145735 Shield Support C Battery Compartment(2)(3) 1
145736 Shield Support B, D & E Battery Compartment, Drive-Thru Mast(2)(3) 1
145737 Shield Support C Battery Compartment, Drive-Thru Rack Mast(2)(3) 1
127921 Shield Support D & E Battery Compartment(4) 1
127923 Shield Support C Battery Compartment(4) . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129087 Shield Support C Battery Compartment, Drive-Thru Rack Mast(4) 1
129089 Shield Support D & E Battery Compartment, Drive-Thru Rack Mast(4) 1
21 060078-026 Screw 6
060078-026 Screw, Drive-Thru Rack Mast 2
22. .... 127722 . . . . . . . . . . . Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
23 060015-006 Screw, Drive-Thru Rack Mast 4
24. .... 127722 . . . . . . . . . . . Spacer, Drive-Thru Rack Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
25 060042-006 Nut, Drive-Thru Rack Mast 4
26. .... 128726 . . . . . . . . . . . LH Pulley Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 125614-002 Tension Rod LH Thread 1
28. .... 128728 . . . . . . . . . . . RH Pulley Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 125614-001 Tension Rod RH Thread 1
30. .... 125615 Turnbuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
31 060021-024 Nut. 1
32 074745-016 Glass Shield 1
33. .... 123459-002 Rubber Molding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(1) AC Hydraulics
(2) DC Hydraulics
(3) 1065 mm (42 in) Power Unit
(6) 2415 mm (95 in) Overhead Guard - Not available on 2260 mm (89 in) collapsed height trucks

Crown 2008 PF17443-4 Rev. 8/10 01.2-1457-004

01 Rev. 8/10
635
POWERU
Mast Guard NIT PARTS CJ\OWI'
in) C)Oll~psed Height

2260, 2415 & 2720
5030, 5335 & 6095 mm (198,
(89, 95 & 107
210 & 240.
In Lift Height
(
....
Ii!
!
!. I
j
(a)

(b) To Mainframe
Figure 21668
01.2-1457-005 Crown 2008 PF17443-0 Rav.8Il0
01 Rev. 8/10
636
POWER UNIT PARTS
CJ\OWrl Mast Guard
40 125686-001* Shield B(3) or C(4) Battery Compartment 1

125686-002* Shield C, D & E(3) or D & E(4) Battery Compartment 1
125686-003* Shield C, D & E Battery Compartment, Operator Comfort Package 1
41 123722-001* Screen(5) B(1) or C(2) 1
123722-002* Screen(6) B(1) or C(2) 1
123722-003* 1
Screen (5) C, D & E (1) or D & E (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
123722-004* Screen(6) C, D &E(1) or D & E(2) 1
140443-001 * Screen (5) C, D & E, Operator Comfort Package. . . . . . . . . . . . . . . . . . . . .. 1
140443-002* Screen (6) C, D, & E, Operator Comfort Package 1
(1) AC Hydraulics
(2) DC Hydraulics
(6) 2415 mm (95 in) Overhead Guard - Not available on 2260 mm (89 in) collapsed height trucks

Crown 2008 PF17443-6 Rev. 8/10 01.2-1457-006

01 Rev. 8/10
637
POWER UNIT PARTS
Mast Guard CJ\OWI'
3025 mm (119 in) Through 4826 mm (190 in) Collapsed Height
6860 mm (270 in) Through 11225 mm (442 in) Lift Height
(a) Drive-In Rack Mast

(b) 11225 mm (442 in) Lift Height
(c) To Mainframe
Figure 21130-01
Crown 2008 PF17445-1 Rev. 7/09

01.2-1457-050
01 Rev. 7/09
638
POWER UNIT PARTS
CJ\owr. Mast Guard
1 . . . . . 060032-066 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
2 060089-012 Wedge Washer 10
3 128895-001 Shim 16 Gage, 1.5 mm (0.06 in) Thick AR
128895-002 Shim 13 Gage, 2.3 mm (0.09 in) Thick AR
128895-003 Shim 12 Gage, 2.8 mm (0.11 in) Thick AR
4. . . . . 127966* . . . . . . . . . . LH Mast Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129623* LH Mast Guard Drive-In Rack Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
133807* LH Mast Guard (1) 11225 mm (442 in) Lift Height. 1
5 125614-002 Tension Rod LH Thread 1
6. . . .. 127969* RH Mast Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129624* RH Mast Guard Drive-In Rack Mast 1
131423* RH Mast Guard & Work Assist Tube 1
132159* RH Mast Guard, Drive-In Rack Mast & Work Assist Tube . . . . . . . . . . . . .. 1
133809-001* RH Mast Guard (1) 11225 mm (442 in) Lift Height. 1
133809-002* RH Mast Guard & Work Assist Tube (1) 11225 mm (442 in) Lift Height 1
7 125614-001 Tension Rod RH Thread 1
8. . . .. 125615 Turnbuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 060021-024 Nut. 1
10 074745-015 Glass Shield 1
11 123459-001 Rubber Molding 2
12 123459-002 Rubber Molding 1
13. . . . . 123944-001 * Screen C Battery Compartment (2) . . . . . . • . . • • • • . . • . • • . . . . . . . . . • . .. 1
123944-002* Screen C, D & E (1) or D & E (2) Battery Compartment. . . . . . . . . . . . . . . .. 1
138795* .. . . . . . . . . Screen with Operator Comfort Package. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) 1220 mm (48 in) Power Unit Only


Crown 2008 PF17445-2 Rev. 7/09 01.2-1457-051

01 Rev. 7/09
639
POWER UNIT PARTS
Mast Guard l!J\OWI'
3025 mm (119 in) Through 4826 mm (190 in) Collapsed Height
6860 mm (270 in) Through 11225 mm (442 in) Lift Height
(a) Drive-In Rack Mast

(b) 11225 mm (442 in) Lift Height
(c) To Mainframe
-
,
I
iHl
Ii
n
II
:1
H
/ I H
,I I' 'I
I ,II
I
I III
I !I
H
/ III
//1 H
I
, II I
;1
III ij
III
III
III '
III I II
/1 I
,1/ II
i
J
I I ,
I /
/
il
l;
;j
I
\ "-
[~
ij "-
"I \
I
I '-
Figure 21131-01
Crown 2008 PF17445-3 Rev, 7/09

01.2-1457-052
01 Rev. 7/09
640
POWER UNIT PARTS
CJ\OWI' Mast Guard
20. . . .. 145730* Shield Support D & E Battery Compartment (1) 1

145731* Shield Support C Battery Compartment (1) . . . . . . . . . . . . . . . . . . . . . . . . . • 1
145732* Shield Support D & E Battery Compartment, Drive-In Rack Mast (1) 1
145733* Shield Support C Battery Compartment, Drive-In Rack Mast (1) 1
145734* Shield Support B, D, & E Battery Compartment (2) 1
145735* Shield Support C Battery Compartment (2) . . . . . . . . . . . . . . . . . . . . . . . . .. 1
145736* Shield Support B, D & E Battery Compartment, Drive-In Mast (2) . . • . . . . . . 1
145737* Shield Support C Battery Compartment, Drive-In Rack Mast (2) 1
137173* Shield Support E Battery Compartment (3) . . . . . . . . . . . . . . . . . . . . . . . . .. 1
21 060078-026 Screw 6
060078-026* Screw, Drive-In Rack Mast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
22. . . . . 127722 Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
23 060015-006* Screw, Drive-In Rack Mast 4
24 127722* Spacer, Drive-In Rack Mast. 6
127722* Spacer, Drive-In Rack Mast (4) . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
25 060042-006* Nut, Drive-In Rack Mast 4
26 133803* Guard (3) (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27. . . . . 138724 Tapped Bar, Operator Comfort Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
28. . . . . 138725-001 Slotted Plate, Operator Comfort Package. . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 138725-002 Slotted Plate, Operator Comfort Package 1
30 060015-012 Screw, Operator Comfort Package 4
31 138726 Shield, Operator Comfort Package 1
32. . . . . 109015 Knob, Operator Comfort Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(1) AC Hydraulics
(2) DC Hydraulics
(3) 10695 mm (421 in) & 11225 mm (442 in) Lift Heights

Crown 2008 PF17445-4 Rev. 7/09 01.2-1457-053

01 Rev. 7/09
641
---------------------------,
POWER UNIT PARTS

Battery Retainers and Spacers CJ\OWr\
/
28
23
(c)
(a) Left Rear

(b) Right Rear
(c) Rotated 180 degrees
Figure 21137
Crown 2008 PF17595-1

01.2-1457-100
642
POWER UNIT PARTS
Battery Retainers and Spacers
1 060015-117 Screw 4
2 060030-012 Flatwasher 4
3 060011-021 Screw 4
4. . . . . 060005-049. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 119274-002* Resistor 24 V FIC 2
119274-003* Resistor 36 V FIC 2
6 060011-001 Screw 4
8 141429 LH Bracket 1
9. .... 123901 Spring Lever 2
10. .... 123898 Switch Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 060005-001 Lockwasher 4
12 060010-004 Screw 4
13. .... 062683 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14. .... 123899 Switch Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
15. .... 060000-046. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
16. .... 123978* Insulator FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17. .... 123897 . . . . . . . . . . . RH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18. .... 141433 Switch Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 (1) Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 (1) Nut. 2
21 (1) Spacer 1
22 (1) Screw 2
23.. . .. 121620-002* Roller Assembly B Battery Compartment 4
121620-003* Roller Assembly C Battery Compartment 4
121620-004* Roller Assembly 0 Battery Compartment. 4
121620-005* Roller Assembly E Battery Compartment 4
24 065081-018 Ball Bearing 2
25 121619-002* Shaft B Battery Compartment 1
121619-003* Shaft C Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
121619-004* , . Shaft 0 Battery Compartment 1
121619-005* Shaft E Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26 121618-002* Roller B Battery Compartment. 1
121618-003* Roller C Battery Compartment. 1
121618-004* Roller 0 Battery Compartment 1
121618-005* Roller E Battery Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 (1) RH Retainer 1
28 (1) LH Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 060016-004 Screw 1
30 119218 Block 1
31 119219-002 Battery Adjuster Screw 1
(1) See Chart 1

Crown 2008 PF17595-2 01.2-1457-101
643
POWER UNIT PARTS
Battery Retainers and Spacers CROWl'
40~
Figure 21141
01.2-1457-102 Crown 2008 PF17595-3
644
POWER UNIT PARTS
l!J\OWr. Battery Retainers and Spacers
40 078723-001 SB-350 Gray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

078723-003 SB-350 Red Connector 1
078723-006 SB-350 Blue Connector 1
078723-009 SB-350 Yellow Connector 1
108801-001 SBE-320 Gray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
108801-003 SBE-320 Red Connector 1
41 060015-008 ,. Screw 2
42. . . . . 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
43 060030-037 Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crown 2008 PF175954

01.2-1457-103
645
----------------------------------------------
POWER UNIT PARTS
Battery Retainers and Spacers CJ\OWI'
Chart 1 Battery Retainers, Spacers and Hardware (1)
Code Index 19 Index 20 Index 21 Index 22 Index 27 Index 28

Number Lockwasher Nut Spacer Screw RH Retainer LH Retainer
05 Not Required Not Required Not Required Not Required 127733-002 122288-002
07 060005-009 060021-011 123168-004 (5) 060017-041 127733-002 122288-002
08 060005-009 060021-011 123168-005 (6) 060017-020 127733-007 122288-002
09 060005-009 060021-011 123168-005 (6) 060017-020 127733-002 122288-002
12 060005-009 060021-011 123168-004 (5) 060017-041 127733-008 122288-003
13 060005-009 060021-011 123168-007 (7) 060017-020 127733-003 122288-003
14 060005-009 060021-011 123168-002 (3) 060017-041 127733-003 122288-003
15 060005-009 060021-011 123168-004 (5) 060017-041 127733-003 122288-003
25 060005-009 060021-011 123168-001 (2) 060017-069 127733-004 122288-004
27 060005-009 060021-011 123168-001 (2) 060017-069 127733-004 122288-004
29 060005-009 060021-011 123168-001 (2) 060017-069 127733-005 122288-005
30 060005-009 060021-011 123168-003 (4) 060017-041 127733-005 122288-005
31 060005-009 060021-011 123168-001 (2) 060017-069 127733-005 122288-005
32 060005-009 060021-011 123168-003 (4) 060017-041 127733-005 122288-005
(1) Part numbers dependent on battery code number. Refer to Chart 2 for AC Hydraulic Trucks and Chart 3 for DC Hydraulic Trucks
for Code Number information.
(2) 32 x 940 x 6 mm (1.25 x 37.0 x 0.25 in)
(3) 32 x 940 x 10 mm (1.25 x 37.0 x 0.38 in)
(4) 32 x 940 x 13 mm (1.25 x 37.0 x 0.50 in)
(5) 32 x 940 x 16 mm (1.25 x 37.0 x 0.62 in)
(6) 32 x 940 x 22 mm (1.25 x 37.0 x 0.88 in)
(7) 32 x 940 x 29 mm (1.25 x 37.0 x 1.12 in)
01.2-1457-104 Crown 2008 PF17595-5
646
POWER UNIT PARTS
CJ\OWf\ Battery Retainers and Spacers
Chart 2 24V Code Numbers
Battery Maximum Battery Size Battery Weight

Amp
Code Compart-
mm In Hour Minimum Maximum
Number ment
(+.00/-6.0 mm) (+.00/-0.25 In) Range
Size kg Ib kg Ib
05 B 360x975x785 14.25x38.38x31.0
06 B 360x925x785 14.25x36.38x31.00 650-850 640 1410 955 2110
07 B 345X975X785 13.62X38.38X31.00 880 640 1410 955 2110
08 B 340x900x785 13.38x35.38x31.00 725-875 640 1410 955 2110
10 C 410x975x785 16.25x38.38x31.00
11 C 410x925x785 16.25x36.38x31.00 780-1020 775 1710 1090 2400
12 C 400x900x785 15.62x35.38x31.00 870-960 775 1710 1090 2400
13 C 385x975x785 15.12x38.38x31.00 990-1080 775 1710 1090 2400
Chart 3 36V Code Numbers
Battery Maximum Battery Size Battery Weight

Amp
Code Compart-
mm in Hour Minimum Maximum
Number ment
(+.00/-6.0 mm) (+.00/-0.25 in) Range
Size kg Ib kg Ib
05 B 360x975x785 14.25x38.38x31.00
07 B 360x975x785 14.25x38.38x31.00 500-550 725 1595 950 2090
09 B 360x975x785 14.25x38.38x31.00 550-600 725 1595 950 2090
10 C 410x975x785 16.25x38.38x31.00 600-720 850 1880 1130 2490
14 C 405x975x785 15.88x38.38x31.00 600-660 850 1880 1175 2585
15 C 400x975x785 15.62x38.38x31.00 660-720 850 1880 1130 2490
24 0 455x980x785 18.00x38.68x31.00 700-1000 950 2120 1350 2980
25 0 450x980x785 17.75x38.69x31.00 770-875 960 2120 1270 2800
26 0 455x975x785 18.00x38.44x31.00 770-1085 960 2120 1350 2980
27 0 450x975x785 17.75x38.44x31.00 770-875 960 2120 1270 2800
28 E 525x980x785 20.75x38.69x31.00 880-1120 1090 2400 1395 3070
29 E 520x980x785 20.50x38.69x31.00 840-1120 1090 2400 1395 3070
30 E 515x980x785 20.25x38.69x31.00 800-1000 1090 2400 1395 3070
31 E 520x975x785 20.50x38.44x31.00 880-1000 1090 2400 1395 3070
32 E 515x975x785 20.25x38.44x31.00 880-1000 1090 2400 1395 3070
Crown 2008 PF17595-6 01.2-1457-105
647
POWER UNIT PARTS
Battery Retainers and Spacers· EE CJ\OW"
23
(a) Left Rear

(b) Right Rear
(c) Rotated 180 degrees
Figure 26732
01.2-1457-150 Crown 2009 PF17685-1
648
POWER UNIT PARTS
CJ\owr. Battery Retainers and Spacers· EE
1 060015-117 Screw 4
2 060030-012 Flatwasher. 4
3 060011-021 Screw 4
4. . . . . 060005-049. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 119274-002* Resistor 24 V FIC 2
119274-003* Resistor 36 V FIC 2
6 060011-001 Screw 4
7. . . . . 060005-036. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9. . . . . 123901 Spring Lever 2
10. . . . . 123898 . . . . . . . . . . . Switch Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 . . . . . 060005-001. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 060010-004 Screw 4
13. . . . . 062683 . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14. . . . . 123899 Switch Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
15 060000-046 Roll Pin 4
16. . . . . 123978* Insulator FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 . . . . . 123897 . . . . . . . . . . . RH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18 141433 Switch Retainer , 1
19 (1) . • . . . . . . . . . . . • • Lockwasher 2
20 (1) Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 (1) Spacer 1
22 (1) . . . . . . . . . . . . . • • Screw 2
23. . . . . 121620-002* Roller Assembly B Battery Compartment 4
121620-003* Roller Assembly C Battery Compartment 4
121620-004* Roller Assembly D Battery Compartment. 4
121620-005* Roller Assembly E Battery Compartment 4
24 065081-018 Ball Bearing 2
25 121619-002* Shaft B Battery Compartment 1
121619-003* Shaft C Battery Compartment 1
121619-004* Shaft D Battery Compartment 1
121619-005* Shaft E Battery Compartment 1
26 121618-002* Roller B Battery Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
121618-003* Roller C Battery Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
121618-004* Roller D Battery Compartment 1
121618-005* Roller E Battery Compartment 1
27 (1) . • . . . . • . . . • . . • . RH Retainer 1
28 (1) . . . . . . . • • • . . . . . LH Retainer 1
29 060016-004 Screw 1
30 119218 Block 1
31 119219-002 Battery Adjuster Screw 1
(1) See Chart 1

to determine buck features. Refer to Introduction.
Crown 2009 PF17685-2 01.2-1457-151
649
POWER UNIT PARTS
Battery Retainers and Spacers l!J\OWI'
40~
Figure 21141
01.2-1457-152 Crown 2009 PF17685-3
650
POWER UNIT PARTS
CJ\OWJ\ Battery Retainers and Spacers
40 078723-001 SB-350 Gray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

078723-003 SB-350 Red Connector 1
078723-006 SB-350 Blue Connector 1
078723-009 SB-350 Yellow Connector 1
108801-001 SBE-320 Gray Connector , 1
108801-003 SBE-320 Red Connector 1
41 060015-008 Screw 2
42. . . . . 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
43 060030-037 Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crown 2009 PF17685-4 01.2-1457-153
651
POWER UNIT PARTS
Battery Retainers and Spacers CROWl'
Chart 1 Battery Retainers. Spacers and Hardware (1)
Code Index 19 Index 20 Index 21 Index 22 Index 27 Index 28

Number Lockwasher Nut Spacer Screw RH Retainer LH Retainer
10 Not Required Not Required Not Required Not Required 126052-001 126051
11 Not Required Not Required Not Required Not Required 126052-002 126051
12 060005-009 060021-011 123168-004 (5) 060017-041 126052-002 126051
13 060005-009 060021-011 123168-007 (7) 060017-020 126052-001 126051
14 060005-009 060021-011 123168-002 (3) 060017-041 126052-001 126051
15 060005-009 060021-011 123168-004 (5) 060017-041 126052-001 126051
24 Not Required Not Required Not Required Not Required 130240 130239
25 060005-009 060021-011 123168-001 (2) 060017-069 130240 130239
27 060005-009 060021-011 123168-001 (2) 060017-069 130240 130239
29 060005-009 060021-011 123168-001 (2) 060017-069 130242 130241
30 060005-009 060021-011 123168-003 (4) 060017-041 130242 130241
31 060005-009 060021-011 123168-001 (2) 060017-069 130242 130241
32 060005-009 060021-011 123168-003 (4) 060017-041 130242 130241
(1) Part numbers dependent on battery code number. Refer to Chart 2 for AC Hydraulic Trucks and Chart 3 for DC Hydraulic Trucks
for Code Number information.
(2) 32 x 940 x 6 mm (1.25 x 37.0 x 0.25 in)
(3) 32 x 940 x 10 mm (1.25 x 37.0 x 0.38 in)
(4) 32 x 940 x 13 mm (1.25 x 37.0 x 0.50 in)
(5) 32 x 940 x 16 mm (1.25 x 37.0 x 0.62 in)
(6) 32 x 940 x 22 mm (1.25 x 37.0 x 0.88 in)
(7) 32 x 940 x 29 mm (1.25 x 37.0 x 1.12 in)
01.2-1457-154 Crown 2009 PF17685-S
652
POWER UNIT PARTS
CJ\OWI' Battery Retainers and Spacers
Chart 2 24 V Code Numbers
Maximum Battery Size Battery Weight

Battery Amp
Code
Compartment mm in Hour Minimum Maximum
Number
Size (+.00/-6.0 mm) (+.00/-0.25 in) Range
kg Ib kg Ib
10 C 410x975x785 16.25x38.38x31.00
11 C 410x925x785 16.25x36.38x31.00 780-1020 775 1710 1090 2400
12 C 400x900x785 15.62x35.38x31.00 870-960 775 1710 1090 2400
13 C 385x975x785 15.12x38.38x31.00 990-1080 775 1710 1090 2400
Chart 3 36 V Code Numbers
Maximum Battery Size Battery Weight

Battery Amp
Code
Compartment mm in Hour Minimum Maximum
Number
Size (+.00/-6.0 mm) (+.00/-0.25 in) Range
kg Ib kg Ib
10 C 410x975x785 16.25x38.38x31.00 600-720 850 1880 1130 2490
14 C 405x975x785 15.88x38.38x31.00 600-660 850 1880 1175 2585
15 C 400x975x785 15.62x38.38x31.00 660-720 850 1880 1130 2490
24 D 455x980x785 18.00x38.68x31.00 700-1000 950 2120 1350 2980
25 D 450x980x785 17.75x38.69x31.00 770-875 960 2120 1270 2800
26 D 455x975x785 18.00x38.44x31.00 770-1085 960 2120 1350 2980
27 D 450x975x785 17.75x38.44x31.00 770-875 960 2120 1270 2800
28 E 525x980x785 20.75x38.69x31.00 880-1120 1090 2400 1395 3070
29 E 520x980x785 20.50x38.69x31.00 840-1120 1090 2400 1395 3070
30 E 515x980x785 20.25x38.69x31.00 800-1000 1090 2400 1395 3070
31 E 520x975x785 20.50x38.44x31.00 880-1000 1090 2400 1395 3070
32 E 515x975x785 20.25x38.44x31.00 880-1000 1090 2400 1395 3070
Crown 2009 PF17685-6 01.2-1457-155
653
POWER UNIT PARTS
Overhead Guard l!J\OWI'
(a) Part of Main Frame

(b) Refer to Electronic Parts for Overhead Guard Accessories
(c) Torque 305 - 339 Nm (225 - 250 ft Ib)
Figure 21152
01.2-1457-200 Crown 2008 PF17599-1
654
POWER UNIT PARTS
CJ\owr. Overhead Guard
1 (1) Overhead Guard 1

2. . . . . 060023-026 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
061004-019 Thread Locking Adhesive AR
(1) See Chart
Crown 2008 PF17599-2 01.2-1457-201
655
1"
POWER UNIT PARTS
Overhead Guard CROWl'
=jJ (c) m
2
/~
(a) Part of Main Frame

(b) Refer to Electronic Parts for Overhead Guard Accessories
(c) Torque 305 - 339 Nm (225 - 250 ft Ib)
Figure 21152
01.2-1457-202 Crown 2008 PF17599-3
656
POWER UNIT PARTS
CROWl' Overhead Guard
Index 1* Overhead Guard
Battery Compartment
Index 1
Description B C D E
360 mm (12.19 In) 415 mm (16.25 in) 455 mm (18.00 In) 525 mm (20.75 In)
Overhead Guard 139740-002 139740-003 139740-004 139740-005
Overhead Guard with
140286-000-22 140286-000-23 140286-000-24 140286-000-25
Work Assist
Overhead Guard with
140286-001-02 140286-001-03 140286-001-04 140286-001-05
Work Light
Overhead Guard with
140286-000-12 140286-000-13 140286-000-14 140286-000-15
RF Terminal Mount
Overhead Guard with
Work Light & 140286-001-12 140286-001-13 140286-001-14 140286-001-15
RF Terminal Mount
Overhead Guard with
140286-001-22 140286-001-23 140286-001-24 140286-001-25
Work Light & Work Assist
Overhead Guard with
140286-010-02 140286-010-03 140286-010-04 140286-010-05
Wire Mesh Cover
Overhead Guard with
Wire Mesh Cover & 140286-010-12 140286-010-13 140286-010-14 140286-010-15
RF Terminal Mount
Overhead Guard with
Wire Mesh Cover & 140286-010-22 140286-010-23 140286-010-24 140286-010-25
Work Assist
Overhead Guard with
Wire Mesh Cover & 140286-011-02 140286-011-03 140286-011-04 140286-011-05
Work Light
Overhead Guard with
Wire Mesh Cover, Work
140286-011-12 140286-011-13 140286-011-14 140286-011-15
Light & RF Terminal
Mount
Overhead Guard with
Wire Mesh Cover, Work 140286-011-22 140286-011-23 140286-011-24 140286-011-25
Light & Work Assist

Crown 2008 PF17599-4 01.2-1457-203
657
I
• I
CJ\OWI'
Notes:
658
r----------- ----
mOWf\
HYDRAULIC PARTS
659
HYDRAUtlC PARTS
AC Hydraulic Reservoir CJ\OWI'
1-
-1-- 5
1 1
8-+(0: @-9
<9- . . ., . .-/"15 1 ~ I
vr::::e "
I............
1
7.:::[
..... ,
, )
I
1
1...... /
/
14/ 1) : 1 v('
15.-/" 'I I
10<~ i
16-ij ct- 20
15-Cf>
I
' .....
:
1
1
-4
20-CP
Part of power unit, RH

bracket and mounting hard-
ware
(
(b) Torque Cap 22 - 27 Nm
~-20 (16 - 20 ft Ib)
16-~
(c) Torque 4.5 Nm (3.3 ft Ib)
20-CP
Figure 21445
02.0-1457-001 Crown 2009 PF17446-1 Rev. 10109
01 Rev. 10109
660
--- - - - - ~ ~ ~ .~ - -
HYDRAULIC PARTS
CJ\OWI' AC Hydraulic Reservoir
o 143728 Reservoir Assembly 1

1 125111 LH Reservoir Assembly 1
121872 LH Reservoir 1
2. . . . . . . . .. 127742 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 122338 Tube 1
4 128255 RH Reservoir Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127901 RH Reservoir 1
5 127740 Filter , 1
127741 Filter Element 1
128005 O-Ring Kit Includes Filter Gasket 1
128292 Cap 1
128293 Bypass 1
6 060014-089 Screw 4
7 127915 Tube 1
8. . . . . . . . . . 061022-003 Clamp AR
9. . . . . . . . .. 127742... . . . . . . . . Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 122338 Tube 1
11 064143-001 Hose Nipple 1
12 064019-030 O-Ring 1
13 085653-347 Green Lead Assembly 1
14 127706 Tube 2
15 061022-010 Clamp AR
16 128903 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 123283 Hose 1
18 123327 RH Hose 1
19 123284 LH Hose 1
20 061022-009 Clamp AR
Crown 2009 PF17446-2 Rev. 10/09 02.0-1457-002

01 Rev. 10109
661
~-----------------------------
HYDRAULIC PARTS
AC Hydraulic Reservoir CJ\OWI'
(a) Part of power unit

(b) To hydraulic tube connected to port T2 on manifold block
(c) To hydraulic tube connected to port T1 on manifold block
(d) Torque 9.5 Nm (7 ft Ib)
32
~/~
);(~ \
Jr' (a)
~I /
/ 31 "'»j
30 I ~
\ ." .- ---
Figure 21723
02.0-1457-003 Crown 2009 PF17446-3 Rev. 10/09
01 Rev. 10/09
662
HYDRAULIC PARTS
l!J\OWr. AC Hydraulic Reservoir
30 060078-024 Screw 2
31 060030-010 Flatwasher. 2
32. . . . . 143029 Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
33 * (1) Suction Hose 1
34. . . . . * (2) Suction Tube " . . . . . . . .. 1
35. . . . . 064173-037. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
36 143053 Inlet Elbow 1
37 . . . . . 060063-042. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
38 064019-116 O-Ring " 1
39. . . . . 064374 . " Suction Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
40 064100-139 Hose 1
41 * (1) Hose 1
42 * (1) Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
43 064270-001 Tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
44 * (1) Hose " 1
45 143730 Tube " 1
46 061022-003 Clamp " AR
47 061022-009 Clamp .. " "" "" AR
(1) See Chart 1 - Hose

(2) See Chart 2 - Suction Tube

Chart 1 - Hose
Battery Index 33 Index 41 Index 42 Index 44

Compartment Suction Hose Hose Hose Hose
C 064173-034 064100-063 064100-115 064100-013

D 064173-034 064100-063 064100-116 064100-111
E 064173-036 064100-104 064100-117 064100-111
Chart 2 - Suction Tube
Index 34
Battery Compartment
Suction Tube
B,C 143734-001
D,E 143734-002
Crown 2009 PF174464 Rev. 10109 02.0-1457-004

01 Rev. 10109
663
HYDRAULIC PARTS
DC Hydraulic Reservoir CJ\OWr\
1-
..- 1
I
16-~
I
1
20 1 -4
\1
C?
20-CP
(a) Part of power unit, RH bracket,

and mounting hardware
(
cp-20 (b) Torque Cap 22 - 27 Nm
(16 - 20 ft Ib)
16-~
20-CP
Figure 21532
02.0-1457-025 Crown 2009 PF17631-1
664
HYDRAULIC PARTS
CJ\owr. DC Hydraulic Reservoir
o. . . .. 143728 . . . . . . . . . . . Reservoir Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 125111 LH Reservoir Assembly 1
121872 , LH Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2. . . . . . . . .. 127742...... . . . .. Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 122338 Tube 1
4 128255 RH Reservoir Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127901 RH Reservoir 1
5. . . . . . . . .. 127740........... Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127741 Filter Element 1
128005 O-Ring Kit Includes Filter Gasket 1
128292 Cap 1
128293 . . . . . . . . . . . Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 060014-089 Screw 4
7 127915 Tube 1
8. . . . . . . . . . 061022-003 Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 127742 Breather 1
10 122338 Tube 1
11 064143-001 Hose Nipple 1
12 064019-030 O-Ring 1
13 085653-347 , Green Lead Assembly 1
14 127706 Tube 2
15 061022-010 Clamp 4
16 128903 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 123283 Hose 1
18 123327 RH Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 123284 LH Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 061022-009 Clamp 4
Crown 2009 PF17631·2 02.0-1457-026
665
HYDRAU[IC PARTS
DC Hydraulic Reservoir CAOWI'
43
I
~
I'~
37
=jJ (e)
37-CP {J', 0. :::"",
40
. _~ ~ 41-- '-/ ~,I
n") ~ ~ ~
: """"-42 "" '"
,,-P2
"a
"",0"
39
. ( b ) " ~;j 37 (a) Part of power unit
,,~ 38 (b) 36 Vdc trucks only

(a) \ (c) To hydraulic tube connected to port T2
/ ,..//
37 on manifold block
~ ,," (d) To hydraulic tube connected to port T1
32-T""""""" ,," on manifold block
(e) Torque 9.5 Nm (7 ft Ib)
36
/
'0,
'0
Figure 21533
02.0-1457-027 Crown 2009 PF17631-3
666
HYDRAULIC PARTS
CJ\owr. DC Hydraulic Reservoir
30 060078-024 Screw , 2
31 060030-010 Flatwasher 2
32 123285 * Suction Tube (Shown) (1) 1
123286 * Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
33 061022-009 Clamp 4
138911 . . . . . . . . . . . Clamp Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
34. . . . . * (2) Suction Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
35 122341 Tee 1
36 061022-015 Clamp 2
37 061022-001 Clamp 4
38. . . . . 064100-083. . . . . . . . Hose (Shown) (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
064173-026 Suction Hose 1
39. . . . . 064507 . . . . . . . . . . . Suction Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
40 060062-005 Screw , 4
41 064260-002 Metric O-Ring 1
42 064143-003 Hose Nipple 1
43 146144-004 Molded Hose (Shown) (1) , 1
064173-026 Suction Hose 1
44 143730 Tube 1
45. . . . . * (2) . . . . . . . . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
46 064270-001 Tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
47 061022-010 Clamp 2
138911 Clamp Cover 2
48 064100-103 Hose 1
125768-002. . . . . . . . Protective Sleeving " 1
49 064100-100 Hose 1
125768-002. . . . . . . . Protective Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
50 061022-003 Clamp 2
138911 Clamp Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
51 * (2) Hose 1
125768-002. . . . . . . . Protective Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) 36 Vdc Trucks Only

(2) See Chart 1 - Hose
• To select appropriate part number. use the data number

Crown 2009 PF17631-4 02.0-1457-028
667
- ---- - - -------------------------
HYDRAULIC PARTS
DC Hydraulic Reservoir CROWl'
• 48
'~
~, tJ, /46
47/ ~ 47
." ,/
33 /\{J .,,~"- (),
~ ~~\ 33 ~
~." ~ !;,CJJ,
44 .,,'U 45 49 '(9
"~ '(d)
37-CP
Part of power unit

36 Vdc trucks only
To hydraulic tube connected to port T2
on manifold block
(d) To hydraulic tube connected to port T1
on manifold block
Figure 21533
Crown 2009 PF17631-5

02.0-1457-029
668
HYDRAULIC PARTS
CJ\OWI' DC Hydraulic Reservoir
Chart 1 • Hose
Battery Index 34 Index 45 Index 51

Compartment Suction Hose Hose Hose
B 064173-027 064100-114 064100-111
C 064173-041 064100-115 064100-013
D 064173-040 064100-116 064100-111
E 064173-042 064100-117 064100-111
Crown 2009 PF17631.e 02.0-1457-030
669
--------------------------
HYDRAULIC PARTS
Manifold Block Hydraulics CROW"
(f)
1
1

(b) See Hydraulic Parts
(c) Only used on trucks equipped with one lift pump
(d) To second lift pump (P2)
(e) To reach carriage hydraulics, right fitting, located on left
lift cylinder
(f) To reach carriage hydraulics, left fitting, located on left
cylinder
(g) To hydraulic tubes connected to lift cylinders
(h) To hydraulic reservoir tee
)
(i) To RH hydraulic reservoir and filter
,.-
1
(b) 1 (i)
\ 1
1
1,,1
I
I
l I~;-(b)
1 •
lh - - ' I·
1'1
I I
Figure 21443-01
Crown 2009 PF17447-1 Rev. 7/10

02.0-1457-050
02 Rev. 7/10
670
HYDRAULIC PARTS
CJ\OWrl Manifold Block Hydraulics
1 * (1) Accessory Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

2 * (1) Accessory Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 * (2) . . . . . . . . . . . • • • Lift Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 064287-012 Hose Assembly (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 064280-010 Adapter 2
6 064019-045 , O-Ring , 2
7 064019-102 O-Ring 2
8 064287-011 Hose Assembly (4) 1
064539-001 Hose Assembly (5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 060062-034 Screw 4
10 064405 Flange Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) See Chart 1 - Accessory Hoses
(2) See Chart 2 - Lift Tube Assembly
(3) 36 V DC Hydraulic Trucks
(4) DC Hydraulic Trucks
(5) AC Hydraulic Trucks

Chart 1 • Accessory Hoses
Index 1 Index 2
Battery Compartment
Hose Assembly Hose Assembly
B&C 064523-001 064513-002
D&E 064513-003 064513-004
Chart 2 - Lift Tube Assembly
Index 3
Battery Compartment Mast Type
Tube
B n 148631
C n 143732-003
D n 143732-004
E n 143732-005
B Drive-in Rack Mast n 146011-004
C Drive-in Rack Mast n 146011-001
D Drive-in Rack Mast n 146011-002
E Drive-in Rack Mast n 146011-003
Crown 2009 PF17447-2 Rev. 7110 02.0-1457-051

02 Rev. 7/10
671
HYDRAULIC PARTS
Steering Control CJ\OWI'
I I
I I
I I
I I
LI IT
I
R'
----'--<11---"< '-L~'",. ---1...---4---
I I I
I
- - ----e---.
LSI
I
I
--D=
(f)
8 9
I /
.-~---f---.,,
-7
@)- - -@- - -tf)}- - +- :
-1
/
11 10
/ \ ";:
\ • (f) 12, ,
\" \ D= / ,','
--2 <&- - -@---tf)}--+ - l-'-~,~~=:J)
f
(\
-3 A d
~-18 . - - -@- -"$- - ... -..J '''---J
16-&. 11
/ 16 (f)
\:
12:
I
(c)
(g) 'tJ
I D= / \" \ D= / :
17
/
8---@---$-- ... __ ..J
11 /-0'-""""12
Ie'
/
.l@"'/ ""10
(f) D=
(a) Lift Pump

(b) Steer Motor
(c) Steer Control Unit
(d) Hose Nipple to S Port on Manifold Block
(e) Manifold Block
(f) Torque 30 - 33 Nm (22 - 24 ft Ib)
(g) Torque 15 -16 Nm (11 -12 ft Ib)
Figure 20784
02.0-1457-100 Crown 2009 PF17448-1
672
HYDRAULIC PARTS
CJ\owr. Steering Control
1 064343-024 Hose Assembly 1

2. . . . . 064495-001. . . . . . . . Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 064281-004 Adapter 2
5 064019-099 O-Ring 2
6 064019-029 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 064083-017 Beaded Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 064019-029 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 064279-005 Adapter 5
11 064019-099 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12 064019-029 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
13 138911 Clamp Cover 2
14 061022-014 Clamp , 2
15 064100-143 Hose 1
16 064280-004 Adapter 1
17 064019-031 O-Ring , 1
18 064019-099 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
061003-003 Cable Tie AR
Crown 2009 PF17448-2 02.0-1457-101
673
HYDRAULIC PARTS
Reach Hydraulics CJ\OWI'
(f) _ _
j-(d)
-15
(a) Bottom of Reach Support

(b) Hose B; Connects to Hydraulic
Tubes Connected to Port B on
Manifold
(c) Hose A; Connects to Hydraulic
20-- -20
Tubes Connected to Port A on
Manifold
23
(d) Lift and Right Reach Cylinders
Mounted to Reach Support
(e) Reach Manifold 23
(f) Top of Reach Support 22
(g) Top of Reach Carriage
(h) Tilt Manifold
(i) Tilt Cylinder Mounted to Bottom
of Reach Carriage
Figure 21540
02.0-1457-300 Crown 2009 PF17449-1
674
HYDRAULIC PARTS
CJ\OW" Reach Hydraulics
1 064061-004 Elbow 6
2 064019-031 a-Ring 6
3. . . . . 064252-046. . . . . . . . Hose RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
064252-047 Hose RD 2
4 064252-045 Hose RR 2
064252-043. . . . . . . . Hose RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 064061-001 Elbow 2
6 064019-031 a-Ring 2
7 077389-005 Tube RR 2
077389-006 Tube RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 061002-001 Clamp 2
9 060013-002 5crew 2
10 060005-004 Lockwasher. 2
11 064171-004 Elbow 2
12 064019-031 a-Ring 2
13. . . . . 064253-079. . . . . . . . Hose RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
064253-080. . . . . . . . Hose RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14. . . . . 122277 Left Hand Tube Capacity 1588 kg (3500 Ib) RR . . . . . . . . . . . . . . . . . . . . .. 1
122242 Left Hand Tube Capacity 2040 kg (4500 Ib) RR, 1360 kg (3000 Ib) RD 1
15. . . . . 122276 Right Hand Tube Capacity 1588 kg (3500 Ib) RR. . . . . . . . . . . . . . . . . . . .. 1
122241 Right Hand Tube Capacity 2040 kg (4500 Ib) RR, 1360 kg (3000 Ib) RD. .. 1
16 064091-006* Plug 2
17 064019-031 a-Ring , 2
18. . . . . 064004-007. . . . . . . . Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
19 064019-031 a-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 064253-081 Hose RR or RD 2
21 064019-031 a-Ring 2
22 064033-002 Bulkhead Connector 2
23 064030-003 Nut. 2
24 064091-002* Plug 1
25 064019-029 a-Ring : . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26 064080-004 Tee 2
27 064019-031 a-Ring 2
28. . . . . 064128-003. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
122176-001 Harness (Tilt, 55) RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

122176-002 Harness (Tilt, 55) RD 1
129324-001 Harness (Tilt, 55, L5) RR 1
129324-002 Harness (Tilt, 55, L5) RD 1

to detennlne truck features. Refer to Introduction.
Crown 2009 PF17449-2 02.0-1457-301
675
HYDRAULIC PARTS
Reach Hydraulics with Tilt & Sideshift CJ\OWI'
-15
(a) Bottom of Reach Support

(c)
(b) Hose B; Connects to Hydraulic (b) I
~~
Tubes Connected to Port B on
Manifold
(c) Hose A; Connects to Hydraulic
Tubes Connected to Port A on
Manifold 19
(d) Left and Right Reach Cylinders I~
Mounted to Reach Support
(e) Reach Manifold 19
(f) Top of Reach Support 18
(g) Top of Reach Carriage
(h) Tilt and Sideshifl Manifold
18
Figure 21541
02.0-1457-350 Crown 2009 PF17450-1 Rev. 7/09
01 Rev. 7/09
676
HYDRAULIC PARTS
CJ\OWI) Reach Hydraulics with Tilt & Sideshift
1 064061-004 Elbow 6
2 064019-031 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 064252-046 Hose RR 2
064252-047 Hose RD , 2
4 064252-045 Hose RR 2
064252-043 Hose RD , 2
5 064061-001 Elbow 2
6 064019-031 O-Ring 2
7 077389-005 Tube RR 2
077389-006 Tube RD 2
8 061002-001 Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9 060013-002 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10. . . . . 060005-004. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 064171-004 Elbow , 2
12 064019-031 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
13. . . . . 064253-079. . . . . . . . Hose RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
064253-080. . . . . . . . Hose RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 122277 Left Hand Tube Capacity 1588 kg (3500 Ib) RR 1
122242 Left Hand Tube Capacity 2040 kg (4500 Ib) RR, 1360 kg (3000 Ib) RD 1
15. . . . . 122276 Right Hand Tube Capacity 1588 kg (3500 Ib) RR. . . . . . . . . . . . . . . . . . . .. 1
122241 Right Hand Tube Capacity 2040 kg (4500 Ib) RR, 1360 kg (3000 Ib) RD 1
16 064091-006* Plug 1.
17 064019-031 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18 064033-002 Bulkhead Connector 2
19 064030-003 Nut. 2
20 064080-004 Tee 2
21 064019-031 O-Ring 2
22 064128-003 Cap 2

Crown 2009 PF1745().2 Rev. 7/09 02.0-1457-351

01 Rev. 7/09
677
HYDRAUliC PARTS
Reach Hydraulics with Tilt & Sideshift Cl\OWI'
""
")
) I
I ~-43
43-~
, 'if
I
--42
42-
0 I
~(C)
40--
--40
(a) Top of Reach Carriage

(b) Tilt and Sideshift Manifold
(c) Sideshift Cylinder Mounted to Sideshift Attachment
(d) Tilt Cylinder Mounted to Bottom of Carriage
Figure 21542
Crown 2009 PF17450-3 Rev. 7/09

02.0-1457-352
01 Rev. 7/09
678
HYDRAULIC PARTS
Reach Hydraulics with Tilt & Sideshift
32. . . . . 064253-009. . . . . . . . Hose RR or RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

33 064061-004 Elbow 4
34 064019-031 O-Ring 4
35 064253-010 Hose RR or RD 1
36 064091-002* Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
37 064019-029 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
38 064091-006 Plug 1
39 064019-031 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
40 064253-081 Hose RR or RD 2
41 064019-031 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
42. . . . . 064004-007. . . . . . . . Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
43 064019-031 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
122176-001 Harness (Tilt, SS) RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

122176-002 Harness (Tilt, SS) RD 1
129324-001 Harness (Tilt, SS, LS) RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129324-002 Harness (Tilt, SS, LS) RD 1

Crown 2009 PF17450-4 Rev. 7/09 02.0-1457-353

01 Rev. 7/09
679
HYDRAULIC PARTS
Mast Hydraulics· TT
~17
I ----'--ll---I~ (a)
(d)
(a) See Cylinder Parts

(b) Connects to Hydraulic Tubes Connected to Ports A & B on
Manifold
(c) Connects to Hydraulic Tubes Connected to Port C on Mani-
fold
(d) Connects to Hydraulic Tubes Connected to Ports A & B on
Reach Manifold
Figure 21007
02.0-1457-400 Crown 2008 PF17577-1
680
HYDRAULIC PARTS
CAOW" Mast Hydraulics· TT
1 126130 Tube 1
2 121856 Tube 1
3 064090-004 Long Connector 2
064019-030 O-Ring 2
4 064034-002 Bulkhead Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. . . . . 064030-003 Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 (1) * Hose Assembly 2
061004-023 10cc Hydraulic Sealant 1
7 (2) * . . . . . . . . . . . . . . Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
061004-023 10cc Hydraulic Sealant 1
8 064030-010 Bulkhead Nut 2
9 123281 Clamp 2
10. . . . . 060015-048 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 . . . . . 060005-007 Lockwasher 1
12 121729 Tube 1
13 121728 Tube 1
14 064097-004 Union Elbow 1
15 121737 Tube 1
16 064061-016 90 Elbow 1
064019-075 O-Ring 1
17 (3) * . . . . . . . . . . . . . . Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
061004-023 Hydraulic Sealant 1
18 060015-049 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 060042-006 Self-Locking Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 126129 Tube 1
(1) See Chart 1 - Hose Assembly Chart 6


to detennine truck features. Refer to Introduction.
Crown 2006 PF175n·2 02.0-1457-401
681
HYDRAULIC PARTS
Mast Hydraulics· TT CJ\OWI'
Chart 1 - Hose Assembly Index 6
Collapsed Height Lift Height Hose Length

Hose
mm In mm In mm In
064254-204 2260 89 5025 198 3054 120.25
064254-205 2415 95 5335 210 3356 132.12
064254-206 2720 107 6100 240 3956 155.75
064254-207 3025 119 6860 270 4553 179.25
064254-208 3325 131 7620 300 5156 203
064254-209 3555 140 8155 321 5601 220.50
064254-210 3785 149 8660 341 6052 238.25
064254-211 4065 160 9300 366 6598 259.75
064254-212 4370 172 10160 400 7195 283.25
064254-309 4520 178 10695 421 7465 293.88
064254-313 4826 190 11227 442 8090 318.50

Hose
mm In mm In mm In
064263-001 2260 89 5025 198 3013 118.62
064263-002 2415 95 5335 210 3312 130.38
064263-003 2720 107 6100 240 3909 153.88
064263-004 3025 119 6860 270 4509 177.50
064263-005 3325 131 7620 300 5105 201
064263-006 3555 140 8155 321 5553 218.62
064263-007 3785 149 8660 341 6001 236.25
064263-008 4065 160 9300 366 6547 257.75
064263-009 4370 172 10160 400 7140 281.12
064263-010 4520 178 10695 421 7499 295.25
064263-011 4826 190 11227 442 8036 316.38
02.0-1457-402 Crown 2008 PF175n-3
682
HYDRAULIC PARTS
l!J\OWI' Mast Hydraulics· TT

Hose
mm in mm In mm in
064254-214 2260 89 5025 198 2505 98.62
064254-215 2415 95 5335 210 2654 104.50
064254-216 2720 107 6100 240 2953 116.25
064254-217 3025 119 6860 270 3258 128.25
064254-218 3325 131 7620 300 3556 140
064254-219 3555 140 8155 321 3778 148.75
064254-220 3785 149 8660 341 4007 157.75
064254-221 4065 160 9300 366 4280 168.50
064254-222 4370 172 10160 400 4578 180.25
064254-310 4520 178 10695 421 4729 186.19
064254-314 4826 190 11227 442 5029 198
Crown 2008 PF17577-4 02.0-1457-403
683
HYDRAULIC PARTS
Drive In Rack Mast Hydraulics· TT CJ\OWI'
~17
(a) :::::--
6-
5---= I~ • I
(d)
(a) See Cylinder Parts

(b) Connects to Hydraulic Tubes Connected to Ports A & B on Manifold
(c) Connects to Hydraulic Tubes Connected to Port C on Manifold
(d) Connects to Hydraulic Tubes Connected to Ports A & B on Reach
Manifold
18-
Figure 21010
02.0-1457-500 Crown 2008 PF17578-1
684
HYDRAULIC PARTS
CJ\owr. Drive In Rack Mast Hydraulics - TT
1 126130 Tube 1
2 129081 Tube 1
3 064090-004 Long Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
064019-030 O-Ring 2
4 064034-002 Bulkhead Fitting .. , 4
5 064030-003 Bulkhead Nut. 4
6 (1) * Hose Assembly 2
7. . . .. (2) * . . . . . . . . . . . . . . Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 064030-010 Bulkhead Nut. 1
9 123281 Clamp 1
10. . . . . 060015-048. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 . . . . . 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 129086 Tube 1
13 129085 Tube , 1
14 064097-004 Union Elbow , , 1
15 129084 Tube 1
16 064061-016 90° Elbow 1
064019-075 O-Ring 1
17. . . .. (3) * Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
18 129083 Tube 1


Crown 2008 PF17578-2 02.0-1457-501
685
HYDRAULIC PARTS
Drive In Rack Mast Hydraulics· TT CJ\OWI'

Hose
mm in mm in mm in
064254-287 2260 89 5025 198 3054 120.25
064254-288 2415 95 5335 210 3356 132.12
064254-289 2720 107 6100 240 3956 155.75
064254-290 3025 119 6860 270 4553 179.25
064254-291 3325 131 7620 300 5156 203
064254-292 3555 140 8155 321 5601 220.50
064254-293 3785 149 8660 341 6052 238.25
064254-294 4065 160 9300 366 6598 259.75
064254-295 4370 172 10160 400 7195 283.25
Chart 2 • Hose Assembly Index 7

Hose
mm in mm in mm in
064263-001 2260 89 5025 198 3013 118.62
064263-002 2415 95 5335 210 3312 130.38
064263-003 2720 107 6100 240 3909 153.88
064263-004 3025 119 6860 270 4509 177.50
064263-005 3325 131 7620 300 5105 201
064263-006 3555 140 8155 321 5553 218.62
064263-007 3785 149 8660 341 6001 236.25
064263-008 4065 160 9300 366 6547 257.75
064263-009 4370 172 10160 400 7140 281.12
02.0-1457-502 Crown 2008 PF17578-3
686
HYDRAULIC PARTS
CJ\OWI' Drive In Rack Mast Hydraulics - TT
Chart 3 • Hose Assembly Index 17

Hose
mm in mm In mm In
064254-214 2260 89 5025 198 2505 98.62
064254-215 2415 95 5335 210 2654 104.50
064254-216 2720 107 6100 240 2953 116.25
064254-217 3025 119 6860 270 3258 128.25
064254-218 3325 131 7620 300 3556 140
064254-219 3555 140 8155 321 3778 148.75
064254-220 3785 149 8660 341 4007 157.75
064254-221 4065 160 9300 366 4280 168.50
064254-222 4370 172 10160 400 4578 180.25
Crown 2008 PF17578-4 02.0-1457-503
687
HYDRAULIC PARTS
_DC_I_AC_Li_ft_Pu_m....;"p -.Il:.g~C;;;;;;..I(E,:< L E CJ\OW"
II 5 7.3 7
G I P5;).. .. 0 I ( f2.{5"3 LJ ...
b ooo/Jer5;:,1 h
67 3 '!-0 'Ji}'2
";0 (a) I
2
ftJ ,
91'
(b)
/
'0 4
! ~"
3-CJ/
CF EF
s
(a) Torque 27 Nm (19.9 ft Ib)
(b) Torque 50-60 Nm (36.9-44.3 ft Ib)
Figure 14354-03
Crown 2006 PF1542D-1 Rev. 2110

02.1-1055-001
03 Rev. 2110
688
HYDRAULIC PARTS
CJ\owra DC/AC Lift Pump
1 . . . .. 133903-001 Internal Gear Pump (DC) (1) . . . . • . . • • . . . . . . . . . . . . . . . • . . . . . . . . . . .. 1

133903-002 Internal Gear Pump (AC) (2) 1
2. . . . . 060063-069. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 064260-004 O-Ring 1
4 140287 Priority Valve Kit 1
5. : 064260-005 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
063002-040 Spline Grease AR
(1) RC 5500 and RRIRD 5700 trucks

(2) RC 5500 trucks only
Crown 2006 PF1542().2 Rev. 2110

02.1-1055-002
03 Rev. 2110
689
HYDRAULIC PARTS
36 V 10 cc Lift Pump l!J\OWI'
(a) Position of gears shown with counterclockwise rotation

(b) Torque 45 - 50 Nm (34 - 38 It Ib)
Figure 21373
02.1-1457-001 Crown 2009 PF17451-1
690
HYDRAULIC PARTS
CJ\owr. 36 V 10 cc Lift Pump
1 . . . .. 138824 36 V 10 cc Lift Pump - No Load Sensing . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

2 (1) Screw 2
3 (1) •.••••.•.....•.• Lockwasher 2
4 (1) End Cover 1
5 (1) . . .. . . .. . . . . O-R',ng . . 2
6 (1) Back-Up Seal 2
7········· (1) Seal 2
8 (1) Bushing 2
9 (1) Bushing 2
10 (1) Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 (1) Driven Gear 1
12 (1) Drive Shaft and Gear 1
13 (1) Mounting Flange 1
14········· (1) Seal 1
15 (1) Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16. . . . . 060005-009. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 060017-054 Screw 2
133570 Pump Seal Kit (Includes Index 5,6,7 & 14) 1

(1) Internal pump components are not available, except seals, due to matched set requirements. Since
components must be replaced as matched sets, pump replacement is more economical.
Crown 2009 PF17451-2 02.1-1457-002
691
HYDRAULIC PARTS
25 cc AC Lift Pump l!J\OWI'
91 (a) I
(a) Torque 25 - 30 Nm (18 - 22 ft Ib)
Figure 21365
02.1-1457-025 Crown 2009 PF17453-1
692
HYDRAULIC PARTS
l!J\OWI' 25 cc AC Lift Pump
1 146633 25 cc Internal Gear Pump 1

2 064260-004 O-Ring 1
4. . . . . 060063-096 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crown 2009 PF17453-2 02.1-1457-026
693
HYDRAULIC PARTS
AC Lift Pump Motor CJ\OW"
(c) (d)
22 ___
fA
23 (~
24", '\.-"., 21 (a)
25-&""
~ ~
IP
(h)
11-'
13--. I
ECR6
14___ I
~
15-, ~~:
16--*~ ~:
I I I
l. 5-<qd),
............ I I
7-
(a) Assembly order when power cables are attached

I
CSt" to motor
~-6
11~~lr"~-9
(b) Power Cable from ACCESS 2 (HCM)
I (c) Flatwasher 060030-232 (Part of Motor)
5-Q (d) Terminal Block 021250 (Part of Motor)
4 _____ (e) Spring Disc 060125-001 (Part of Motor)
(f) Torque 32 - 36 Nm (24 - 27 ft Ib)
(g) For motor assembly purposes, torque 7 - 11 Nm
(5 - 8 ft Ib); when connecting power cables to
I motor, torque 23 - 24 Nm (17 -18 ft Ib)
/
" (h) Torque 24 - 36 Nm (18 - 27 ft Ib)
--2
___
(f)--l1P
'-~----------------~ ~----------------~/
'V'"
1
Figure 20928
02.2-1457-001 Crown 2008 PF17455-1
694
HYDRAULIC PARTS
l!J\OWr. AC Lift Pump Motor
o 021254-001 36 V AC Pump Motor Assembly 1

1 021343 36 V AC Pump Motor 1
2. . . . . . . . . . 021079-008 Tie Bolt 4
3. . . . . . . . . . 060030-359 ., . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 021106 Drive End Head 1
5. . . . . . . . .. 060046-020 ., . . . . . Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 065081-054 Ball Bearing 1
7 021337 Rotor Assembly 1
8. . . . . . . . . . 021120 Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 021062-001 Motor Nameplate 1
10 060125-001 Spring Disc 3
11 . . . . . . . . . . 060063-046 .,. . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12 021245 Terminal End Head Assembly (Includes Index 5, 11, 13-16) 1
021237 Terminal End Head 1
13 021223 Bearing Retainer 1
14 146080-005 Ball Bearing Sensor 1
15 060061-032 Screw 2
16 062749-001 Clip 2
17. . . . . . . . . . 062756-001 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18. . . . . . . . . . 062798-001 Connector Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19. . . . . . . . . . 065003-271 Sleeving (For Thermal Sensor Wire) . . . . . . . . . . . . . . . . . . . . . . . .. 1
20. . . . . . . . . . 060059-020 Nut 4
21 021250 Terminal Block 1
22 060061-013 Screw 4
23 021313 Spacer 3
24. . . . . . . . . . 060030-232 .,. . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
25. . . . . . . . . . 060059-028 ., ..... Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crown 2008 PF17455-2 02.2-1457-002
695
HYDRAULIC PARTS
AC Lift Pump Motor CROWl'
35
36~ I
.@
~
37-)~y
<
r"
I
I
I
I
I
(a)-- I
I
J
40
~
I
'""lir'
42
• (c) IJ=

(b) AC Lift Pump Motor Assembled
(c) Maximum Torque 40.7 Nm (30 ft Ib)
Figure 21485
02.2-1457-003 Crown 2008 PF17455-3
696
HYDRAULIC PARTS
CJ\owr. AC Lift Pump Motor
35 060059-029 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
36 060030-382 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
37 093786-001 Vibration Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
38 021255 Motor Isolation Mount 1
39 060075-082 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40 060030-026 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41 060075-002 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
42 060075-047 Screw 1
Crown 2008 PF17455-4 02.2-1457-004
697
HYDRAULIC PARTS
DC Lift Pump Motor CJ\OWr\
2-¢
~-3
1
I
I 18 20 8
I
I \ \ I
,
I 17- ++++-{l
5 , I
I I
/ I , I 19 10
'J' ,
, I, I
i~
I, I
IJI : 22 - tp:I:ID- -: ~~ 23 ""-

,I I I 'I I "
, :1 21 24 . . . . . . . ~
'" '" '" 7
/ "
I,
'//
'"
/""
/""
-==-......11=
27
-0
\
I::1
I
// /
/25
/
cD.
(b) ~ ~
/ 1~ __ ~:-25." II
//",ij/
/
+-lI\ I 23
/ 26-=-~ • _ J-27
8 10' @:/ / ,~ II ., _ ........
'
:4- 28 l-..j;JI I
c~C) 14 ~-0:,
, I I 25 - : //
II~:\13 I
:I 24-~ . 25 23
\ , I / ,
" <D 'YJ-16 '-," I

\
12 - E:il V
----""'15 ' ,' "
,23 I
I
\ I I
ECR3 I
I
-11
~
(a)/ (b) Torque 14.7 - 19.2 Nm (10.84 - 14.16 ft Ib)
(c) Torque 15.8 - 17 Nm (11.65 - 12.54 ft Ib)
Figure 20954-01
02.2-1457-050 Crown 2009 PF17456-1 Rev. 9/09
01 Rev. 9/09
698
HYDRAULIC PARTS
CROWl' DC Lift Pump Motor
o 021293 36 V DC Pump Motor Assembly (Shown) 1

021297 24 V DC Pump Motor Assembly 1
1 060078-004 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 060046-016 Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 020135 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 021062-002 Motor Nameplate 1
6 060078-011 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 021284 Frame and Field Assembly (Shown) (1) .......••.•••............. 1
021299 Frame and Field Assembly (2) 1
8 060005-054 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9 060078-006 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 060021-053 Nut 2
11 021287 Drive End Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
021288 . . . . . . . . . . . Drive End Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 062749-001 Attachment Clip 1
13 060061-032 Screw 1
15. . . . . . . . .. 146080-007 Ball Bearing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16. . . . . . . . . . 065003-267 Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
061003-004 Cable Tie 1
17 021100 Commutator End Head Assembly (Shown) (1) 1
021298 Commutator End Head Assembly (2) . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
020081 Commutator End Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18. . . . . . . . . . 020026. . . . . . . . . . . Insulating Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19. . . . . . . . . . 060030-248 . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 060021-053 Nut 1
21 020025-001 Terminal Insulator 1
22 060017-101 Screw 1
23. . . . . . . . . . 060078-011 Screw : 4
24. . . . . . . . .. 020024 Terminal and Lead Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
25 021154-003 Brush (Shown) (1) 4
021159-004 Brush (2) . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . . 4
113652 Brush Kit (1) 1
120860 . . . . . . . . . . . Brush Kit (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26. . . . . . . . . . 020018 Brush Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
113329 . . . . . . . . . . . Spring Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27. . . . . . . . . . 020082 Terminal and Lead Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28. . . . . . . . . . 060032-033 .. . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
29 060017-047 Screw 2
(1) 36 V DC Pump Motor

(2) 24 V DC Pump Motor
Crown 2009 PF17456-2 Rev. 9/09 02.2-1457-051

01 Rev. 9/09
699
HYDRAULIC PARTS l!f\OWn
AC Lift Pump Motor - EE
22-T -0 (c) (d)
24" ~...
23 ~ 27
I T- 22
25- .... ~ 21/ ... ~
I ... I
I ,," I (a)
-----1~::::J
~I'" -26 :
,
(h) II ,
11-i " I
~ II I
II I
ECR6 13~:: :
14~1:: I
15 - T I ::: 20 :
16--i -
~
I:11/
:1' 3
I
... ,)
...
l A
I "
5-CP: ::+~" . . . I· II I(
I
("
I
I
I
..
I I
I I
,
I
'.'I
IW
I
~
I
7- I
I
I
I :I : 22
I A (a) Assembly order when power cables are
I
I
128 I i/ ~"""""---11 attached to motor
1 I I I ... \ ~) (b) Power Cable from ACCESS 2 (HCM)
I~
~-6
I 1,./
I
10
.
I
I I,,'" (c) Flatwasher 060030-232 (Part of Motor)
1 1
I I I
... ( (d) Terminal Block 021250 (Part of Motor)
5-Q I
I ,,'" I (e) Spring Disc 060125-001 (Part of Motor)
4-........ : 0'''' (f) Torque 32 - 36 Nm (24 - 27 ft Ib)
~-9
I
I (g) For motor assembly purposes, torq.ue 7
I ... - 11 Nm (5 - 8 ft Ib); when connecting
I power cables to motor, torque 23 -
I
24 Nm (17 -18 ft Ib)
I
I (h) Torque 24 - 36 Nm (18 - 27 ft Ib)
I ~8
I
I
I
I
I I
2- I ... /
I
(f) IF> I
I ...
V ...
'-~---~---------'v"'"
-----------_/
1
Figure 21446
02.2-1457-100 Crown 2009 PF17457-1
700
------------------------ --------
HYDRAULIC PARTS
AC Lift Pump Motor - EE
o 021254-002 36 V AC Pump Motor Assembly - EE 1

1 021281 36 V AC Pump Motor - EE 1
2. . . . . . . . . . 021079-008 Tie Bolt 4
3. . . . . . . . . . 060030-359 .. . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 8
4 021315 Drive End Head 1
5. . . . . . . . . . 060046-020 .. . . . . . Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 2
6 065081-054 Ball Bearing , 1
7 021337 Rotor Assembly 1
8. . . . . . . . . . 021120 Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. 1
9. . . . . . . . . . 021062-001 Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. 1
10. . . . . . . . . . 060125-001 Spring Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ... 3
11 . . . . . . . . . . 060063-046 .. . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ... 7
12 021317 Terminal End Head Assembly (Includes Index 5, 11, 13-16) 1
021307 Terminal End Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 1
13. . . . . . . . . . 021223 Bearing Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 1
14. . . . . . . . .. 146080-005 .. . . . . . Ball Bearing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 1
15. . . . . . . . . . 060061-032 .. . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... 2
16. . . . . . . . . . 062749-001 Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... 2
17. . . . . . . . . . 062756-001 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 1
18. . . . . . . . . . 062798-001 Connector Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 1
19 065003-271 Sleeving (For Thermal Sensor Wire) 1
20 060059-020 Nut 4
22 060061-013 Screw 8
23 021313 Spacer 3
24. . . . . . . . . . 060030-232 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . .. 3
25. . . . . . . . . . 060059-028 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . .. 3
26 021331-001 Foam Seal. 1
27 021318 Terminal Front Cover 1
28 021319 Terminal Back Cover 1
065031-001 Sealant AR
Crown 2009 PF17457-2 02.2-1457-101
701
HYDRAULIC PARTS
AC Lift Pump Motor· EE CJ\own
38
39""
I
.@
~
40-)~y
<

(b) AC Lift Pump Motor Assembled
(c) Maximum Torque 40.7 Nm (30 ft Ib)
Figure 21487
02.2-1457-102 Crown 2009 PF17457-3
702
HYDRAULIC PARTS
CAOWI' AC Lift Pump Motor· EE
38 060059-029 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
39 060030-382 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
40 093786-001 Vibration Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41 021255 Motor Isolation Mount 1
42 060075-082 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
43 060030-026 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
44 060075-002 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 060075-047 Screw 1
Crown 2009 PF174574 02.2-1457-103
703
HYDRAULIC PARTS
Manifold Block CJ\OWI'
(a) Replace Plug with 064143-015
Hose Nipple Elbow on all DC
0)
IP (........__11 Trucks and AC Trucks without EE
9-- ---~IP
r
(j) (b) Torque 41 - 43 Nm (30 - 32 ft Ib)
........__10 9 11 (c) Torque 23 - 24 Nm (17 - 18 ft Ib)

~ 6 \ / (d) Torque 14 -15 Nm (10 - 11 ft Ib)
(c)
IP I,I I
(c) "-
__
~ (e)
(f)
Torque 47 - 54 Nm (35 - 40 ft Ib)
Torque 47 - 54 Nm (35 - 40 ft Ib);
6
, ::6--
I\
I
I I
8 w _10
: ~
(g)
(h)
Torque Coil Nut 7 - 9 Nm (5 - 7 ft Ib)
Torque68-75Nm(50-55ftlb)
Torque 34 - 41 Nm (25 - 30 ft Ib);

I)". I I __ 7 I _13 Torque C oilNut4-7Nm(3-5ftlb)
Ig I~ 4 I RV1 (i) Torque 68 - 75 Nm (50 - 55 ft Ib);
I \ I~ -----(d) I (e) Torque Coil Nut 7 - 9 Nm (5 -7 ft Ib)
7.. . . . . . . I 8 I, • IP I . IP
IP ~ I"J.. I U) Torque 69 - 76 Nm (51 - 56 ft Ib)
(d) IT-5 I I
4-': II I I ,8._14 (k) Torque 54-61 Nm(40-45ftlb);
II~ 12 I I ~ TorqueCoilNut7-9Nm(5-7ftlb)
5--; : :: -PVl / ) I (d) IP
I I I I (k) /
25 - ~:: :: • / ~/ / IP
(b) ~I I I I / (f)
_.~-l1P ~ I: I I : SCV
/ I \ II I / / 15
26 I \" II ( / /
I "" 1 II II ( //
\"" i I~I~I
"I~ol,;,l-~: / / //~.
I I I ( /
1
~ ~ ~ c::::B::.@ 0"
I""':a>I _.0fJ / /" / -" 5 (d)
4.
IP
IP
•
(a)(c)
2
IP ~
.... ~
•
I 0°1
..~
.1, ..
~./,.
~,,~
.~
J'!!
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..... "J~
,......
"-./// ////// . . """"
..............
./
/
/ / / / / -" ""
.....
./
/
... /
/
-......
"
"""41\
" lIP
.....
/
~.
/
(f)
PVA
16
tfW""
~ m
'(I......
... Mil
~ ..........".........
..... / " , /
........
,," ...... /
.~
\~ 'Q) .::- """_/ / / / / / -"" " "" ~ (i)
~/ ~~.......... ~............ ~ ~ ..... ,-"" ". .... 11 ~........... ...... ..... ..... . . . SVL
3_ /(: ".:-",,;:'...,,':..,,:.::-~/// """"""":"",, /17 S~~Y
,
tr
")" """':."",,~/24 """ "" "~/ _.~-I
~ // /) /.>")~ ~,,"""
@"")
2/ ORF4 I (b) IP
~ \
(c) ~
4
I 5
('
""
(
"
""
("
"
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<"
"
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"
'().
""
_ 23 (g)
P C l " " .......
_ _ 22 "" '() • C IP
",," " " 19
I I- 18
(d) " "" """ """ """ 5 " "" '@(2)

-==--I~ ............ ............ ........................ .~ ...........
" " "
................................... ,,'6/ (d) .~ " '0 I
"" " ,,~- 4 (f) /' ~
"" "" "" SVA 3
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"" ""
" " .................... 5. ~
"""""""" I ~)
"" "(J ..-/
......... ~ • (e) IP
RV2
"~__ 20
Figure 21100
Crown 2008 PF17458-1 Rev. 9/10

02.4-1457-001
02 Rev. 9/10
704
HYDRAULIC PARTS
CJ\OW" Manifold Block
o. . ... 143696 Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 143694 Manifold Block 1
2 064091-002 Plug 3
064143-015 Hose Nipple Elbow 1
064019-029 O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3. . . . . . . . . . 064019-029 O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 064091-006 Plug 6
5 064019-031 O-Ring 6
6 064280-006 Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7 064019-029 O-Ring 2
8 064019-101 O-Ring 2
9 064280-017 Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 064019-075 O-Ring 2
11 064019-102 O-Ring 2
12 135800-001 Proportional Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
104164-005 Coil 1
111790-023 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 145115 Relief Valve 1
111790-020 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 123887 Nipple 1
15 117304-005 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
104164-005 .. . . . . . Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
111790-020 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 135724-001 Proportional Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
104164-005 . . Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
111790-020 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 135723-001 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
104164-005 Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
111790-023 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18 064091-001 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 064019-030 O-Ring : 1
20 138361-002 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
111790-005 . . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
21 117385-004 Solenoid Valve 1
104164-005 Coil 1
111790-029 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
22 147680 Compensator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
111790-024 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
23 106845-008 Orifice Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
24 117377-003 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
104164-002 Coil 1
111790-016 Seal Kit. 1
25 064143-001 Hose Nipple Elbow 1
26 064019-030 O-Ring 1
Crown 2008 PF17458-2 Rev. 9/10 02.4-1457-002

02 Rev. 9/10
705
HYDRAULIC PARTS
Manifold Block CJ\OWI'
•
46-1
PCA
(i)
Il=
I
I
I
• (e) Il=
38
I
~
@>-39
I
__ 45
~ l·
CV2
(g)
Il=
$-48
ORF3
(I)
• Il=
(g)
MVL
(f)
Il= 42 (1!; , -. '"
" "" '"
40 41 ,,",," ","
I Il= '" \ ";:":",,,,,
(e) 39 '" ~" ,,'"
38
"'" ~
\~" ,,"
"
~"" "","
/",,/
50
~
~-'" 37
(a) Part of Power Unit Rotated for Clarity
............ 35 (b) Replace Plug with 064280-020 Elbow on 36 Vdc Trucks
@ (d) (c) Replace Plug with 064370-004 Elbow and 137638-001
Pressure Transducer on all AC and DC Trucks; Torque
\ Il=
36 (d)
(e)
Pressure Transducer 18 - 22 Nm (13 -16 ft Ib)
Torque 69 - 76 Nm (51 - 56 ft Ib)
Torque 23 - 24 Nm (17 - 18 ft Ib)
/ "'--... (a)
(f) Torque 14 -15 Nm (10 - 11 ft Ib)
(g) Torque 47 - 54 Nm (35 - 40 ft Ib)
(h) Torque 41 - 43 Nm (30 - 32 ft Ib)
(i) Torque 68 - 75 Nm (50 - 55 ft Ib)
G) Torque 95 - 108 Nm (70 - 80 ft Ib)
(k) Torque 20 - 23 Nm (15 - 17 ft Ib)
(I) Torque 8 - 9 Nm (6 - 7 ft Ib)
Figure 21101
Crown 2008 PF17458-3 Rev. 9/10

02.4-1457-003
02 Rev. 9/10
706
HYDRAULIC PARTS
cnOWfl Manifold Block
35 064280-013 Adapter 1
36 064019-102 O-Ring 1
37 064019-075 O-Ring 1
38 064091-002 Plug 3
39 064019-029 O-Ring 3
40 064091-006 Plug 5
064370-004 Elbow 1
064019-031 O-Ring 1
137638-001 Pressure Transducer 1
41 064019-031 O-Ring 5
42 145114 Manual Lower Valve 1
111790-016 Seal Kit. . . . . . . . . . . . . . . .................................... 1
43 064091-007 Plug . . . . . . . . . . . . . . . . . .................................... 1
064280-020. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . .................................... 1
064019-102 O-Ring 1
064019-045 O-Ring. . . . . . . . . . . . . . . .................................... 1
44 064019-045 O-Ring 1
45 117380-002 Check Valve. . . . . . . . . . . .................................... 1
111790-020 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
46 145084 Compensator Valve 1
111790-026 Seal Kit. . . . . . . . . . . . . . . .................................... 1
47 123255-003 Check Valve 1
111790-023 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
48 145119 Orifice Plug 1
49 114816-004 Check Valve 1
111790-016 Seal Kit. . . . . . . . . . . . . . . .................................... 1
50 060063-015 Screw. . . . . . . . . . . . . . . . .................................... 2
Crown 2008 PF17458-4 Rev. 9/10 02.4-1457-004

02 Rev. 9/10
707
HYDRAULIC PARTS
Reach Assembly Manifolds CJ\OWrl
CQ
Reach
~-IF=>
(c)
CBV 1
4 SVR
-R1
---8
\
I I
\ T2
T1
T3
B A
CQ Tilt and Sideshift

SVS
19
--13
I
I T2
T1
I
(a) Top of Reach Support
SS2 (b) Top of Reach Carriage
-(d) (c) Torque 34 Nm (25 ft Ib)
I IP
(d) Torque 27 Nm (20 ft Ib)
CQ Tilt
~ Clh/'
/~~"
/22
;
/f((-(b)
1 (
"(;(\\~""
II
23/ ' I
v~,..
"',.---.
1..-
"
()<."
14
17- SVT
\
\ T2
T1
Figure 21537-01
Crown 2009 PF17643-1 Rev. 9/09

02.4-1457-200
02 Rev. 9/09
708
HYDRAULIC PARTS
CAOWI' Reach Assembly Manifolds
1 122167-001* Solenoid Valve Assembly 1

2 104164-015 Coil 24 V 1
3 123977 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 121819 Counter Balance Valve 2
5 111790-002 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
6 060016-088 Screw 2
8 125928 Manifold Block Assembly (includes expansion plugs) , 1
9 060015-064* Screw 1
10 122167-001* Solenoid Valve Assembly 2
11 104164-015 Coi124 V 1
12 111790-028 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 122171* Manifold Block Assembly (includes expansion plugs) , 1
14 122167-001 Solenoid Valve Assembly 1
15 104164-015 Coi124 V 1
16 111790-028 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 122172* Manifold Block Assembly (includes expansion plugs) 1
18 060015-019 Screw 1
19. . . . . 143859-002 Solenoid Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 104164-015 Coil 24 V ,. 1
21 111790-028 Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
22. . . . . 060015-064*. . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
23 060015-019 Screw 1
Note: Regardless of truck battery voltage. the ACCESS 123® system powers solenoids with 24 V.

Crown 2009 PF17643-2 Rev. 9/09 02.4-1457-201

02 Rev. 9/09
709
CJ\OWI'
Notes:
710
mow"
DRIVE UNIT PARTS
711
DRIVE UNIT PARTS
Drive Unit CROWl'
14---0
13 0
12 @
S cp
I
11---0
10_~ 16
9 Q
I cb
I
15---BI
I
I
I
I
I '" '"
'" '"
" ;
'" '"
Figure 33875
03.0-1452-005 Crown 2007 PF17161-1 Rev. 10/10
02 Rev. 10/1 0
712
DRIVE UNIT PARTS
CJ\OWI' Drive Unit
o. . . .. 134469 Drive Unit Service Assembly Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

134468 Drive Unit Service Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
1 131877 Housing Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 064198-002 Drain Plug " 1
061004-005 Hydraulic Sealant Adhesive 1
3 064020-003 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
061004-005 Hydraulic Sealant Adhesive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 064091-005 Plug 1
061004-005 Hydraulic Sealant Adhesive 1
5 064019-033 O-Ring 2
6 127413 Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 085586 Pinion Shaft 1
9 065089-004 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 085580 Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
061004-026 Thread Locking Adhesive 1
11 085928-001 Shim 0.20 mm (0.008 in) Thick AR
085928-002 Shim 0.25 mm (0.010 in) Thick AR
12 085927 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 064138-003 Oil Seal , 1
14 060009-097 Ring Retaining 1
15 086015 Idler Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 064019-061 O-Ring 1
Crown 2007 PF17161-2 Rev. 10/10 03.0-1452-006

02 Rev. 10/10
713
DRIVE UNIT
Drive Unit PARTS CJ\OWI'
50
""
"
~
"" 48
47
\
/
\
""
""
"
(a) Drive Tire & Hub

(b) Refer to Drive Unit .
~
for Torque V I Maintenance
( ) a ue and Se
C Torque to 18 9 quence
(a) d) . Nm (14 ft Ib)
((e) Torque to 610 Nm (450 ft Ib)
Torque to 1356
. Nm (100 ft Ib)
Figure 33876
03.0-1452-007 Crown 2007 PF17161-3 .....v.10/10

D_
02 Rev. ,10/10
714
DRIVE UNIT PARTS
CJ\OWrl Drive Unit
30 078885-003 Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
31 127974(2) Axle 1
065005-003 Anti-seize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
32 087412 Seal 1
065005-001 Gasket Sealer AR
33 065024 Bearing Cone 1
34 065023 Bearing Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
35 083513 Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
36 065018 Bearing Cup 1
38 128942 Preload Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
39 128941(2) Hub 1
41 128297(2) Matched Gear & Pinion (1) . . . . . . . . . . • . . • . . . • . . . . . . . . . . . . . . . . .. 1
42 131101 Locking Bolt 1
43 078885-003 Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
061004-026 Adhesive Thread Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
44 089239-001 Bulk Wire Lock, Cut to Required Length . . . . . . . . . . . . . . . . . . . . . . . .. 1
45 128725 Locknut 1
46 110559 Screw 2
47 083500 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
48 128447-001 Gear Cover 1
49 060005-008 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
50 060016-031 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(1) Gear and Pinion are Matched Set

(2) Parts are Not Serviceable
Crown 2007 PF17161-4 Rev. 10/10 03.0-1452-008

02 Rev. 10/10
715
DRIVE UNIT PARTS
Drive Unit
(a)
" ~-l c:jI I
81
/'
I
I
i/80 /79
61 I , ~ e
6~! ~O /62 i
~78
6~\"'" @ :
\
l r:~/77
~o
0, / 7 6
~ 75
~/
~74
~/73
~72
~;:71
® I
I
./
I
I
/'
(a) Torque to 20 - 27 Nm (15 - 20 ft Ib)
Figure 33877
03.0-1452-009 Crown 2007 PF17161-6 Rev. 10/10
02 Rev. 10/10
716
DRIVE UNIT PARTS
CAOWI' Drive Unit
60 061008-004 Key Woodruff 1

61 065052 Bearing Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
62 065051 Bearing Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
64 134258 Retainer 1
65 060005-008 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
66 060016-004 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
67 083531 Spacer 2
68 065081-003 Bearing Ball 2
69 060009-039 Ring Retaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
70 086016 Gear Idler 1
71 083511 Flatwasher Special. 1
72 060044-006 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
73 060043-006 Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
74 087386 Gear 1st Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
75 060044-005 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
76 060043-005 Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
77 083501 Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
065005-001 Gasket Sealer AR
78 086618 Cover 1
79 064020-004 Plug Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
80 060005-037 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
81 060016-030 Screw 4
82 128297(2) Matched Gear & Pinion (1) 1
83 061011-020 Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
84 060005-009 Lockwasher 2
85. . . . . 060017-007 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(1) Gear and Pinion are a matched set

(2) Parts are not serviceable
Crown 2007 PF17161-e Rev. 10/10 03.0-1452-010

02 Rev. 10/10
717
DRIVE UNIT PARTS
Drive Unit Lubrication System
19
20
17
15
TS, TSP, SP 3000, SP 3200, SP

3400, SP 3470, SP 3480, SP
13
3471, SP 3481, SP 3505, SP
3510, SP 3511, SP 3512, SP
3520, SP 3521, SP 3522, SP
3550 SP 3570, SP 3571, SP
3580, SP 3581, RRIRD 5200,
RRIRD 5200S, RRIRD 5700 and
RRIRD 5700S
11
1
1
(a) Tubing is installed through cored hole in casting
Figure 21934
03.0-1452-200 Crown 2001 PF13029-1 Rev. 9/09
06 Rev. 9/09
718
DRIVE UNIT PARTS
Drive Unit Lubrication System
1 091780 Oil Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

2 085990 Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 064019-059 a-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 064019-047 a-Ring 2
5 065002-003 Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 085987 Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 085988 Plug 1
8 065002-007 Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 083479 Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 085989 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 064169-001 Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 060015-125 SetScrew 2
13 085936 Tube 1
14 064168-001 Connector 1
15. . . . . 064020-002. . . . . . . . Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 076048-001 Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 085935 Tube 1
18 060015-010 Screw 1
19. . . . . 085584 . . . . . . . . . . . Spacer Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 064170-001 Elbow , 1
Crown 2001 PF13029-2 Rev. 9/09 03.0-1452-201

06 Rev. 9/09
719
DRIVE UNIT PARTS
Traction Motor· M1 CROWl'
/' --------~'\
~ I
I I
I I I
I I
~ I
I I I I
I
I I
I
I
I
I
I
I
I
I
I
I
I -13
I
I
I
I
I
I
® I
I
-a
I
I
I -14
I
C)-9
I
I
I
15-G) ~-1a
I
I
I ®-19
I I
I ~~IIVl,," I
I
I
-10 -16
(b) Torque 32 - 36 Nm (23.60 - 26.55 ft Ib)

I
I
I
I
:
v 17
(c) Maximum Torque 23 - 24 Nm (17.0 - 17.7 ft Ib) ~
- - - --'"
Figure 21155-01
03.1-1457-003 Crown 2010 PF17897·1
720
--------- ---
DRIVE UNIT PARTS

CJ\owr. Traction Motor· M1
o 021359* Traction Motor 24 V 1

021357* Traction Motor 36 V 1
1 060059-020 Locknut .. ..... .... ... ..... .. ... ...... .. ..... ... ....... 4
2 021361 Brake End Head Assembly 1
4 060061-013 Screw 2
5 021212-001 Screw 3
6 060125-001 Spring Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7 060059-028 Flanged Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 065089-003 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 021113-002* Stator 24 V 1
021069-002* Stator 36 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 . . . . . . . . . . 062804-005 Power Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12 021062-001 Motor Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 021353 Rotor 1
14 020962 Fan 1
17 021079-002 Screw 4
18 060018-012 Screw 4
19. . . . . 060005-043. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

",
Crown 2010 PF17897-2 03.1-1457-004
721
DRIVE UNIT PARTS
EE Traction Motor - M1 CJ\OWl'
(._-------_.)
I
(a)
=3 1-----8
I
-13
2-
11111
14-.
I
15-(;)
I
I
I
I
I
I
I I I I
I I I '
I
I
I
I
14
~
II .~~
~~
..-~
I~~~~
..- 5
-10
~ ...... ' l\ .....
..- ..-&'&,,"-" 6
..- ..-..... 11
..- ... 7
=O~(b-)_.
'~-12
,-----------
~
17
(a) Torque 32 - 36 Nm (23.60 - 26.55 ft Ib)

(b) Maximum Torque 23 - 24 Nm (17.0 - 17.7 ft Ib)
Figure 23397
03.1-1457-100 Crown 2010 PF179lJO.1
722
DRIVE UNIT PARTS
l!J\OWI' EE Traction Motor - M1
o 021358 Traction Motor 36 V - EE 1

1 060059-020 Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 021375 Brake End Head 1
4 060061-013 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 021212-001 Screw 3
6 060125-001 Spring Disc 3
7 060059-028 Flanged Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 065089-003 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 021069-002 Stator 36 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 062804-005 Power Terminal 3
12 021062-001 Motor Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 021353 Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 020962 Fan 1
15 050012-024 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
065031-002 Sealant. AR
17 021079-002 Screw 4
18 060018-012 Screw 4
19. . . . . 060005-043. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crown 2010 PF17900-2

03.1-1457-101
723
DRIVE UNIT PARTS
Traction Tire CROWl'
(a) Smooth Tread

(b) Center Groove Tread
(c) 22° Router Sipe Tread
(d) 22° Thin Sipe Tread
(e) Diamond Sipe Tread
Figure 21327-01
03.2-1457-001 Crown 2009 PF1762D-1 Rev. 9/09
01 Rev. 9/09
724
DRIVE UNIT PARTS
CJ\owr. Traction Tire
1 (1) Hub 1
2······ (1) Poly Tire 1
Quantities listed for one traction tire
(1) Refer to Chart 1
Chart 1
Index 1 Index 2 Size

Hub Tire mm in
121502 121501-342-01 330 x 140 x 240 mm 13 x 5.5 x 9.5 in
121502 121501-342-02 330 x 140 x 240 mm 13 x 5.5 x 9.5 in
121502 121501-342-03 330 x 140 x 240 mm 13 x 5.5 x 9.5 in
121502 121501-342-04 330 x 140 x 240 mm 13x5.5x9.5in
121502 121501-352-01 330 x 140 x 240 mm 13 x 5.5 x 9.5 in
121502 121501-243-04 330 x 140 x 240 mm 13 x 5.5 x 9.5 in
Traction tire second dash number equals compound number, third dash number
equals tread type. See application charts.
Crown 2009 PF1762G-2 Rev. 9/09 03.2-1457-002

01 Rev. 9/09
725
DRIVE UNIT PARTS
Traction Tire CJ\OWI'
1~
(a) Smooth Tread

(b) Center Groove Tread
(c) 22° Router Sipe Tread
(d) 22° Thin Sipe Tread
(e) Diamond Sipe Tread
Figure 21327-01
03.2-1457-003 Crown 2009 PF17620-3 Rev. 9/09
01 Rev. 9/09
726
DRIVE UNIT PARTS
CJ\owr. Traction Tire
Tire Application Chart
Application Type
Composition Wet/ Dock Boards Heavy Floor
-0 g>-o Freezer Rough Floors Loads Long Debris
c: ...
::J Q) .- c:
~::JQ)
... «~
0.0 "'0.0 Q) Q) Resistant to Floor Debris Runs Resistant
lire Series a.E ro a. E ... c:
E ::J ~E::J 0"E
.J:: ro
Chunking Resistant to Resistant to to Flat
oZ C:oz
ot) C/)J: Chunking Extreme Spotting
t)
z Heat
200 Series 243 83A polyester • • •
Mid-Range
300 Series 342 352 gOA polyester • • • •
High
Capacity
200 Series Mid-Range wheels are designed for light to medium loads and short to medium runs.
300 Series High Capacity are for the typical demands of most applications. High capacity tires are designed for high capacities and long
runs.
Tread Application Chart
Third Dash
Tread Type Application
Number
-01 Contour/Smooth All Purpose
Center Groove Dissipates heat and provides better traction. Heave loads,
-02
long runs, extreme heat.
-03 22° Router Sipe Increased traction. Designed for wet/freezer application.
-04 22° Thin Sipe Increased traction. Designed for wet/freezer application.
-05 Diamond Sipe Increased traction. Designed for wet/freezer application.
Crown 2009 PF176204 Rev. 9/09 03.2-1457-004

01 Rev. 9/09
727
CJ\OWrl
Notes:
728
mow"
ELECTRICAL PARTS
729
ELECTRICAL PARTS
Electrical Components AC CJ\OW"
\
"
1m
iW
I
(a) Optional Keyless Key

Switch
(b)
Figure 21003-01
04.0-1457-007 Crown 2010 PF17903-1 Rev. 7/10
01 Rev. 7110
730
ELECTRICAL PARTS
l!J\OW" Electrical Components AC
1 142517-001 ACCESS 2 - Hydraulic Control Module (AC Hydraulics) 1

2. . . . .060063-045. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 060125-001 Spring Disc 5
4 060013-044 Screw 3
6 145688* Fan Duct C Battery Compartment. 1
145692-001* Fan Duct D Battery Compartment. 1
145692-002* Fan Duct E Battery Compartment 1
7 126489 Fan 1
8. . . . . 060031-029 Speed Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9 060078-024 : Rolling Thread Screw 3
10 143537 Fan Duct 1
11 060062-016 Screw 9
12 060030-012 Flatwasher 3
13. . . . . 115565 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129615 Smart Travel Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14. . . . . 060015-003 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15. . . . . 060005-022. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 147631-001 Horn 1
17 060042-018 Locknut 1
18. . . . . 144937 . . . . . . . . . . . Key Switch Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19. . . . . 143952 . . . . . . . . . . . Key Switch Assem Iy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123537 Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062702-003 Connector (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . 1
062703-005 Connector Insert (1) . • . . . . . . . . . . . . . • . . . . . . . . . . • • . . . . . . . . . . . . . 1
062704-003 Contact (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
107739 Key Ring Assembly (1) 4
107151-002 Key (1) 2
107763 . . . . . . . . . . . Key Ring (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 060030-026 Flatwasher. 6
21 060005-009 Lockwasher 2
22 060021-011 Nut. 2
23 060017-041 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
24. . . . . 143953 . . . . . . . . . . . Keyless Key Switch Assembly (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062623 Keyless Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062702-003 Connector (1) 1
062704-003 Contact (1) 4
062703-005 Connector Insert (1) . . . • . . . . . . . . • • . . • . . • . . . • • • . • . • . . . . . . . . . . . 1
25. . . . . 119240 Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26 060030-075 Flatwasher 1
(1) Not Shown
(2) Optional

Crown 2010 PF17903-2 Rev. 7/10 04.0-1457-008

01 Rev. 7/10
731
ELECTRleAL PARTS
Electrical Components AC CAOWI'
WARNING
Braking and Slip Control will not

operate correctly if ACCESS 4 is ACCESS 4
not installed as instructed. Module
must be securely fastened to the
truck and calibrated before driving.
67
"
I
I
I
I
I
47 I
f ' '. :
I
4~, I __ /48!
44-0'-~,O) :" F~I~3
I
:,{~
" '; I,IIj----.-_I" '" ,-
I "I ~
ll! 58 / ~tr~{@)
n~
Q
J."
I
FAN1
/" /
57/ ..... , , ,. ,.,.
,./
,. ,. ,. I
~r1: /53
.'" ~ ,.;. ~'l>
"/
51
"_ "
,I " , /63
c:: -
....
---
/
65
\"
III\I~/
\,
56~;:Y>' <~l~
I '&.... ~~ ~ ~,
66 \/J
64
f1/
I \\ -60
61
55L".,."
ACCESS 3
43
=lI (b) •
62
54
(a) Door Rotated 180·
(b) Torque 15 Nm (11 ft Ib)
Figure 21004-01
Crown 2010 PF17903-3 Rev. 7/10

04.0-1457-009
01 Rev. 7110
732
ELECTRICAL PARTS
CJ\owr. Electrical Components AC
41 141779 ACCESS 4 - Vehicle Control Module (VCM) 1

42 060078-026 Rolling Thread Screw 6
43 144583-001 ACCESS 3 - Traction Control Module (TCM) 1
44 107716-003 Plug 1
45 069378 Cleanout Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
46 060031-019 Speed Nut. 4
47 143846 Fan Duct 1
48 060031-029 Speed Nut. 3
50 126489 Fan, 36 V Trucks 1
108682 Fan, 24 V Trucks 1
51 060013-044 Screw 3
52. .... 060063-045. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
53 060125-001 Spring Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
54. .... 143748 . . . . . . . . . . . RH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
55. .... 060062-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
56 060014-002 Screw 4
57 060016-003 Screw 1
58. .... 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
59 145979 Fan Bracket. 1
60. .... 060065-009. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
61 060030-045 Flatwasher 3
62 128458 Fan Guard 1
63 126489 Fan, 36 V Trucks 1
108682 Fan, 24 V Trucks 1
64 060042-020 Nut. 3
65 060030-119 Flatwasher 3
66 060030-187 Flatwasher 1
67 130074 Fan Louver 1
68. . . . . 060013-047 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crown 2010 PF17903-4 Rev. 7/10 04.0-1457-010

01 Rev. 7/10
733
ELECTRICAL PARTS
Electrical Components AC CJ\OWI'
85
91
88-T
(a)
//
•
/
r
/
@
I
I
I
ECR1
-80
84-)//"'" /
~
I
81-~--83 ~-BRK1
i I I
87-ti -82
"86 .
~ ~,
"',?;>r==!"!~~_~"~
~,.... ~f
4J "
"'~
90
\ =I
91
(b) •
(a)
(b)
Torque 18 - 22 Nm (13.3 -16.2 ft Ib)
Torque 6 Nm (4.4 ft Ib)
Figure 23399
04.0-1457-011 Crown 2010 PFl7903-0 Rev. 7/10
01 Rev. 7110
734
ELECTRICAL PARTS
CJ\owr. Electrical Components AC
80. . . . . 146433 Traction Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

81 146430 Bracket 1
82 060014-023 Screw 1
83 060005-005 Lockwasher 1
84. . . . . 094973 . . . . . . . . . . . Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
85 060021-005 Nut. 1
86 060014-093 Screw 2
87 060005-005 Lockwasher 2
88 060062-038 Screw 1
89 143911 ACCESS 5 - Steer Control Module (1) 1
90 060078-026 Screw (1) 4
91 060062-040 Screw (1) 5
(1) Electronic Power Steering Trucks Only
Crown 2010 PF17903-6 Rev. 7/10 04.0-1457-012

01 Rev. 7/10
735
ELECTRICAL PARTS
Electrical Components DC CJ\OWI'
2
./ Access 2
5 ' • 1
I:' /
i
I
I
I
\
....
.... ....
.... .... .... ....
.... ....
.... ....
.... .... .... ....
.... ....
.... ....
.... .... .... ....
.... .... .... ....
15
HN
(a) Torque 15 Nm (11 ft Ib)
Figure 21005
04.0-1457-106 Crown 2010 PF17904-1
736
ELECTRICAL PARTS
CROWl' Electrical Components DC
1 145852-001 ACCESS 2 - Hydraulic Control Module (DC Hydraulics) 1

2 060059-037 Nut. 4
3 060062-072 Screw 4
4 142423 Deflector Plate 1
5 060078-024 Screw 5
6. . . . .060065-009 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8 145704* Fan Duct B Battery Compartment. 1
145705* Fan Duct C Battery Compartment 1
145706-001* Fan Duct D Battery Compartment 1
145706-002* Fan Duct E Battery Compartment 1
9 130376 Fan. 36 V Trucks 1
146556 Fan. 24 V Trucks 1
10 060059-033 Nut. 4
11 134894 Fan Duct 1
12. . . . . 115565 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129615 Smart Travel Alarm 1
13. . . . . 060015-003 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14. . . . . 060005-002. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 147631-001 Hom 1
16 060042-018 Locknut 1
17. . . . . 144937 Key Switch Mount , 1
18. . . . . 143952 . . . . . . . . . . . Key Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
123537 Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062702-003 Connector(1) 1
062703-005 Connector Insert(1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062704-003 Contact(1) 1
107739 Key Ring Assembly(1) 4
107151-002 Key(1) 2
107763 . . . . . . . . . . . Key Ring (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 060030-026 Flatwasher 6
20. . . . . 060005-009. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 060021-001 Nut. 2
22 060017-041 Screw 2
23. . . . . 143953 . . . . . . . . . . . Keyless Key Switch Assembly, Optional. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062623 Keyless Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062702-003 Connector(1) 1
062704-003 Contact(1) 4
062703-005 Connector Insert(1) 1
24 119240 Insert 1
25 060030-075 Flatwasher 1
(1) Not Shown

Crown 2010 PF17904-2 04.0-1457-107
737
ELECTRICAL PARTS
WARNING
Braking and Slip Control will not

operate correctly if ACCESS 4 is
not installed as instructed. Module
must be securely fastened to the
truck and calibrated before driving.
(a) Door Rotated 180·

(b) Torque 15 Nm (11 ft Ib)
AC~1:SS 3
54
Figure 21016
Crown 2010 PF17904-3

04.0-1457-108
738
ELECTRICAL PARTS
CJ\OWrl Electrical Components DC
40 141779 ACCESS 4 - Vehicle Control Module (VCM) 1

41 060059-001 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
42 060062-071 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
43 144583-001 ACCESS 3 - Traction Control Module (TCM) 1
44 107716-003 Plug 1
45. . . . . 069378 . . . . . . . . . . . Cleanout Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
46 060031-019 Speed Nut. · ······· 4
47 143846 Fan Duct 1
139476* Fan Duct Freezer/Corrosion 1
48 060031-029 Speed Nut 3
49. . . . . 143750 . . . . . . . . . . . LH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
50. . . . . 126489 Fan, 36 V Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
108682 Fan, 24 V Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
51 060013-044 Screw 3
52. . . . . 060063-045. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
53 060125-001 Spring Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
54. . . . . 043748 . . . . . . . . . . . RH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
55. . . . . 060062-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
56 060014-002 Screw 4
57 060016-003 Screw 1
59 108682 Fan, 24 V Trucks 1
126489 Fan, 36 V Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
60 145979 Fan Bracket. 1
61 060065-009 Screw 3
62. . . . . 060030-045. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
63 128458 Fan Guard 1
64 060016-096 Screw 2
65 060042-020 Nut. 2
66 060030-119 Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
67 060030-187 Flatwasher. 2
68. . . . . 130074 Fan Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
69. . . . . 060013-047 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2010 PF17904-4 04.0-1457-109
739
ELECTRICAL PARTS
85
88-r
=lI (a)
,,'
•
"
r
"
@
I
I
I
ECR1
-80
84_~" "
"'"
~-_:~
I
-BRK1
81-·t-83~-
Iii I
87-it -82
""'86 _,e~~
"t1i»-~:rr'"il.l'nll--M1
(a) Torque 18 - 22 Nm (13.3 -16.2 ft Ib)
Figure 23410
04.0-1457-110 Crown 2010 PF17904-5
740
ELECTRICAL PARTS
CJ\OWf\ Electrical Components DC
80. . . . . 146433 Traction Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

81 146430 Bracket 1
82 060014-023 Screw 1
83 060005-005 Lockwasher 1
84. . . . . 094973 Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
85. . . . . 060021-005. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
86 060014-060 Screw 2
87 060005-005 Lockwasher 2
88. . . . . 060062-038 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2010 PF17~

04.0-1457-111
741
ELECTRICAL PARTS
Contactors & Fuses
,/ ,
1
I
I
I
I
I
I
I
I
I
I
12
....
"-
J
"
(a) Refer to Contactor

Hold bottom nut while tightening upper nut. Torque all four
(b) nuts on contactor to 14 Nm (10.3 ft Ib)
Figure 20926.{)2
04.1-1457-350 Crown 2008 PF17461-1 Rev. 2110
02 Rev. 2110
742
ELECTRICAL PARTS
CJ\OWI' Contactors & Fuses
o 146182* Contactor Board Assembly (includes contactor) (1) 1

143078* Contactor Board Assembly (includes contactor) (2). . . . . • . • . . . . . . . . . . . . 1
1 143955 Fuse and ED Contactor Panel 1
2 133794 Fuse Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 060062-045 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 060005-006 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 061123 Spacer 1
6 132083-003 Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
113729-021 Label 1
7 132083-003* Fuse (1) 1
113729-021 Label .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
132083-004* Fuse (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
113729-040 Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 137634 Bus Bar 1
9 060062-070 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 060030-060 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11 143961 Bus Bar 1
12 060061-016 Screw 4
13 143966 Diode Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) Trucks with 24V AC Hydraulics

(2) Trucks with 36V DC Hydraulics


Crown 2008 PF17461-2 Rev. 2110
04.1-1457-351
02 Rev. 2110
743
ELECTRICAL PARTS
CJ\OWI' Contactors & Fuses
25 060062-063 Screw 2
26 060005-006 Lockwasher 2
27 062897-004 Fuse (1) 6
28 062897-001* Fuse (1) (2) 1
29 062897-006 Fuse (1) (3) 1
30 143958 Fuse Block 1
31 123084* Bracket (2) 1
32 060061-007* Screw (2) 2
33 060005-005* Lockwasher (2) 2
34 060078-024* Screw(2) 2
35 060059-001 Nut (4) 4
36 060005-008 Lockwasher (4) • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
37 060030-017 Flatwasher (4) 2
38 132083-001 Fuse (4) 1
113729-020 Label (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
39 060014-075 Screw (4) . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • . . • 2
40 805824 Fuse Holder (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . • • . . . . . . . . . . . . . . . 1
41 060078-024 Screw (4) 2
42 142457 Mounting Bar (4) •................••............•.............. 1
43. . . .. 132083-001 Fuse (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
113729-020 Label (5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) Replace only with genuine Crown fuses. Automotive fuses rated for 32 Vdc are not approved.
(2) Trucks with 36V DC Hydraulics
(3) Trucks with camera option
(4) Trucks with Electronic Power Steering
(5) Trucks with DC Hydraulics
.. To select appropriate part number, use the data number

Crown 2008 PF174614 Rev. 2110 04.1-1457-353

02 Rev. 2110
745
ELECTRICAL PARTS
Contactors & Fuses EE CJ\OW"
""
,
~11
"- ...
(a) Refer to Contactor

(b) Hold bottom nut while tightening upper nut. Torque all four
nuts on contactor to 14 Nm (10.3 ft Ib)
(c) Torque to 3.4 Nm (2.5 ft Ib)
Figure 22383-01
04.1-1457-400 Crown 2009 PF17679-1 Rev. 6110
03 Rev. 6/10
746
ELECTRICAL PARTS
CJ\owra Contactors & Fuses EE
o 143077* Contactor Board Assembly (includes contactor) EE 1

1 143955 Fuse and ED Contactor Panel 1
2 133794 Fuse Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 060062-045 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 060005-006 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 061123 Spacer 3
6 143962-001 Fuse 50 Amp 1
113729-042 Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 143962-002* Fuse 400 Amp 1
113729-041 Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 137634 Bus Bar 1
9 060062-070 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 060030-060 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11 143961 Bus Bar 1
12 060061-061 Screw 4
13 143966 Diode Assembly 1

Crown 2009 PF17679-2 Rev. 6110 04.1-1457-401

03 Rev. 6/10
747
ELECTRICAL PARTS
Contactors & Fuses EE l!J\OWI'
i-34
()
\~~~~ CAUTION
\~rt~~1~~1
,
;
fl\
~
-
Replace only with genuine Crown
fuses, Automotive fuses rated for
32 Vdc are not approved.
'\ ~
43":""(C..:.-}_ _ ~
FU11 I I
I I
I I
I
I
I
(a) Refer to Contactor (DC Hydraulic Trucks Only)

(b) FU12 is on Electronic Power Steering Trucks Only
(c) DC Hydraulic Trucks Only
Figure 22384
Crown 2009 PF17679-3 Rev. 6110

04.1-1457-402
03 Rev. 6110
748
ELECTRICAL PARTS
CJ\owr. Contactors & Fuses EE
25 060062-063 Screw 2
26 060005-006 Lockwasher 2
27 062897-004 Fuse, 15 Amp 6
28 062897-001* Fuse, 5 Amp (1) 1
29 062897-006 Fuse, 2 Amp 1
30 143958 Fuse Block 1
31 123084* Bracket (1) . . . . . . . . . . . . . . . . . . . . . . . . . • • . • • . . . . . • . . • • . . . . . . . . . . . 1
32 060061-007* Screw (1) 2
33 060005-005* Lockwasher (1) 2
34 060078-024* Screw (1) . . . . . • . • . . . . . • • . . . . . . . . . . . . . . . • . • . . . . . • . . . . . • . . . . . . . 2
35 060059-001 Nut (2) 4
36 060005-008 Lockwasher (2) 2
37 060003-017 Flatwasher (2) . . . . • . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . • . . . . . . . . 2
38 143962-003 Fuse (2) 1
113729-047. . . . . . . . Label (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
39 060014-075 Screw (2) . . . . . . . . . . . . . . . • . . . . . . . . . . . . • • . . . . . . . . . . . . . . • . . . . . . . 2
40 805824 Fuse Holder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
41 060078-024 Screw (2) 2
42 142457 Mounting Bar (2) 1
43 132083-001 Fuse (1) 1
113729-020 Label (1) 1
(1) Trucks with 36 V DC Hydraulics

(2) Trucks with Electronic Power Steering

Crown 2008 PF17679-4 Rev. 6110

04.1-1457-403
03 Rev. 6/10
749
ELECTRICAL PARTS
Distribution Panel CAOW"
I
I
J
J
I
I
I
J
I
I
I
I
I
I
I
I
I
I
J
I
J
I
J
I
4~~ ~/4
5-~
Figure 20934
04.3-1457-001 Crown 2008 PF17462-1 Rev. 10/09
01 Rev. 10109
750
ELECTRICAL PARTS
CJ\owr. Distribution Panel
1 143973-001 Distribution Panel, 24 V Trucks 1

143973-002 Distribution Panel, 36 V Trucks 1
2 062640-001 Relay, 24 V Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
062640-002 Relay, 36 V Trucks 2
3 062669 Signal Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 104401-017 Spacer 4
5 104401-019 Spacer 4
6 143974 Distribution Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 060013-040 Screw 4
Crown 2008 PF17462·2 Rev. 10109 04.3-1457-002

01 Rev. 10/09
751
ELECTRICAL PARTS
Contactor CJ\OW"
Model Function
PE 3500 A,B
PC 3500 A,B
TR3500 A,B
SP 3000 P1, P2 1
SP 3200 P1, P2
SP 3400 P1, P2
SP 3500 P1, P2
RR3000 1A,P1
RR3500 1A, P1
RS 3000 1A, P1
II I:
RS 3500 1A, P1
RD 3000
RD 3500
*RRlRD 5000
1A,P1
1A,P1
P2
8-[}" ~-: 5
*RRlRD 5000S P2
1- ~II
*RRlRD 5200 P2 I
*RRlRD 5200S P2
*RRlRD 5200 (AC) P2
*RRlRD 5200S (AC) P2
*RRlRD 5700 P2
*RRlRD 5700S P2
I
9~
~
I
-----0
*Regardless of truck battery voltage,

the ACCESS 123® system powers
contactors with 24 volts.
NOTE: On EV100 SCR motor control

systems, the contactors controlled by
the control card (Le. forward, reverse,
1A, FW), regardless of battery volt-
age, require 24 volt coils. Refer to the
applicable contactor panel page for
the correct contactor part number and
function.
Figure 17843-02
Crown 1993 PF9905-1 Rev. 2/10

04.4-6535-050
19 Rev. 2110
752
ELECTRICAL PARTS
CJ\OWI' Contactor
o. . . . . 110613-003 24 V Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
1 117157 Fixed Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 117158 Moving Contact , 1
3 114436 Cover " 1
4 107351 Screw 2
5 117159 Return Spring 1
6 117160 Coil. 1
7 118935 Cap End 1
8 117161 Dust Shield 2
9 123601 Bushing 1
117162 Contact Kit Includes Indexes 1, 2 & 9 1
Crown 1993 PF9905-2 Rev. 2110

04.4-6535-051
19 Rev. 2110
753
ELECTRICAL PARTS
Contactor CJ\OWI'
-------(a)
---2
I I
I I
Model Function
*RRlRD 5700 ED1, ED2 1~~1\----3
*RRlRD 57005 ED1, ED2
* Regardless of truck battery voltage, the

ACCESS 123<8> system powers contactors
with 24 V
0- 9
(a) Torque 8 - 9.5 Nm (5.9 - 7.0 ft Ib)
Figure 22047
Crown 2009 PF17463-1

04.4-1457-001
754
ELECTRICAL PARTS
CJ\OWrl Contactor
o. . ... 11 0613-008. . . . . . . . Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 107351 Screw 2
2 147318 Cover 1
4 147321 Insulator 1
5 147315 Moving Contact 1
6 147322 Washer 1
7 147314 Plunger 1
8 147313 Coil. 1
9 118935 End Cap 1
Crown 2009 PF17463-2 04.4-1457-002
755
ELECTRICAL PARTS
Contactor • EE l!J\OWI'
--11
--12
-----10
9 ---~f__-+I
--8
=(JI--=-.
(a)---------=-~~I~_
......
7--
Model Function
*RRlRD 5700 ED1, ED2
G 6
* Regardless of truck battery voltage, the

ACCESS 123® system powers contactors
with 24 V
~_5 4
~ 3
~ 2
--1
(a) Torque 8 - 9.5 Nm (5.9 - 7.0 fllb)

0-- 13
Figure 22046
Crown 2009 PF1773O-1

04.4-1457-100
756
ELECTRICAL PARTS
CROW" Contactor - EE
o. . ... 118280-006 Contactor - EE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 147312 Coil 1
2 147314 Plunger 1
3 147322 Washer 1
4 147315 Moving Contact 1
7 147318 Top Cover 1
8 147319 Arc Shield 2
9 107351 Screw 2
11 119134 Upper Shroud 1
12 136758 Screw 2
13 118935 End Cap 1
Crown 2009 PF1773G-2

04.4-1457-101
757
ELECTRICAL PARTS
Multi-Task Control Handle CROW"
91 (a) ~~
2-~-
"
-3
RES23
RES24
RES9 /
17"~J
15 "
"'-.. "
16"", "",,~
roJi'
,
)
RES8 "dEr"
19-',-
" ,,
'~
18 22/
(a) Torque 2.82 ± 0.28 Nm (25 ± 2.5 in Ib)
Figure 20935-03
Crown 2008 PF17464-1 Rev. 1/10

04.6-1457-001
03 Rev. 1110
758
ELECTRICAL PARTS
CJ\OWrl Multi-Task Control Handle
o 140751-001 Multifunction Control Support & EDS Assembly 1

140751-003* Multifunction Control Support & EDS Assembly - FIC , 1
1 140985-001 Support , 1
140985-002* Support - FIC , 1
2 060014-086 Screw 4
3 123747 EDS Button Assembly , 1
5 060009-002 Retaining Ring , 1
6 093603 Switch Insulator , 1
7 062753 Positive Break Switch 1
061003-004 Cable Tie , 2
8 060011-021 Screw , 1
9 060005-049 Lockwasher , 1
10 060077-008 Groove Pin , 1
11 060031-017 Speed Nut , 1
12 060012-070 Screw 2
13 122255 Tie Mount 2
061003-002 Cable Tie 2
14 060012-075 Screw , 2
15 060005-001 * Lockwasher - F/C , 6
16 060010-003* Screw - FIC , 6
17 062033-054* Resistor - F/C , 3
18 147276 MFC Heater Assembly 1
19 119274-003 Resistor Assembly , 1
20 060059-066 Nut 2
21 123945 Bracket. , 1
22 060064-001 Screw , 2
* To select appropriate part number. use the data number

to detennine truck features. Refer to Introduction..
Crown 2008 PF17464-2 Rev. 1/10 04.6-1457-002

03 Rev. 1/10
759
ELECTRICAL PARTS
36 POT1
37 "
I-~~/"""
1
I I-
I I
I I
: ~!-39
: 38/
I RES11
I
I
I
I
41""'<-' ,
a RES22 ,
/~
a RS
42 39
-42
~~~(a 43 ~(b)
35
SSS
44 "e
/ ./~::I
/45
46 47
J.j ~... / "/a:'

....... 49
I (a) Black
55
./' • (b) Yellow
Figure 20936-01
04.6-1457-003 Crown 2008 PF17464-3 Rev. 1110
03 Rev. 1/10
760
ELECTRICAL PARTS
CROWl' Multi-Task Control Handle
35 140750-001 Multifunction Control Assembly 1

140750-002* Multifunction Control Assembly - F/C 1
36. . . . . . . . .. 122322 Multifunction Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
37 140745-001 Traction Position Potentiometer Assembly 1
140745-002* Traction Position Potentiometer Assembly - FIC 1
38 125302* Heater - FIC (Included with Potentiometer Assy) 1
39. . . . . . . . . . 060045-030 . . . . . . . Screw ,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40 140743-001 Hydraulic Position Potentiometer Assembly 1
140743-002* Hydraulic Position Potentiometer Assembly - FIC 1
42 140747 Optical Switch Assembly 1
43 060011-026 Screw 2
44 140738 Handle Harness with Thumbwheel Assembly (1) 1
45. . . . . . . . .. 126690 Upper Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
46 060000-117 Roll Pin 1
47 060000-118 Roll Pin 1
48 123673-001 Dust Cover 1
49. . . . . . . . . . 060032-057 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50. . . . . . . . .. 122255........... Tie Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
51 060012-075 Screw 1
52 140741-001 Accessory Position Potentiometer Assembly 1
140741-002* Accessory Position Potentiometer Assembly - F/C 1
54. . . . . . . . .. 126691 . . . . . . . . . . . Lower Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
55. . . . . . . . . . 060013-039 Screw 4
(1) Includes HNS, SSS, TBS, TDS

Crown 2008 PF17464-4 Rev. 1/10 04.6-1457-004

03 Rev. 1/10
761
ELECTRICAL PARTS
-, ...-
'-~
Figure 2093!H)1
04.6-1457-005 Crown 2008 PF17464-5 Rev. 1/10
03 Rev. 1/10
762
ELECTRICAL PARTS
CJ\owr. Multi-Task Control Handle
65 123751 Cover 1
66. . . . . 060062-027 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
67 060030-204 Flatwasher. 3
68 147024 Strap 2
69 060059-027 Nut. 4
Crown 2008 PF17~ Rev. 1/10 04.6-1457-006

03 Rev. 1/10
763
ELECTRICAL PARTS
75 76
~/ [Q/
Insert Symbols
~
o
\
\
\
D
\
\
\
\
\
\
Figure 20939
Crown 2008 PF17464-7 Rev. 1/10

04.6-1457-007
03 Rev. 1/10
764
ELECTRICAL PARTS
CJ\owr. Multi-Task Control Handle
75 137671-006* MFC Insert - Side Shift Left 1

76. . . .. 137671-017* MFC Insert - Reach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

to determine buck features. Refer to Introduction.
Crown 2008 PF17464-8 Rev. 1/10 04.6-1457-008

03 Rev. 1/10
765
ELECTRICAL PARTS
ACCESS 1 • Enhanced/COM Display CROWl'
13
~
/'0
12
\.
'"
~-
11-~"''''",
I ~)
\. \)
\
(a) Enhanced
(b) Enhanced with COM
Figure 20940
04.8-1457-001 Crown 2008 PF17465-1 Rev. 7/10
01 Rev. 7/10
766
ELECTRICAL PARTS
CJ\OWfl ACCESS 1 • Enhanced/COM Display
1 143086 Display Module - Enhanced 1

143726 Display Module - Enhanced with CDM 1
2. . . . . 143105 Switch Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
147146 Switch Overlay, Trucks with Thermo Assist and ZSS 1
3 062595-001 Panel Mount Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4. . . . . 062595-002. ....... Panel Mount Switch .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. . . . . 062595-003. ....... Panel Mount Switch ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 143090 Display Mounting Bracket 1
7. . . . . 060059-036. ....... Locknut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9 060015-117 Screw 2
10 061092-001 Pyramidal Lockwasher 2
11 . . . . . 060031-026. ....... Speed Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 060021-086 Nut. 2
13 123151 Cushion Mount 2
Crown 2008 PF17465-2 Rev. 7/10

04.8-1457-002
01 Rev. 7/10
767
ELECTRICAL PARTS
ACCESS 1 • Enhanced/COM Display CROWl'
K3
\}:;f------,::_+_ 34
RES1
28
e
~J 33
. . \...., . . e
I ,../
26~~ ... ~ ... ~ ......

/~ .,.A I
(3d--(a)
@l'~~~ I @l'~!J~ ,,--32
I 30 ®
25 29 RES3 ~31
RES2
Figure 21756
Crown 2008 PF17465-3 Rev. 7/10

04.8-1457-003
01 Rev. 7/10
768
------------ ---
ELECTRICAL PARTS
CJ\owr. ACCESS 1 • Enhanced/COM Display
25 060011-012* Screw(1) 2
060011-012* Screw(2) 4
060011-012* Screw(3)(4) 2
26 060005-036* Lockwasher(1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
060005-036* . . . . . . . Lockwasher(2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
060005-036* Lockwasher(3)(4) 2
27 060021-023* Nut(1) 2
060021-023* Nut(2) 4
060021-023* Nut(3)(4) 2
28 110761-021 * Resistor Assembly(3) 1
062033-055 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
110761-022* Resistor Assembly(4) , 1
062033-028 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 110761-019* ,. Resistor Assembly(2) , 1
062033-034 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
30 110761-020* Resistor Assembly(1) 1
062033-032 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
110761-018* Resistor Assembly(2) , 1
062033-032 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
31 060021-001 Nut. 2
32. . . . . 060005-009 ,. Lockwasher. . . . . . . . . . . . . . . . . . ................................ 2
33. . . . . 060030-080 ,. Flatwasher. ,... .... ... .......... 4
34 060017-010 , Screw , 2
35. . . . . 145729 ,. Display Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
36 062337-008* Relay 24 V , 1
062337-009* Relay 36 V 1
37 060012-016 Screw 2
38. . . . . 060005-048 ,. Lockwasher. . . . . . . . . . . . . . . . . . ................................ 2
39 060021-003 Nut. ' 2
(1) 24V Trucks equipped with Fan on Overhead Guard

(2) 36V Trucks equipped with Fan on Overhead Guard
(3) 24V Trucks equipped with Dome Light on Overhead Guard
(4) 36V Trucks equipped with Dome Light on Overhead Guard

Crown 2008 PF17465-4 Rev. 7/10 04.8-1457-004

01 Rev. 7/10
769
ELECTRICAL PARTS
Height Sensor CJ\OWI'
Figure 20947
Crown 2008 PF17574-1

04.8-1457-100
770
ELECTRICAL PARTS
CJ\owr. Height Sensor
o. . . .. 127782-021 * Height Encoder Assembly (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

127782-022* Height Encoder Assembly (2) • • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127782-023* . . . . . . . Height Encoder Assembly (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127782-024* Height Encoder Assembly, 24 V F/C (1) 1
127782-026* Height Encoder Assebmly, 24 V F/C (3) 1
127782-030* Height Encoder Assembly (4) . . . . . • . . . . • . . . . . . . . . . . . . . . . • . . . • . . . • 1
1 127704 Bracket. 1
2 128688 Friction Wheel 1
3 127707 Arm 1
4 127684.. , Spring 1
5 143954-001* Encoder Assembly (1) 1
143954-002* Encoder Assembly (2) 1
143954-003* Encoder Assembly (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
143954-004* Encoder Assembly (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . • • • • . • . 1
6 128898 Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 060014-094 Screw 2
8 128888 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 128912 Sensor Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 061085-001 Clip 1
11 060038-003 Cotter Pin 1
12 129132-001 Heater Assembly, 24 V F/C 1
129132-002 Heater Assembly, 36 V F/C 1
13 125256 Heater Retainer F/C 1
(1) 5025,5335 & 6100 mm (198, 210 & 240 in) Lift Height
(2) 6860, 7620 & 8155 mm (270, 300 & 321 in) Lift Height
(3) 8660, 9300, 10130, 10695 mm (341, 366, 400 & 421 in) Lift Height
(4) 11225 mm (442 in) Lift Height

Crown 2008 PF17574-2 04.8-1457-101
771
ELECTRIGAL PARTS
Control Cable· TT Mast CJ\OWI'
(a) Extended WorKing Length
(b) Trucks with Drive Thru Mast Only
(c) Refer to Yoke
(c)
1~
I
4-
345 mm (a)
(13.5 in)
~
12- (a)
345mm
~ 18- mm
(a)
12-£'j mm(a)(b)
(13.5 in)
'(21.5 in)
~ '"
Figure 20948
Crown 2008 PF17575-1 Rev. 5110

04.8-1457-200
01 Rev. 5/10
772
ELECTRICAL PARTS
CJ\OWI' Control Cable - TT Mast
1 (1) Control Cable, 8 Conductor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

2. . . . . 105449 Cable Grip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
061003-004 Cable Tie 4
3 122914 Extension Spring 1
4. . . . . 085429 . . . . . . . . . . . Extension Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 061002-011 Harness Clamp 1
6 060015-008 Screw 1
8 060042-006 Nut. 1
9 073805-006 Strain Relief 1
10 (2)* Control Cable, 5 Conductor (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 084531* Cable Grip (3) 1
061003-004* Cable Tie (3) . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . • . . . . . . . . . . . . . . . . 4
12. . . . . 085429* .. . . . . . . . . Extension Spring (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
..... 122914* Extension Spring, Drive Thru Mast (3) 1
13 061002-026* Harness Clamp (3) 1
14 060015-008* Screw (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . • . 1
15 060042-006* Nut (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 073805-001 * Strain Relief Bushing (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 073805-001 * Strain Relief Bushing, Drive Thru Mast Only (3) . . . . . . . . . . • • . . . . • . . . .. 1
18 085429* ., Extension Spring (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

(3) Trucks with CDM only

Crown 2008 PF17575-2 Rev. 5110 04.8-1457-201

01 Rev. 5110
773
TABLE OF CONTENTS
Control Cable· TT Mast CJ\OWI'
Chart 1
INDEX 1 • Control Cable, 8 Conductor
Collapsed Height Lift Height* Index 1

mm in mm in Part Number
2260 89 5025 198 143967-001

2415 95 5335 210 143967-002
2720 107 6100 240 143967-003
3025 119 6860 270 143967-004
3325 131 7620 300 143967-005
3555 140 8155 321 143967-006
3785 149 8660 341 143967-007
4065 160 9300 366 143967-008
4370 172 10160 400 143967-009
4520 178 10695 421 143967-010
4825 190 11225 442 143967-011
Index 1 (Control Cable, 8 Conductor) cable can also be pur-
chased by the foot, Crown part number 119203-001 (multiply lift
height inches by 0.12 for minimum feet needed), in 75 m (250 ft)
rolls, Crown part number 119203-002, or 150 m (500 ft) rolls,
Crown part number 119203-003.
04.8-1457-202 Crown 2008 PF17575-3 Rev. 5110
01 Rev. 5110
774
ELECTRICAL PARTS
CJ\owr. Control Cable· TT Mast
,
,
Chart 2
INDEX 10 - Control Cable, 5 Conductor
Collapsed Height Lift Height· Index 10

mm in mm in Part Number
2260 89 5025 198 143968-001

2415 95 5335 210 143968-002
2720 107 6100 240 143968-003
3025 119 6860 270 143968-004
3325 131 7620 300 143968-005
3555 140 8155 321 143968-006
3785 149 8660 341 143968-007
4065 160 9300 366 143968-008
4370 172 10160 400 143968-009
4520 178 10695 421 143968-010
4825 190 11225 442 143968-011
Index 10 (Control Cable, 5 Conductor) cable can also be pur-
chased by the foot, Crown part number 119203-004 (multiply lift
height inches by 0.13 for minimum feet needed), in 75 m
(250 ft) rolls, Crown part number 119203-005, or 150 m (500 ft)
rolls, Crown part number 119203-006.
Crown 2008 PF17515-4 Rev. 5110 04.8-1457-203

01 Rev. 5/10
775
ELECTRICAL PARTS
Connectors l!J\C1wn
l
(d , \ (e)
/
(a) Insert
(b) Front
(c) Rear
(d) Extraction Tool
(e) Crimping Tool
Figure 15471-01
04.8-1457-300 Crown 2008 PF17466-1
776
ELECTRICAL PARTS
Connectors
Connector Part Number Chart
# of Insert Seal Plug

Index Connector Designation Terminal
Terminals
1 062701-006 (1) PC201 12 062704-004 062703-012 -
1 062755-010 (1) PC202 12 062797-004 062798-012 062754-002
1 062755-009 (1) PC203 12 062797-004 062798-012 -
1 062755-008 (1) PC204 12 062797-004 062798-012 062754-002
1 062755-006 (1) PC205 12 062797-004 062798-012 -
1 062755-006 (1) PC220 12 062797-004 062798-012 062754-002
1 062755-007 (1) PC221 8 062797-004 062798-010 -
1 062701-003 (1) PC225 4 062704-004 062703-006 062754-001
1 062701-002 (1) PC403 3 062704-004 062703-004 -
1 062701-003 (1) PC406 4 062704-004 062703-006 -
1 062701-004 (1) PC407 6 062704-004 062703-008 -
1 062755-003 (1) PC408 4 062704-004 062798-006 -
1 062701-006 (1) PC410 12 062704-004 062703-012 -
1 062701-001 (1) PC417 2 062704-004 062703-002 -
1 062701-005 (1) PC418 8 062704-004 105607-418 -
1(2) 062755-003 (1) PC426 4 062797-004 062798-006 -
1 062701-004 (1) PC440 6 062704-004 062703-008 062754-001
1 062701-004 (1) PC607 6 062704-004 062703-008 062754-001
1 062701-003 (1) PC609 4 062704-004 062703-006 -
1 062701-003 (1) PC612 4 062704-004 062703-006 062754-001
1 062755-003 (1) PC613 4 062797-004 062798-006 -
1 062755-001 (1) PC614 2 062797-004 062798-002 -
1 062755-003 (1) PC630 4 062797-004 062798-006 -
1 062755-001 (1) PC631 2 062797-004 062798-006 -
1 062755-004 (1) PC645 4 062797-004 062798-008 062754-002
(1) Service requires 062737-002 Crimping Tool and 062706 Extraction Tool
(2) DC Main Harness Only
Crown 2008 PF17468-2 04.8-1457-301
777
ELECTRICAL PARTS
Connectors CJ\OWl'
#of
Index Connector Designation Terminal Insert Seal Plug
Terminals
1 062701-003 (1) PC650 4 062704-004 062703-006 -
1 062755-002 (1) PC654 3 062797-004 062798-004 -
1 062701-004 (1) PC671 6 062797-004 062703-008 062754-002
1 062701-001 (1) PC824 2 062797-004 062703-002 -

1 062755-002 (1) PC845 3 062797-004 062798-004 -
1 062755-004 (1) PC652 6 062797-004 062798-008 -
1 062755-004 (1) PC653 6 062797-004 062798-008 062822-001
1 062755-002 (1) PC654 3 062797-004 062798-004 -

1 062755-004 (1) PC806 6 062704-004 062798-008 -
1 062701-003 (1) PC816 4 062704-004 062703-006 -
1 062701-001 (1) PC819 2 - - -
1 062701-003 (1) PC661 4 062704-004 062703-006 -
1 062701-002 (1) PC662 3 602704-004 062703-004 -
2 062702-004 (1) JC407 6 062704-003 062703-007 -
2 062702-004 (1) JC440 6 062704-004 062703-007 062754-001
2 062702-004 (1) JC607 6 062704-003 062703-007 602754-001
2 062702-003 (1) JC650 4 062797-003 062703-005 -

2 062702-002 (1) JC662 3 062704-003 062703-003 -
2 062702-003 (1) JC816 4 062704-003 062703-005 -
2 062702-001 (1) JC824 2 062704-003 062703-001 -
(1) Service requires 062737-002 Crimping Tool and 062706 Extraction Tool
04.8-1457-302 Crown 2008 PF17466-3
778
ELECTRICAL PARTS
CROWl' Connectors
# of
Index Connector Designation Terminal Insert Seal Plug
Terminals
3 062379-005 PC807 12 - - -
3 062379-012 PC808 5 - - -
4 062720-001 PC401 23 062721-001 - 062822-001
4 062720-001 PC402 23 062721-001 - 062822-001
4 062720-004 PC405 14 062721-002 - 062822-001
4 062720-006 PC411 35 062721-001 - 062822-001
4 062720-002 PC412 35 062721-002 - 062822-001
4(1) 062720-002 PC425 35 062721-001 - 062822-001
4 062720-001 PC651 23 062721-001 - 062822-001
062037-020 PC490 8 - - -
062535-008 JC606 2 062536-002 - -
(1) DC Main Harness Only
Crown 2008 PF174664 04.8-1457-303
779
ELECTRICAL PARTS
Strobe Light l!J\OWI'
1--
'-3
I
I
I
6--
Figure 1228-Q4
04.9-10.0-550 Crown 1992 PF9364-1 Rev. 3110
11 Rev. 3/10
780
ELECTRICAL PARTS
CJ\owr. Strobe Light
o 112951-001 Strobe Light Amber 1

112951-002 Strobe Light Red 1
112951-003 Strobe Light Blue 1
1 * Power Supply (*Strobe Light Replacement is More Economical) . . . . .. 1
2 113619 Locknut 0.5 inch 1
3 113615 Strobe Lamp : 1
4 113614 O-Ring 1
5 113611 Lens Amber 1
113612 Lens Blue 1
113613 Lens Red 1
6. . . .. 113620 . . . . . . . . . . . Lens Blackout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 1992 PF9364-2 Rev. 3110 04.9-10.0-551

11 Rev. 3/10
781
ELECTRICAL PARTS
Freezer Corrosion CJ\OWI'
!\',
~)
ii 1/
I {
1\\
i ((
i; \I'
t'~
(a)

(b) Part of Mast Guard
Figure 21943
04.9-1457-001 Crown 2009 PF1n19-1
782
ELECTRICAL PARTS
CJ\OW" Freezer Corrosion
1 123903-001* FIC Panel, 36 V Trucks 1

123903-002* FIC Panel, 24 V Trucks 1
2 094362-002 Fuse 2
3 062337-006* Relay, 36 V Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062337-003* Relay, 24 V Trucks 1
4 062496-003 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 060012-076 Screw 4
6. . . . . 104401-001 Spacer 4
7 060091-001 Insert Nut. 4
8. . . . . 142892-002 Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 060021-023 Nut. 2
10. . . . . 060005-036. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 060011-005 Screw 2

Crown 2009 PF17719-2 04.9-1457-002
783
ELECTRICAL PARTS
Overhead Guard Accessories CJ\OWI)
C"',
1
1
1
I
,,
I
1
1
1
cQ"11
1
1
1
1
i~
I
1
"'- I
LGT4 ~ (", I
(b)" 11, ,
"r1ih i
L=~
~--
~
""=(
i
1
l
,'" '" I
'I ,
'I') , j
1
;---...... I
~21
~~
23/
5881 1"25
"24 16--

17
(b) See Electrical Strobe Light
Figure 21941-01
04.9-1457-050 Crown 2009 PFl7718-1 Rev. 10110
02 Rev. 10/10
784
ELECTRICAL PARTS
CJ\OWf\ Overhead Guard Accessories
1 . . . . . 060015-037 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. . . . . 123787 Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 128458 Guard 2
4 060042-015 Self-Locking Nut 4
5. . . .. 107853 . . . . . . . . . . . Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
108026-080. . . . . . . . Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 143900 Cover (1) . . . . . . . • . • . . • . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . 1
7 060013-008 Screw 2
8 060030-045 Flatwasher. 8
9 108682 Fan 1
10. . . . . 060013-044. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
11 . . . .. 123795 Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 125018-013 Cable Duct AR
13. . . . . 123786 . . . . . . . . . . . Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 060015-031 Screw 4
15. . . . . 123794 . . . . . . . . . . . Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 123793 Louver 2
17 060012-076 Screw 4
18 012510 Washer 4
19. . . . . 123884 Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 060014-043 Screw 3
21 123880 Bracket 1
22 060015-037 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 112533 Filter 1
24 060013-003 Screw 3
25 060005-004 Lockwasher 2
(1) Only on Trucks with Drive Thru OHG and No Strobe Light
Crown 2009 PFl7718-2 Rev. 10110

04.9-1457-051
02 Rev. 10/10
785
ELECTRICAL PARTS
Overhead Guard Accessories Cl\OW"
(a) LGT3 Right Worklight

(b) LGT2 Left Worklight
(c) Part of Left Hand Mast Guard
(d) Mast Mounted Worklights
(e) Overhead Guard Mounted Worklights
Figure 21942-01
04.9-1457-052 Crown 2009 PFl7718-3 Rev. 10/10
02 Rev. 10/1 0
786
ELECTRICAL PARTS
CJ\owr. Overhead Guard Accessories
35. . . . . 123683 . . . . . . . . . . . Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

123782 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
36 123783 Black Lens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
37 123781 Clear Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
38 116364 Bulb 1
39 060078-024 Screw 2
40 061021-002 Bushing 1
41 060030-161 Flatwasher 4
42. . . . . 060045-026 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
43. . . . . 123980 Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
44. . . . . 123962 . . . . . . . . . . . Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 060017-045 Screw 4
46 104296-004 Spotlight 36 V (Mast Mounted) (1) 2
102195 Bulb 36 V 2
104296-005 Spotlight 24 V (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
087195-001 Bulb 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
47 104296-002 Spotlight 36 V (OHG Mounted) (1) 2
102195 Bulb 36 V 2
104296-003 Spotlight 24 V (1) 2
087195-001 Bulb 24 V 2
(1) Includes Mounting Hardware
Crown 2009 PFl77184 Rev. 10/10 04.9-1457-053

02 Rev. 10/10
787
CJ\OW"
Notes:
788
CROWl'
BRAKE PARTS
789
BRAKE PARTS
Caster l!J\OWI'
/" ....
( ....
I
I
I
I
I
(a) Torque 68 - 75 Nm (50 - 55 ft Ib)

(b) Torque 136 - 163 Nm (100 -120 ft Ib)
Figure 21244
05.3-1452-050 Crown 2001 PF13119-1 Rev. 1/09
02 Rev. 1/09
790
r---------,----------------
BRAKE PARTS
CJ\owr. Caster
o. . . .. 127817 . . . . . . . . . . . Caster Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

127846* Caster Assembly FIC 1
1 060043-008 Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 060044-008 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 125506 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 065129-003 Metallic Seal 1
8 125488 Pivot Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 065132 Bearing Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 065133 Bearing Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 065129-004 , . Metallic Seal 1
12 060030-331 Flatwasher AR
13 060030-311 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 065081-067 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 127723-302 Caster Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 060000-029 Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 125490 Caster Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18 127818 Axle 1
19 060019-072 Screw 4
20 126781 Spacer 4

Crown 2001 PF13119-2 Rev. 1/09 05.3-1452-051

02 Rev. 1/09
791
BRAKE PARTS
Brake CJ\OWI'
15, 1
14~9
'\
12 ~
13,
~ '~
~~
1---1
~4
~(a)
1
" 1
'v
(a) Traction Motor
Figure 21233
05.3-1452-100 Crown 2001 PF1312D-1 Rev. 1109
04 Rev. 1/09
792
BRAKE PARTS
CJ\OWI' Brake
o 127633 Brake 1
1 125807 Magnet Coil & Body 1
062037-012 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
062036-003 Contact Pin 4
105606-609 Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 119042 Compression Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
3 119044 Inner Armature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 119043 Outer Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 119046 Brake Pad Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 Rivet 12
7. . . . . . . . .. . Brake Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8 125808 Brake Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 118167 Adjuster 1
10. . . . . 060016-058 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11 . . . . . 119677 Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 118166-001 Nut. 1
13 118166-002 Nut. 1
14. . . . . 060030-082 Flatwasher. AR
060030-067 Flatwasher. AR
127373 Brake Service Release Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

129694 Brake Release Tool Adapter Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2001 PF1312~2 Rev. 1/09

05.3-1452-101
04 Rev. 1/09
793
l!J\OWI'
Notes:
794
mown
STEERING PARTS
795
STEERING PARTS
Hydraulic Steering System CJ\OWI'
~/I/
1/· tL2
3
Figure 21260-01
Crown 2010 PF17890-1 Rev. 10/10

06.0-1457-007
01 Rev. 10/10
796
STEERING PARTS
CJ\owr. Hydraulic Steering System
1 . . . . . 060020-052 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
2. . . . . 125845-001 Pull Dowel Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. . . . . 100779 . . . . . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 .. : .. 060016-076 Screw 2
5. . . .. 125362 Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 060017-024 Screw 4
11 . . . . . 127412 . . . . . . . . . . . Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 061011-020 Dowel Pin (1) 2
13 060017-066 Screw (1) 2
060017-007 Screw (1) 2
061004-026 Thread Locking Adhesive (1) 1
14 060005-009 Lockwasher (1) 2
15 125304 Ring Gear (1) 1
16 065129-001 Metallic Seal (1) 1
17 065126 Bearing Cone (1) 1
18 065125 Bearing Cup (1) 1
19 064214-002 Oil Seal (1) 1
(1) Included in Drive Unit Service Kit. Refer to Drive Unit Parts.
Crown 2010 PF17890-2 Rev. 10/10 06.0-1457-008

01 Rev. 10/10
797
STEERING PARTS
'----(a)
,
\ "
(a) Steer Motor

(b) Torque 31± 1.4 Nm (23 ± 1.0 ft Ib)
'"
<If''~ I I
~ •0
Figure 21261-02
06.0-1457-009 Crown 2010 PF17890-3 Rev. 10/10
01 Rev. 10/10
798
STEERING PARTS
l!J\OWI' .
Hydraulic Steering System
./

31 092157 Gear Idler Assembly 1
084586 1
Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
32 060009-095 1
Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
33 065010-005 1
Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
35 065081-033 Ball Bearing 1
37 121710 Pinion Gear 1
38 060016-076 Screw 2
39 121711 Stud 1
40 128134 Threaded Shaft 1
41 . . . . . 121837 Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
42 060030-288 Flatwasher 2
43 060042-020 Lock Nut 2
Crown 2010 PF178904 Rev. 10/10 06.0-1457-010

01 Rev. 10/10
799
STEERING PARTS
60~
I
62 I 0"
""'- II"" .J "61
63 ""'- II
~64 ~r~~
(d) 65-1 ~---66
67 Q)
69 ~- 68
7°-~::?1""""
72-- " ~71
91"":-:'-- 1~1
(c)
73"",
74 l ",, , , "',',' l' ",'" ~""'75
76-........ ",~:
~ ([5' 1
~I
77--'\i) ~
I \~\'
,821
I 1
/ I G~7J':"
.~~-.-- 1I
78 I '.1 I 1
i .' :'~: .. ~ '(b) ~

'\~; ~:~~
1
i· ",,,,,,,,,,
(a)--lll'-, :' _,
--'~.!I+. -- 1 ' ....
.......
79--@ . ~I
....
.."
------:: \/ ,-79
80 81/ ~80
81
(b) Steer Control Unit
(c) Torque 53 - 61 Nm (39 - 45 ft Ib)
(d) Torque 33.9 ± 6.8 Nm (25 ± 5 ft Ib)
Figure 2127~3
06.0-1457-011 Crown 2010 PF17890-6 Rev. 10/10
01 Rev. 10/10
800
STEERING PARTS
l!J\OWI' Hydraulic Steering System
60. . . . . 123678 Steer Knob Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

61 060000-002 Roll Pin 1
62 123674 Tiller 1
63 060016-019 Screw 1
64 060005-008 Lockwasher 1
65 060016-091 Screw . . . . . . . . . . . . . . . . . . . . . . . ............................... 2
66. . . . . 148326 Tiller Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
68 065179-005 Ball Bearing Sensor 1
69 060030-057 Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
71 060017-102 Screw 2
72 148323 Tiller Support 1
73 060017-032 Screw 1
74. . . . . 060030-119. ....... Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
75 060017-077 Screw 2
76. . . . . 060030-119. ....... Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
77 060017-010 Screw 1
78. . . . . 123694 . . . . ....... Brace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
79 060030-119 Flatwasher 3
80. . . . . 060005-009. ....... Lockwasher. . . . . . . . . . . . . . . . . . . ............................... 3
81 060021-011 Nut. 3
82. . . . . 148324 . . . . ....... SCU Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2010 PF178~ Rev. 10/10 06.0-1457-012

01 Rev. 10/10
801
STEERING PARTS
(a) Drive Unit

(b) Torque 31 ·41 Nm (25 - 30 ft Ib)
Figure 21642
Crown 2009 PF1766~1 Rev. 10110

06.0-1457-100
02 Rev. 10/10
802
STEERING PARTS
CJ\OWI' Electronic Power Steering System
1 . . . . . 060020-052 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 125845-001 Pull Dowel Pin 2
4 060016-076 Screw 1
5. . . .. 125362 . . . . . . . . . . . Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 125475-084 Shim' 2.1 mm (0.084 in) Thick AR
7 060017-024 Screw 4
9 065128 Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 . . . . . 127412 . . . . . . . . . . . Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 061011-020 Dowel Pin (1) . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . . . . . • • . . . . . 2
13 060017-066 Screw (1) 2
060017-007 Screw (1) 2
061004-026 Thread Locking Adhesive (1) . . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 060005-009 Lockwasher (1) 2
15 125304 Ring Gear (1) 1
16 065129-001 Metallic Seal (1) . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . • . . . • . • . . .. 1
17 065126 Bearing Cone (1) 1
18 065125 Bearing Cup (1) 1
19 064214-002 Oil Seal (1) 1
(1) Included in Drive Unit Service Kit. Refer to Drive Unit Parts.
Crown 2009 PF17669-2 Rev. 10/10

06.0-1457-101
02 Rev. 10/10
803
STEERING PARTS
Electronic Power Steering System CROWl'
@
o~
~'----../0\
~~o
'~
i
).I
I
.
.\
\l
II
~ I
/
I'
!{
(a) Steer Motor

(b) Torque 31 ± 1.4 Nm (23 ± 1.0 ft Ib)
Figure 21643-01
06.0-1457-102 Crown 2009 PF1766~ Rev. 10/10
02 Rev. 10/10
804
STEERING PARTS
Electronic Power Steering System

31 092157 Gear Idler Assembly 1
084586 Idler Gear 1
32 060009-095 Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
33 065010-005 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
35 065081-033 Ball Bearing 1
37 121710 Pinion Gear 1
38 060016-076 Screw 2
39 121711 Stud 1
40. . . . . 128134 Threaded Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
41 . . . . . 121837 Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
42 060030-288 Flatwasher. 2
43 060042-020 Lock Nut 2
Crown 2009 PF176694 Rev. 10/10

06.0-1457-103
02 Rev. 10/10
805
STEERING PARTS
Electronic Power Steering System CROWl'
60~
~
62 " ' ........."61
11"..1
63 II
~ ~
~",-"" ....... /~
=ft 64. J .~
(c) 65-« ~ --66
67 I
Q:)
~ 68
8 5 _ a / - 69
86-"
7272~;'/~'~""""73
~~/~J" ~78
74 /W ~~).
~~ I
I ~-80
,
I
I
I
I
79
75 I "7/81 :
:82-1 II RPS2 (b) I
•• ~83 / ;
184/
(a)-- I /
I
+ ',
"
~72
~76
77

(b) Potted side of sensor must be mounted away from magnet
(c) Torque 33.9 ± 6.8 Nm (25 ± 5 ft Ib)
Figure 21641-01
06.0-1457-104 Crown 2009 PF17669-0 Rev. 10/10
02 Rev. 10/1 0
806
STEERING PARTS
Electronic Power Steering System
60. . . . . 123678 Steer Knob Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 060000-002 Roll Pin 1
62 123674 Tiller 1
63 060005-008 Lockwasher , 1
64 060016-019 Screw 1
65 060016-091 Screw 2
66. . . . . 144017 Tiller Mount 1
68 065081-023 Ball Bearing 1
69 060009-036 Retaining Ring , 1
70 144019 Tiller Support 1
71 060017-032 Screw 1
72 060030-119 Flatwasher 5
73 060017-077 Screw 2
74 060017-010 Screw , 1
75 123694 Brace 1
76 060005-009 Lockwasher 3
77 060021-011 Nut. 3
78 145211 Magnet 1
79 060065-015 Screw 1
80. . . . . 144343 Sensor Mounting Plate 1
81 060030-204 Flatwasher 2
82 060015-012 Screw 2
83. . . . . 062948 . . . . . . . . . . . Steering Command Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
84 060061-005 Screw 2
85 144289 Wear Rod 1
Crown 2009 PF1766~ Rev. 10/10 06.0-1457-105

02 Rev. 10/10
807
STEERING PARTS
Steering Feedback Sensor CJ\OWI'
2----
----6
~-11 (b)
+----7
~-12
I
//
o c
9-----,-
10---
(a) Electronic Power Steering clip mounting

(b) Hydraulic Steering clip mounting
Figure 21637-01
06.0-1457-200 Crown 2009 PF17668-1 Rev. 9/09
02 Rev. 9/09
808
STEERING· PARTS
CJ\OWrl Steering Feedback Sensor
1 060015-096 Screw 2
2 147158 Steering Feedback Sensor Bracket. 1
3. . . . . 065081-031. . . . . . . . Ball Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4. . . . . 060061-046 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 062936-002 Steering Feedback Sensor Assembly 1
8 060065-015 Screw 1
9 145211 Magnet 1
10. . . . . 145626 Feedback Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 060014-087 Screw 1
12 062749-001 Connector Clip Attachment. 1
13 145515* Mounting Bracket (1) 1
14 060021-005* Nut (1) 1
15 060014-087* Screw (1) 2
(1) Electronic Power Steering Truck Only


Crown 2009 PF17668-2 Rev. 9/09
06.0-1457-201
02 Rev. 9/09
809
STEERING PARTS
Steer Motor l!J\own
I
7 I
I
./
5
4
3 16
1
15
/'
I
Figure 5836S-01
06.2-1452-001 Crown 2001 PF13123-1 Rev. 5/06
02 Rev. 5/06
810
STEERING PARTS
CJ\OWrl Steer Motor
o. . . . . 121659 Steer Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 125175 Screw 4
2 125176 Flange 1
3 125177 Exclusion Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 125178 Backup Washer 1
5 125179 Pressure Seal 1
6 125180 Seal , 1
7 125181 Thrust Bearing Race 1
8 125182 Thrust Needle Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 125183 Output Shaft 1
10 125184 Output Shaft 1
11 125185 Drive 1
12 125186 Seal 3
13 125187 Spacer Plate 1
14 Geroler (Not Serviceable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
15 125189 End Cap 1
16 125190 Screw 7
125191 Seal Kit Includes 3, 4,5,6 and 12 1
Crown 2001 PF13123-2 Rev. 5106 06.2-1452-002

02 Rev. 5/06
811
STEERING PARTS
Electronic Power Steering Motor CJ\OWI'
M4
1~
Figure 21753
06.2-1457-050 Crown 2009 PF17468-1
812
STEERING PARTS
CAOWI' Electronic Power Steering Motor
1 143912 Steer Motor 1
Crown 2009 PF17468-2 06.2-1457-051
813
STEERING PARTS
Steer Control Unit CJ\OWI'
(c)
---1
(b)
(d)
(a)
(e)
(a) Right
(b) In
(c) Left
(d) Tank
(e) Load Sensor
Figure 21277
Crown 2009 PF17469-1

06.3-1457-001
814
STEERING PARTS
l!J\OWr. Steer Control Unit
1 131246 Steer Control Unit 1
Crown 2009 PF17469-2 06.3-1457-002
815
CJ\OWI'
Notes:
816
--------------------
mow"
LIFTING MECHANISM PARTS
817
Removable Outrigger Ends CJ\OWI'
Figure 19502
07.2-1452-500 Crown 2001 PF13125-1 Rev. 5110
02 Rev. 5/10
818
CJ\OWf\ Removable Outrigger Ends
*Load Wheel Size 100 X 75 mm (4.0 X 2.88 in)
Number
Index Part Number Part Name
Required
123415-001 Outrigger End 2
1 Outrigger End
123425-001 2
with Tip
2 115003-002 Location Pin 4
4 060020-041 Screw 4
6 060021-092 Nut 4
* Choice of part number depends on load wheel size. Load wheel
is included in the truck data number (located on the truck data
plate). Quantity listed is per truck.
Number
Required
1 Outrigger End
123425-002 2
with Tip
4 060020-041 Screw 4
6 060021-092 Nut 4

Crown 2001 PF13125-2 Rev. 5110 07.2-1452-501

02 Rev. 5/10
819
----------_.-- ----_.

Removable Outrigger Ends CRown
I
Number
Required
1 Outrigger End
123425-005 2
with Tip
4 060020-039 Screw 4
6 060021-092 Nut 4
Number
Required
1 Outrigger End
123425-003 2
with Tip
4 060020-039 Screw 4
6 060021-092 Nut 4

to detennlne truck features. Refer to Introduction.
07.2-1452-502 Crown 2001 PF13125-3 Rev. 5110
02 Rev. 5/10
820
CJ\OWI' Removable Outrigger Ends
*Load Wheel Size 125 X 105 mm (5.0 X4.12 in)
Number
Required
1 Outrigger End
123425-004 2
with Tip
4 060020-039 Screw 4
6 060021-092 Nut 4

,
Number
Required
1 Outrigger End
123425-006 2
with Tip
4 060020-039 Screw 4
6 060021-092 Nut 4

Crown 2001 PF131254 Rev. 5/10 07.2-1452-503

02 Rev. 5/10
821
Mast· TT 144 mm (5.69 in) Channel CJ\OWI'
(b) ECR2 (Height Sensor) is standard on collapsed heights
more than 3025 mm (119 in) and optional on 3025 mm
(119 in) and below
(c) HGTS12 is standard on collapsed heights on or less than
ECR2 3025 mm (119 in) and is not required if ECR2 is present
17 (b) (d) Cover is used on trucks with collapsed height of 3325 mm
(131 in) (one side shown)
(e) Torque value 305 - 340 Nm (225 - 250 ft Ib)
(f) Torque value 190 - 215 Nm (140 - 160 ft Ib)
:
:
21-r~
22
(c)
HGTRS
24 ---+J+-j-ll-.JJIY1 15
'----20
HGTS12 25
19 ----+H-~JPo, 8
4
6""
7~~/".i
V'.
•
91i--="""
18 --''---f_:t4J--l...J/:Y::::
4
7 (d)
Figure 19267-01
Crown 2009 PF17824-1 Rev. 9/10

07.2-1457-001
03 Rev. 9110
822
Cl\OWrl Mast· TT 144 mm (5.69 in) Channel
1. . . . . 060023-009 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 060021-049 Nut. 4
4 121681-006 Shim AR
121681-012 Shim AR
5 060020-048 Long Screw 5700 series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
060020-042 Long Screw 5700S series left side 1
060020-048 Long Screw 5700S series right side 1
7 060042-019 Self Locking Nut 2
8. . . .. . Mainframe, refer to chart 1
9. . . . . 060020-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 060005-014 Lockwasher 4
11 . . . . . 080069 . . . . . . . . . . . Block Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 074481-001 Shim Stop AR
13. . . . . 107563-001 Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 092747-001 Poly Stop 2
15 060015-004 Screw , 2
16. . . . . 123400 Column Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 060030-130 Shim AR
18 060095-001 Set Screw 2
19 123316-001 Switch Assy. 2260 & 2415 mm (89 & 95 in) collapsed height 1
123316-002 Switch Assy. 2720 & 3025 mm (107 & 119 in) collapsed height 1
20 060061-008 Screw 2
21 060015-064 Screw 2
22. . . . . 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 060014-090 Screw 2
24 143985-001* Proximity Sensor (1) : 1
143985-002* . . . . . . . Proximity Sensor (2) . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . •• 1
143985-003* Proximity Sensor (3) 1
25 126901 Shim 1
(1) 2260 - 2720 mm (89 -107 in) collapsed height/5025 - 6100 mm (198 - 240 in) lift height
(2) 3025 - 3555 mm (119 -140 in) collapsed height/6860 - 8155 mm (290 - 321 in) lift height
(3) 3785 - 4520 mm (149 - 178 in) collapsed height/8660 to 10695 mm (341 - 421 in) lift height

Crown 2009 PF17824-2 Rev. 9110 07.2-1457-002

03 Rev. 9/10
823
- - - - - - - - - - - ------- .. _ - - - - -- - --- --

Mast - TT 144 mm (5.69 in) Channel CJ\OWI'
(119 in) and below
17 (b)
(d) Cover is used on trucks with collapsed height of 3325 mm
16 (131 in) (one side shown)
(f) Torque value 190 - 215 Nm (140 - 160 ft Ib)
(c)
HGTRS
24 ---ffi-JI--D>-1 15
'-----20
HGTS12 25
19 ---#+4-->' 8
4
=!If----
3~}J"
(a) =!I-=- 7 (d)
Figure 19267-01
Crown 2009 PF17824-3 Rev. 9110

07.2-1457-003
03 Rev. 9110
824
CJ\OWI' Mast - n 144 mm (5.69 in) Channel
INDEX 8 - Mainframe (Non-removable Outrigger Ends)

(RR5200/5200 (AC) 2040 kg (4500 Ib) Capacity)
1st Dash Number Collapsed

Load Wheel Size
Height/Lift Height
E:£
E.-
E·~ E.~
.-
E'CE
E .-
E .- c E
E
E
E
E
E.-
E
E.-
E
E.-
Ea:> It)N Ea:> It)N
It)Il:! 0'- It) .- o£ o£ O.~
Part It) a:> 0"'": It)«! 0"'":
T'""-.:t (t') .~ (t') .~ 00 <0 0 NO
Number r--.C\.i T'""-.:t r--.N T'""-.:t
T'""X o a:> It) a:> T'""-.:t a:>r--. <00
Xx XX XX XX
X It) ~O'l
OT'""
~O'l
1t)T'"" !e~ !eN
It) ..... t::(t')
It) .....
It) .
It) 0 It) 0 <0 ..... T'"" ..... Or--. NO'l NT'""
0
o 0. 0
o 0. NO
<0 0
N . N . NO'l -.:tit) r--.T'"" 0T'"" (t')(t')
T'""~ T'""~ T'""~ T'""~ NS Ne N~ N_ (t')S (t')S
129028- X 104 105 106 107 108
129028- X 304 305 306 307 308
129028- X 204 205 206 207 208
129028- X 404 405 406 407 408
129028- X 504 505 506 507 508
Note: The second dash number is the same as the truck's inside strad-
dle dimension 863 - 1550 mm (34 - 61 in).

(Tapered)

Load Wheel Size
Height/Lift Height
.- E
E'C E·~
E.- E
E .~
E E--
c E
E
E
E.- E.-
E E
E.-
Part E~ It)N Ea:>
0'- It)N It) .- O.~ o .~ o -~
It) a:> 0"'": (t') .~
It)«! 0"'": (t') .~ 0 0 <0 0 NO
Number r--.C\.i T'""-.:t o a:>
r--.N T'""-.:t It) a:> T'""-.:t a:>r--. <00
Xx XX XX ~O'l XX ~O'l !e~ ~N t::(t')
It) .....
0
OT'""
<0 .....
It) 0 It) 0
It) T'""
T'"" ..... Or--. It)NO'l
.....
NT'""
o 0. 0 o 0. N .NO'l N . -.:tit) NO 0T'""
r--.T'"" (t')S (t')(t')
T'""~ T'""~ T'""~ T'""~ N e N~ N- (t')S
129028- X 604 605 606 607 608
129028- X 804 805 806 807 808
129028- X 704 705 706 707 708
129028- X 904 905 906 907 908
Note: The second dash number is the same as the truck's inside
straddle dimension 863 -1550 mm (34 - 61 in).
Crown 2009 PF17824-4 Rev. 9/10

07.2-1457-004
03 Rev. 9/10
825
(119 in) and below
17 (b)
(d) Cover is used on trucks with collapsed height of 3325 mm
16 (131 in) (one side shown)
(f) Torque value 190 - 215 Nm (140 -160 ft Ib)
17
(c)
HGTRS
24 15
~20
HGTS12 25
19 ,./ 8
4
"<5
6 I (f)
~~
I
=II •
7 ~,. 1/'. • I
.... I
(a) ~5
(f)
=II
18
4
3~)Y"
(a) =II 7 (d)
Figure 19267-01
Crown 2009 PF17824-0 Rev. 9110

07.2-1457-005
03 Rev. 9/10
826
r-----------------------------------------------------------

CJ\OWI' Mast· TT 144 mm (5.69 in) Channel
INDEX 8 - Mainframe (Removable Outrigger Ends)


Load Wheel Size
Height/Lift Height
E- E£ E c E'2 E E E E E
E'2 E .£ E·- E .- E E E_ E_ E_
Part E;x) I{)N Eco I{)N I{) It'.! 0 - I{)- 0.£ 0.£ 0.£
I{) co 0"'"": I{)«! 0"'"": ..... -.:r M .£ C'? .£ 0 0 <0 0 NO
Number r--N ..... -.:r r--N ..... -.:r ..... X °co 1.0 co ..... -.:r cor-- <0 0
Xx XX XX XX ~O> ~O> ~N ~N t:::M
0 0 0 0 I{) 0
o . o . Nlri N .
I{) 0
..... ~ ..... ~ ............ ..... ~
XI{)
I{) 0 .
<0
NS
<0-- .....
NO> '<tl{) r-- 0
Ne C\le NS
--
0 ..... 1.0 ..... 0 - -
Nr-- NO> I{)--
I{)-- N .....
0 ..... MM
MS MS
129029- X 104 105 106 107 108
129029- X 304 305 306 307 308
129029- X 204 205 206 207 208
129029- X 404 405 406 407 408
129029- X 504 505 506 507 508
Note: The second dash number is the same as the truck's inside strad-
dle dimension 863 - 1550 mm (34 - 61 in).

(Tapered)

Load Wheel Size
Height/Lift Height
E- Ec E E E E E
E£ E .£ E£ E .- E E E_ E_ E_
Part E co I{)N Eco I{)N 0 - I{)- 0.£ 0.£ 0.£
I{)«! 0"'"": I{)«! 0"'"": M.£ M .£ 0 0 <0 0 NO
Number r--N ..... -.:r r--N ..... -.:r °co I{) co ..... -.:r cor-- <00
Xx XX XX
I{) 0
XX ~O>
I{) 0 .....
~O'l
I{) ..... ~~ ~N
Or-- I{)-- t:::M
NO> I{)--
N .....
o0 0. 0 o 0. N' N 0 . <0-- NO> ..... --
-.:r1.O NO
r-- ..... 0 ..... MM
..... ~ ..... ~ ..... ~ ..... ~ Ne Ne N ....... MS MS
129029- X 604 605 606 607 608
129029- X 804 805 806 807 808
129029- X 704 705 706 707 708
129029- X 904 905 906 907 908
Note: The second dash number is the same as the truck's inside
straddle dimension 863 - 1550 mm (34 - 61 in).
Crown 2009 PF17824-e Rev. 9/10 07.2-1457-006

03 Rev. 9/10
827
(a)-
,
,
!
I
I
~.
! !
!
I-(c)
(a) LH Lift Cylinder

(b) Mainframe
(c) RH Lift Cylinder
Figure 19462-01
Crown 2009 PF17824-7 Rev. 9/10

07.2-1457-007
03 Rev. 9/10
828
CJ\owr. Mast· TT 144 mm (5.69 in) Channel
31 060038-017 Cotter Pin 2

32 121679 Guide 1
33. .... 123281 Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
34 060015-015 Screw 1
36. .... 124010 Load Sensor Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
37. . . .. . Mast Chain, refer to chart 2
38. .... 086499 . . . . . . . . . . . Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
39 060000-055 Roll Pin 16
40. .... 075385 Anchor Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
41 060021-028 Nut. 12
42. .... 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
43 121667 Guide 1
44 121679 Guide 1
45 060015-015 Screw 1
47 076470-025 Clevis Pin 2
48. .... 060030-191. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INDEX 37 • Mast Chain
Collapsed Required (When Cutting Minimum Order Quantity

Lift Height
Height Length From Bulk) Part Number Quantity Box Length
mm in mm in mm in Links m ft
5030 198 2260 89 2115 83.25 111 073991-123 1 4.5 15
5335 210 2415 95 2265 89.25 119 073991-123 1 4.5 15
6100 240 2720 107 2572 101.25 151 073991-124 1 6 20
6860 270 3025 119 2875 113.25 151 073991-124 1 6 20
7620 300 3325 131 3180 125.25 167 073991-125 1 7.5 25
Note: Replace both mast chains at the same time. When ordering chain, order the number of feet required for
your particular truck. The appropriate minimum order quantity is listed in the above chart. Cut the chain to the
length required for your truck. Refer to Lifting Mechanism Maintenance for cutting chain procedure.
Crown 2009 PF17824-8 Rev. 9/10 07.2-1457-008

03 Rev. 9/10
829
Mast· TT 144 mm (5.69 in) Channel CAOWI'
70
70
(- --
I
-.. 68
I
~
I
I
66 57 I
I
I
I
car
I
60 64 62 59
72
70
76~77 75
70~
79 78
Figure 19268"{)1
Crown 2009 PF17824-S Rev. 9110

07.2-1457-009
03 Rev. 9/10
830
CJ\owr. Mast· TT 144 mm (5.69 in) Channel
50 060017-059 Screw 1
060017-094 Screw with Load Sensor and F/C 1
51 060005-009 Lockwasher 1
52 060030-078 Flatwasher 1
53 121624-001 Shaft 1
121624-003 Shaft with Load Sensor and F/C 1
54. . . . . 119655-001 Pulley 2
55. . . . . 060030-192. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
58 065081-045 Ball Bearing 2
59. . . . . 117556-001 Chain Pulley (includes Index 57 and 58) 2
117557-001 Chain Pulley 2
60 060019-071 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
61 127513-001 Pulley with Load Sensor and F/C 1
62 060030-332 Flatwasher 2
63. .... 127874-001 Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
64 127513-001 Cable Pulley 1
65 060030-192 Flatwasher 1
66 121623 Hose Pulley 1
67 060015-043 Screw 2
69. .... 123400 Column Roller 4
70 060030-130 Shim AR
71 060095-001 Set Screw 4
72. . . .. . 2nd Stage Mast, refer to chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
73. . . .. . Spring, refer to chart 2
063002-007 Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
74 128014 Spring Ram 2260 - 3025 mm (89 -119 in) Collapsed Height 2
128013 Spring Ram 3325 - 4370 mm (131 -172 in) Collapsed Height 2
75 060009-101 Retaining Ring 2260 - 3025 mm (89 - 119 in) Collapsed Height 2
060009-045 Retaining Ring 3325 - 4370 mm (131 - 172 in) Collapsed Height. 2
76 121622 Lower Stop 2
77 . . . . . 060030-277. . . . . . . . Flatwasher AR
78 124019 Bumper 2
79 060017-056 Screw 2
Crown 2009 PF17824-10 Rev. 9/10 07.2-1457-010

03 Rev. 9/10
831
Mast· TT 144 mm (5.69 in) Channel CAOW"
70
-- " 68
~
66 57
60 64 62 59
72
70
76~77 75
7a~
79 78
Figure 19268-01
Crown 2009 PF17824-11 Rev. 9/10

07.2-1457-011
03 Rev. 9/10
832
CJ\OWI' Mast· TT 144 mm (5.69 in) Channel
INDEX 72 and 90 • 2nd and 3rd Stage Mast


HeighULift Height
Index Part E E E E E
E E E_ E_ E_
Number Number 10 o£ o .~ o .~
N -.~ 10 -
('1')£ 00 (00 NO
°eo 10 eo
~O) ~O)
T"""-.:t eo ...... (00
OT""" lOT""" ~~ 10--
~N t::('I')
10--
0 ......NT"""
NO)
(0-- T"""-- NO
NO) -.:t 1O ...... 0T""" ('1')('1')
N~ N e NT""" _ ('I')S ('I')S
72 127876- 004 005 006 007 008
90 124891- 004 005 006 007 008
Note: The second dash number is the same as the
truck's inside straddle dimension 863 - 1550
(34 - 61 in).
INDEX 73 • Mast Spring
Lift Height* Collapsed Height One Each Required

mm in mm in Spring Spring
5030 198 2260 89 122399 Bronze 128011 Red
5335 210 2415 95 122399 Bronze 122399 Bronze
6100 240 2720 107 122399 Bronze 119031 Gray
6860 270 3025 119 119031 Gray 119031 Gray
7620 300 3325 131 119031 Gray 119031 Green

Crown 2009 PF17824-12 Rev. 9/10 07.2-1457-012

03 Rev. 9/10
833
Mast· TT 144 mm (5.69 in) Channel CAOWI'
90-
105 . . . . . . .
107
106-
~
-108
102
100-~ -109
101/~~t1 I
I
/ .... )
99
FLS 91 (f) •
96
\--
e
112-{f)'fj
(a) Yoke 113/ __
(b) Free Lift Cylinder e"
(c) Install clamps with the cut edge to the outside of the bend / 113
96 I /
(d) Reach Carriage I '@
(e) Mast Chain
91 (f)
;::::::115 '0- 112
(f) Torque 40 - 50 Nm (30 - 35 ft Ib). ....
I....
'-114
94
I
~~-93
91---\1
Figure 19269-02
Crown 2009 PF17824-13 Rev. 9/10

07.2-1457-013
03 Rev. 9110
834
cnowr. Mast - TT 144 mm (5.69 in) Channel
90. . . .. 3rd Stage Mast, refer to chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

91 121738 Guard 1
92 060017-032 Screw 2
93 060005-009 Lockwasher 2
94 060021-011 Nut. 2
95. . . . . 132466 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
97. . . .. . Carriage Chain, refer to chart 2
98 075385-004 Chain Anchor 2
99 123316-003 Switch (includes switch, leads, terminals and JC label) 1
108306 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
100 . . . . 060061-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
101 060030-012 Flatwasher. 2
102 . . . . 060005-005. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
103 084985 Pin 2
104 060017-050 Screw 2
105. . . . 103270 . . . . . . . . . . . Poly Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
106 128016 Spring Ram 2
107 060000-080 Roll Pin 4
108 122919 Rod 2
109. . .. . Carriage Spring, refer to chart 2
110 075385-003 Chain Anchor 2
111 060095-001 Set Screw 2
112 123400 Roller Column 6
113 060030-130 Shim AR
114 060038-003 Cotter Pin 4
115 060021-028 Nut. 8
116 060000-055 Roll Pin 10
117 086499 Pin , 2
061003-004 Cable Tie 140 mm (5.6 in) AR

061003-005 Cable Tie 290 mm (11.4 in) AR
Crown 2009 PF17824-14 Rev. 9/10 07.2-1457-014

03 Rev. 9/10
835
Mast· TT 144 mm (5.69 in) Channel CROW"
~-(a)
--111 ~
~~~
~ 97-~ 1
116
I
90-
110-~~/
t \
~ 117
~l
),I I
,. ,," ,
I ! i Lj
(d) ""- '" (" I I
a;" 1,,"
',,>- 105'-.... ~:::::::1151 I
;~~". ~ I (c)
i:;~
106-
107
,I
1"'-- ,," I' I 95I d!
II n' i/i
v ~ ",,"I t I ~ I --"AJ
I
!,
I "llJJ' !
II -108
114 I
fi ;/
j~-(b)
102 rl!1 I 113 112
100:>~~ ; (c~~ :
, I
1
-109 ( :'+'
: : $/(e)
.~ ~Il
/' "
99
FLS .
I " II , ~.
103/
'1' ;/'~
107
I
/
'@Y/J-112
' ,)
113 =(I (f)
96
• :""",,/ t~ . .
; 98-,
117
I \"
e
1
",," 116
/ \
116
112-{j)'@
(a) Yoke
113/
(b) Free Lift Cylinder e" I
(c) Install clamps with the cut edge to the outside of the bend / I 113
I I /
96 '@
(d) Reach Carriage I I
(e) Mast Chain

={I (f)
: ;::::115 '0- 112
(f) Torque 40 - 50 Nm (30 - 35 ft Ib). I .... 1'. . .
I '-114
1 94
: I
~~--93
91---\1
Figure 19269-02
Crown 2009 PF17824-15 Rev. 9/10

07.2-1457-015
03 Rev. 9/10
836
CAOWI' Mast - TT 144 mm (5.69 in) Channel
INDEX 97 - Carriage Chain
Collapsed Required (When Cutting Minimum Order Quantity

Lift Height*
Height Length From Bulk) Part Number Box Length
5030 198 2260 89 073991-122 3 10
5335 210 2415 95 073991-122 3 10

6100 240 2720 107 073991-123 4.5 15
6860 270 3025 119 073991-123 4.5 15
7620 300 3325 131 073991-123 4.5 15

Note: Replace both mast chains at the same time. When ordering chain, order the number of feet
required for your particular truck. The appropriate minimum order quantity is listed in the above chart.
Cut the chain to the length required for your truck. Refer to Lifting Mechanism Maintenance for cutting
chain procedure.
INDEX 109 • Carriage Spring

5030 198 2260 89 128012 Red 119049 Gray
5335 210 2415 95 128012 Red 119049 Gray
6100 240 2720 107 119049 Gray 119049 Gray
6860 270 3025 119 119049 Gray 119049 Gray
7620 300 3325 131 119049 Gray 119049 Gray

Crown 2009 PF17824-16 Rev. 9110 07.2-1457-016

03 Rev. 9/10
837
Mast· TT 184 mm (7.25 in) Channel l!J\OWI'
ECR2
17 (b)

(b) ECR2 (Height Sensor) is standard on collapsed
heights more than 3025 mm (119 in) and optional
on 3025 mm (119 in) and below
(c) (c) HGTRS is standard on collapsed heights on or
HGTRS less than 3025 mm (119 in) and is not required if
24 ---+H-+-Jl.--:£~ 15 ECR2 is present
~20 (d) Cover is used on trucks with collapsed height of

3325 mm (131 in) (one side shown)
HGTS12 25
(e) Torque 305 - 340 Nm (225 - 250 ft Ib)
19 ---+l+--Wl-..JI. 8
(f) Torque 190 - 215 Nm (140 -160 ft Ib)
4
~5
I (f)
I cjJt--==-
I
I
~5
(f)
cjJl--====-
18 --f---f---77t-m~
4
7
(d)
Figure 19267-02
07.2-1457-100 Crown 2009 PF17825-1 Rev. 7/10
04 Rev. 7/10
838
,.....------------------------------------------- ------------

Mast· TT 184 mm {7.25 in} Channel
1 060023-009 Screw 4
2 060005-046 Lockwasher. 4
3 060021-049 Nut. 4
4 121681-006 Shim AR
121681-012 Shim AR
5 060020-048 Long Screw 5700 series 2
060020-042. . . . . . . . Long Screw 5700S series left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
060020-048 Long Screw 5700S series right side 1
8. . . .. . Mainframe, refer to chart 1
9 060020-015 Screw , 4
10 060005-014 Lockwasher 4
11 . . . . . 080069 . . . . . . . . . . . Block Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 074481-001 Shim Stop AR
13. . . . . 107563-001 Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 092747-001 Poly Stop 2
15 060015-016 Screw , 2
16. . . . . 123400 Column Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 060030-130 Shim AR
18 060095-001 Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
19 123316-001 Switch Assy. 2260 & 2415 mm (89 & 95 in) collapsed height. 1
123316-002 Switch Assy. 2720 & 3025 mm (107 & 119 in) collapsed height 1
20 060061-008 Screw 2
21 060015-064 Screw 2
22. . . . . 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 060014-090 Screw 2
24 143985-001 * Proximity Sensor (1) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1
143985-002* Proximity Sensor (2) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1
143985-003* Proximity Sensor (3) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1
143985-004* Proximity Sensor (4) 1
25 126901 Shim 1
(1) 0 - 2720 mm (0 - 107 in) collapsed heighUO - 6100 mm (0 - 240 in) lift height
(2) 2720 - 3555 mm (107.1 - 140 in) collapsed heighU6100 - 8155 mm (240.1 - 321 in) lift height
(3) 3555 - 4520 mm (140.1 - 178 in) collapsed heighU8155 to 10695 mm (321 - 421 in) lift height
(4)4520 - 4826 mm (178.1 - 190 in) collapsed heighU10695 to 11227 mm (421 - 442 in) lift height
Crown 2009 PF17625-2 Rev. 7110 07.2-1457-101

04 Rev. 7/10
839
(RR 5200/5200 (AC) 2040 kg (4500 Ib) Capacity)
Load Wheel Size 1st Dash Number Collapsed HeighULift Height
E
E
E- E_
E
E- c
E
E--:- E .......
c
E c
E·- E
E E
E
E
E_
E
E_
E
E_
E
E_
E
E_
E
E_ E
o-
Part 10 .!: E.E 10 .- E.!: 10 .- 1O~ 10- lO- o.!: o.!: o.!: 1O.E o.!: 0.E co.!:
ON 000 oN "",00 000 ON ..-"it N.!: M.!: 00 COo NO 10..- CO..- °co "-0
Number ..- ..- ""'00 ..- ..- ..- ..- 000 10 00 00"", COo "-N MCO 00
X~ XN X~ XN X~
..-X ~O) ~O)
"-"it
~N ~N t:::M ~~ ~~ ~~ "-"it
X IO 0"- 10 ..-
..-- 0- 10- 10- 10 0 ina; 10 0 o('J
128899-
..-
X
- -
0>< lOX lOX oX oX
o "it NIO NIO ~~ ~~
..- ..- -
10 . co-
COO NO)
NS Ne
304
"it 10
Ne?.
305
N"'"
"",0
NS
306
NO)
0"-
MS
307
N"-
MM
MS
308
10
M _"it
10..-
309
00 "it COco
""'..-
M _ "it0..-
_ ""''''''
M..-
"it _
128899- X 204 205 206 207 208 209 210 211 212
128899- X 404 405 406 407 408 409 410 411 412
128899- X 504 505 506 507 508 509
129030- X 109 110 111 112
129030- X 209 210 211 212
Note: The second dash number is the same as the truck's inside straddle dimension 863 through
1550 mm (34 through 61 in).

(Tapered with side shift only)
Load Wheel Size 1st Dash Number Collapsed HeighULift Height

E
E E E E E E E E E E E E
E- E_ E.E
E- c ~£ E c E E E_ E_ E_ E_ E_ E_ o-
Part 10 .!: 10·- 10 .- 10 - 10 - o.!: 0.E o .!: 1O.!: o .!: o .!: co .!:
ON 000 ON 000 ON N.!: M .!: 00 COo NO 10..- CO..- °co "-0
Number ..- ..- ""'~ ..- ..- ""'00 ..- ..- 000 10 00 00"", COo
X~ XN X "it XN X~
~O) ~O)
"-"it
~£::! ~N t:::M
"-N
~~ ~~ MCO ~~
00
:!::~
0"- 10 ..-
..-- 0"", 10- 10- 10 0 ina; 10 0 ON
- - -
0>< lOX lOX oX oX co-
NO) NO NO) N"- 10 "it COco
00 "it 0..-
"it 10 MM
o "it NIO NIO ~~ ~~
..- ..- ..- Ne Ne?. ""'..-
N_ 0"-
MS MS 10..-
M_ M _ "it _
""'..- ""''''''
M..-
"it _
128899- X 804 805 806 807 808 809

128899- X 704 705 706 707 708 709 710 711 712
128899- X 904 905 906 907 908 909 910 911 912
129030- X 310 311 312
129030- X 410 411 412
07.2-1457-102 Crown 2009 PF17825-3 Rev. 7/10
04 Rev. 7/10
840
CJ\OWI) Mast - TT 184 mm (7.25 in) Channel

Load Wheel Size 1st Dash Number Collapsed Height/Lift Height

E
E- E_ E_ E_ E_ E_ E_ E_
10'- ~£
E-c Ec E E o-
Part 10 .!: E.!: 10'- 10 - 10 - o.!: o .!: o.!: IO.!: oJ: o.!: co .!:
ON OCO ON OCO ON N .!: (t).!: 00 COo NO 10,- CO,- °co '-0
Number ,- ,- r--~ ,- ,- r--CO ,- ,- lOCO '-"<t cor-- COo (t)co 00
°co '-N ~~ ~~
X~ XN X~ XN X~ ~O)
oX 0'- ,---
~O)
10 ,- ~~
~N t::(t)
or-- 10--
NO) 10--
N'-
~~
10 0 10 05
10 0
:!::~
ON
128900-
ox lOX lOX oX
- - -
0"<t NIO NIO ~~
,- ,-
X
,- ~~ Ne
co--
NO)
304
"<t
305
1O No
r--,- 0'-
Ne N_ (t)S (t)S
306 307
(t)(t)
308
1O"<t
(t) _
10,-
309
CO~
(t) COco
_ 0,-
r--,-
"<t-
r--r--
(t),-
"<t -
128900- X 204 205 206 207 208 209 210 211 212
128900- X 404 405 406 407 408 409 410 411 412
129030- X 510 511 512
129030- X 610 611 612


E
E_ E_ E_ E_ E_ o
10 .- ~£
E- E- Ec E E E_ E_ -
E.!: c o .!: 0.£ o .!: IO.!: oJ: o .!: co.!:
Part IO'!: 10 .- 10 -
10 -
(t) .!:
OCO
ON ON OCO ON N .!: 00 COo NO 10,- CO,- °co '-0
(t)co 00
Number r--co ,- ,- r--co lOCO '-"<t cor--COo
~(t) ~~ ~(t) :!::~
,- ,- ,- , - '-N
°co
X~ XN X~ XN X~ ~O) ~O) ~~ ~N t::(t)
10 05 10--
ox lOX lOX oX oX co--0'-
10'- Or-- 10-- 10--
NO) (t)(t)
N'- 10 0 coO ON
- - -
,--- NO 1O"<t r--r--
0"<t NIO NIO ~~ NO)
"<t 1O r--,- 0'- (t) CO~
_ (t) _ OCO (t),-
r--,- "<t _
,- ,- ,- ~~ Ne Ne N_ (t)S (t)S 10,-
"<tS
128900- X 804 80ei 806 807 808 809
128900- X 704 70e; 706 707 708 709 710 711 712
128900- X 904 905 906 907 908 909 910 911 912
129030- X 810 811 812
129030- X 910 911 912
Crown 2009 PF178254 Rev. 7/10 07.2-1457-103

04 Rev. 7/10
841
Mast· TT 184 mm (7.25 in) Channel CROWl'
(RR5 200/52005 (AC) 2040 kg (4500 Ib) Capacity)
E E
E E E E
E_ E_ 0- 10 -
Part 10 .£ 0.£ (0.£ 0>.£
lOT'"" 0(0 T'""o (OT'""
Number T'""N "'(0 0 0 ON
~~
10 ~'"
10- ~~ :c~
0 (00 ON °co
lOoq- 0(0 N"
"" oq-lOT'""
'"309-
lOT'""
oq-S "'T'""
oq- - -
128899- X 304 305 306 307 308
128899- x 204 205 206 207 208 209 220 221 222 223
128899- X 404 405 406 407 408 409 420 421 422 423
128899- X 504 505 506 507 508 509
129030- X 109 120 121 122 123
129030- X 209 220 221 222 223
Note: The second dash number is the same as the truck's inside straddle dimension 863 through 1550 mm (34
through 61 in).


E E
E E E E E E E E E E E E E
§~
E_ E - E_ E_ E_ E_ E_
Part
E-
10.£ E.£ c:
10 .-
E E
10 .-
10
c E
- 10 - 0.£
E_
0.£ 0.£ 10.£ 0.£ 0.£
o-
(0.£ 10 -
0>.£
ON OCO ON oco ON N.£ '" .£ 00 (00 No lOT'"" (OT'"" 0(0 T'""o (OT'""
T'""oq- (00 T'""N
t::", ~~ ~~
Number T'"" T'"" ,,~ T'"""-: "CO T'"" T'""
°co lOCO co" "'(0 00 ON
X~ XN Xoq- XN X~ ~O> ~O> se~ seN ~~ ~:! ~~
oX oX
OT'"" 10 T'""
(0- oq-IO
T'""- 0" 10-
NO>
10- 10 0
NT'"" lOoq- iDa> 10 0 ON °co
Ox lOX lOX NO ",'" COoq- (0(0
"" N"
'"809- '" -
T'Ooq-
"" _ T'NIO
"" _ NIO NO> 0T'"" lOT'"" 0T'"" lOT'""
T'""_ ~~ ~~ N e N e "T'""
N_ ",S ",S "T'""
oq- -
"'T'""
oq- - oq- -
128899- X 804 805 806 807 808
128899- X 704 705 706 707 708 709 720 721 722 723
128899- X 904 905 906 907 908 909 920 921 922 923
129030- X 320 321 322 323
129030- X 420 421 422 423
07.2-1457-104 Crown 2009 PF17825-0 Rev. 7110
04 Rev. 7/10
842
CJ\OW~ Mast - 11 184 mm (7.25 in) Channel

E E E
E- E_ E .!:
E- c ~:£ Ec E
10 .- 1 0 - 10-
E E_ E_ E_ E_ E_ E_ o
o.!: o .!: o.!:
- 10-
IO.!: oo!: <0 .!: O).!:
o .!:
. Part 10 .!: 10 .-
ON oeo ON 0<0 ON N .!: ("t).!: 00 <0 0 NO 10 ..... <0 ..... 0<0 ..... 0 <0 .....
..... ..... r--~ ..... ..... r--<O .......... °eo 10 eo ..... ~ eor-- ("t)<o
~~ ~("t) ~~ :!::~
Number <00 ..... N 0 0 ON
X~ XN X~ XN X~ ~O) ~O) ~~ 10-- ~N t::("t) ~£2
<0-- ..... --
0 ..... 10 ..... Or-- NO) 10--
N ..... 10 0 iOOi 10-- <0 0
ON °eo
128900-
- ..... - ..... -
Ox lOX lOX
O~ NIO NIO
.....
X
oX oX NO)
lOCO
..... .;:; ~~ N~ N e
304
~IO
305
NO 0 .....
r--
N.....
306
_ ("t)S
307
("t)("t)
("t)S
308
IO~
10 .....
("t)_
309
eo~
r-- ..... 0<0 r--r-- Nr--
("t)_ ~S ("t) ..... 10 .....
~- ~-
128900- X 204 205 206 207 208 209 220 221 222 223
128900- X 404 405 406 407 408 409 420 421 422 423
129030- X 520 521 522 523
129030- X 620 621 622 623

(RR5 200/52005 (AC) 2040 kg (4500 Ib) Capacity)
E E
E E_ E E E E E E E E E E E
E_ E_ E_ E_ E_ E_ o E
E- E- c ~:£ Ec E E - 10 -
Part 10 .!: E .!: 10 .- 10 .- 10 - 10 - o.!: oo!: o .!: 10 .!: o .!: o.!: <0 .!: O).!:
ON oeo ON 0<0 ON N .!: ("t).!: 0 0 <0 0 NO 10 ..... <0 ..... 0<0 ..... 0 <0 .....
Number ..... ..... ..... ..... .......... ..... ("t)<o
~~ ~£2 ~:! ~~
r--eo r--<O °eo 10 eo ~ eor-- <00 ..... N 0 0 ON
~O) ~O) ~N ~N t::("t) ~£2
X~ XN X~ XN X~ 0
NO) ..... --
..... 10 ..... 0-- 10-- 10-- 10
Nr-- NO) N ..... IO~ 0 iOOi 10 0 ON °eo
128900-
.....
X
- ..... - ..... -
OX lOX lOX
O~ NIO NIO
oX oX <0--
~IO r-- 0
804 805
0 ..... ("t)("t) 10 .....
..... .;:; ~~ N~ N e N S ("t)S ("t)S
lOCO
806 807
("t)_
808 809
eo~
("t)_
<0<0 r--r-- Nr--
r-- ..... 0 ..... ("t) ..... 10 .....
~- ~- ~-
128900- X 704 705 706 707 708 709 720 721 722 723
128900- X 904 905 906 907 908 909 920 921 922 923
129030- X 820 821 822 823
129030- X 920 921 922 923
Crown 2009 PF178~ Rev. 7/10 07.2-1457-105

04 Rev. 7/10
843
(Tapered)
E
E_ E_ E E_ E_ E_ E_ E_ E_ o
Part E.£
E-
10 .£ E.£ 10 .- c- §:£ c E
10'-
E
10-
E
10
(").£ - 0.£ 0.£ 0.£ 10 .£ 0.£ 0.£ co .£
-
ON ON 000 ..... oN 000 ON N .£ 00 COo NO 10 ..... co ..... °co ..... 0
Number 1"- .......... ..... 1"-00 ..... 1"-00 ..... ..... 10 00
o 00- ..... -.:t 001"- COo ..... N (")CO 0 0
X~ X~ XN X~ XN X~ J:e0)
J:eo> seN
0 ..... seN 1::::(") ~£2 ~~ ~(") ..... -.:t
10 .....
0 ..... 10 ..... 10 ..... 10 0 100; COO 10 ..... ON
..........
- - - -
oX o x lOX lOX oX oX co ..... NI"- NO> N ..... IO-.:t OO-.:t OCO 1"-1"-
0-.:t 0-.:t NIO NIO lOCO NO)-.:t 1O 1"-0 0 ..... (")(")
10 ..... 1"- ..... (") .....
..... ~ ~~ N~ Ne?- N~ (")~ (")~ -.:t~ -.:t-
..... ..... ..... ..... (")- (")-
128893- X 104 105 106 107 108 109

128893- X 304 305 306 307 308 309
128893- X 204 205 206 207 208 209 210 211 212
128893- X 404 405 406 407 408 409 410 411 412
129031- X 310 311 312
129031- X 410 411 412
INDEX 8 • Mainframe (Removable Outrigger Ends)

(Tapered)

E
E_ E_ E E_ E_ E_ E_ E_ E_ o
Part E.£
E-
10 .£ E.£ 10 .- c- §:£ c E E
10 .-
10
(") -.£
E
10- 0.£ 0.£ 0.£ 10.£ 0.£ 0.£ co .£
-
ON ON 000 ON 000 ON N .~ 00 COo NO 10 ..... CO ..... °co ..... 0
.......... I"-CX! ..... "'": 1"-00 ..........
10 00 ..... -.:t COo ..... N (")CO 0 0
Number 1"-",":
X-.:t X~ XN X-.:t XN X~ J:eo>
000
J:e0) seN
001"-
seN 1::::(") ~£2 ~~ ~£2 ::!::~
10 .....0 ..... 0 ..... 10 ..... 10 ..... 10 0 100; 10 0 ON
.......... NI"- NO> N .....
- ..... - ..... - ..... -
oX o x lOX lOX oX oX co-- IO-.:t OO-.:t COco 1"-1"-
0-.:t NIO NIO -.:t 1O NO) 1"-0 0 ..... (")(")
10 ..... 1"- ..... -.:t_ (") .....
0 ..... -.:t_
0-.:t
..... ~~ ~~ N~ Ne?- N~ (")~ (")~ (")- (")-
128893- X
128893- X 804 805 806 807 808 809
128893- X 704 705 706 707 708 709 710 711 712
128893- X 904 905 906 907 908 909 910 911 912
129031- X 810 811 812
129031- X 910 911 912
07.2-1457-106 Crown 2009 PF17825-7 Rev. 7/10
04 Rev. 7/10
844
CROW" Mast· TT 184 mm (7.25 in) Channel

(Tapered)

E E
E E E E E
E_ E_ E_ 0- 0-
Part 10 .5 0.5 0.5 co.5 co .5
lOT"" COT"" °co T""o T""o
T""N C"'>co 0 0
Number
~~ ~~ ~~ :!::~
00
:!::~
10 0
IO v
iOas
CO
10 0
COco
ON
t'--t'--
ON
t'--t'--
lOT"" v 0T""
t'--T"" C"'>T"" C"'>T""
C"'>_ C"'>_ V _ V _ V _
128893- X 104 105 106 107 108 109

128893- X 304 305 306 307 308 309
128893- X 204 205 206 207 208 209 220 221 222 223
128893- X 404 405 406 407 408 409 420 421 422 423
129031- X 320 321 322 323
129031- X 420 421 422 423
Note: The second dash number is the same as the truck's inside straddle dimension 863 -1550 mm (34 - 61 in).

(Tapered)

E E
E E E E E E E E E E E E E
E_
§~
E_ E E_ E_ o
Part
E-
10.5 E.5 c-
10 .-
E c
E
10 .-
10 - 10
E E_
0.5
E_
0.5
E_
0.5 10 .5 0.5 0.5 co .5
- 0-
co .5
ON oco ON oco ON N.!: C"'> -.5 00 COo NO lOT"" COT"" °co T""o T""o
Number T"" T""
°co lOCO T""v T""N
T"" T"" t'--~ T""",":
X~ XN Xv
t'--CO
XN X~ ~O) ~O) seN
cot'--
seN
COo
t::C"'> ~C') ~~ ~C"'>C"'>co 0 0
:!::~
00
:!::~
0>< lOX lOX oX oX
OT"" 10 T""
CO- T""- lO
0 -
Nt'-- 10-
NO) 10-
NT"" 10-
10 0v
iOas
CO v COO
lO- ON
t'--t'--
ON
t'--t'--
T"" v
_ T"" _ T"" _ NO) t'--0 0T"" C"'>C"'> IO t'--T"" OCO C"'>T""
° NIO NIO ~~ ~~ N!£. vN e N:::' C"'>:::. C"'>:::. C"'>:::. C"'>_ v:::' v _
C"'>T""
v _
128893- X 604 605 606 607 608 609
128893- X 804 805 806 807 808 809
128893- X 704 705 706 707 708 709 720 721 722 723
128893- X 904 905 906 907 908 909 920 921 922 923
129031- X 820 821 822 823
129031- X 920 921 922 923
Note: The second dash number is the same as the truck's inside straddle dimension 863 - 1550 mm (34 -
61 in).
Crown 2009 PF17825-8 Rev. 7/10 07.2-1457-107

04 Rev. 7/10
845
Mast· TT 184 mm (7.25 in) Channel Cl\OWr\
3~ !/32
37
36/~·t~33
. 34
(a)-- II
~I
I ;
! I--(c)

(b) Mainframe
Figure 22756
07.2-1457-108 Crown 2009 PF17825-9 Rev. 7/10
04 Rev. 7/10
846
mowr. Mast - TT 184 mm (7.25 in) Channel
31 060038-017 Cotter Pin 2

32 121679 Guide 2
33 123281 Clamp 1
34 060015-015 Screw 2
36. . . . . 124010 Load Sensor Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
37. . . .. . Mast Chain, refer to chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
38 086499 Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 8
39 060000-055 Roll Pin 16
40 075385 Anchor Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
41 060021-028 Nut. 12
42 060038-003 Cotter Pin 6
43 121667 Guide 1
44 076470-025 Clevis Pin 2
45 060030-191 Flatwasher. 2
INDEX 37 - Mast Chain
Collapsed Minimum Order Quantity

Required Part
Lift Height Height
(When Cutting From Bulk) Number Quantity Box Length
Length
5030 198 2260 89 2115 83.25 111 073991-123 1 4.5 15
5335 210 2415 95 2265 89.25 119 073991-123 1 4.5 15
6100 240 2720 107 2572 101.25 151 073991-124 1 6 20
6860 270 3025 119 2875 113.25 151 073991-124 1 6 20
7620 300 3325 131 3180 125.25 167 073991-125 1 7.5 25
8155 321 3555 140 3410 134.25 179 073991-125 1 75 25
8660 341 3785 149 3640 143.25 191 073991-125 1 7.5 25
9300 366 4065 160 3945 155.25 205 073991-123 2 4.5 15
10160 400 4370 172 4210 167.25 221 073991-123 2 4.5 15
10695 421 4520 178 4365 171.75 229 073991-123 2 4.5 15
Note: Replace both mast chains at the same time. When ordering the chain, order the number of feet required
for your particular truck. The appropriate minimum order quantity is listed in the above chart. Cut the chain to
the length required for your truck. Refer to the Lifting Mechanism Maintenance section for the chain cutting
procedure.
Crown 2009 PF17825-10 Rev. 7/10 07.2-1457-109

04 Rev. 7/10
847
57
~
8 1' ................
57 ............
54 ~ 59 ............
6~ 56
70
53~~
_fv' 55
517~ (-
I
--
52 / .... 68
50
I
~
I
I
66 57 I
I
I
I
or
I
60 64 62 59
72
70
76~77 75
7a~
79 78
Figure 19268-01
Crown 2009 PF17825-11 Rev. 7/10

07.2-1457-110
04 Rev. 7110
848
Mast·11 184 mm (7.25 in) Channel
50 060017-059 Screw 1
060017-094 Screw with Load Sensor and F/C 1
51 060005-009 Lockwasher 1
52 060030-078 Flatwasher. 1
53 121624-001 Shaft 1
121624-003 Shaft with Load Sensor and F/C 1
54. . . . . 119655-001 Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 060030-192 Flatwasher 1
57 117556-001 Chain Pulley 2
117557-001 Chain Pulley 2
58 060009-062 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
59 065081-045 Ball Bearing 2
60 060019-071 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
61 127513-001 Pulley with Load Sensor and F/C 1
62 060030-332 Flatwasher 2
63. .... 127874-001 Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
64. .... 127513-001 Cable Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
65 060030-192 Faltwasher 1
66. .... 121623 Hose Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
67 060015-043 Screw 2
69. .... 123400 Column Roller 4
70 060030-130 Shim AR
71 060095-001 Set Screw 4
72. . . .. . 2nd Stage Mast, refer to chart 1
73. . . .. . Mast Spring, refer to chart 2
063002-007. . . . . . . . Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
74 128014 , Spring Ram 2260 - 3025 mm (89 -119 in) Collapsed Height 2
128013 Spring Ram 3325 - 4370 mm (131 -172 in) Collapsed Height 2
75 060009-101 Retaining Ring 2260 - 3025 mm (89 -119 in) Collapsed Height. 2
060009-045 Retaining Ring 3325 - 4370 mm (131 - 172 in) Collapsed Height. 2
76. . . . . 121622 Lower Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
77 . . . . . 060030-277. . . . . . . . Flatwasher. AR
78 124019 Bumper 2
79 060017-056 Screw 2
Crown 2009 PF17825-12 Rev. 7/10 07.2-1457-111

04 Rev. 7/10
849
Mast - TT 184 mm (7.25 in) Channel cnoWI'
57
~
8 1' ............ , ....
57 ........
54 ~ 59 ............ ,
6~ 56
70
53~~
_f./ 55
51~~ (- -
50
/ 52
I
I
I
I
,. . .
-.--- 68
66 57 I
I
I
I
I
60 64 62 59
72
70
76~77 75
7a~
79 78
Figure 19268-01
Crown 2009 PF17825-13 Rev. 7/10

07.2-1457-112
04 Rev. 7110
850
CROWl' Mast· TT 184 mm (7.25 in) Channel
INDEX 72 and 90 - 2nd and 3rd Stage Mast
1st Dash Number Collapsed Height/Lift Height
E E E E E E
E E E E E
E E E_ E_ E_ E_ E_ E_ o -
E_
Index Part 10 - 10- o .!: o .!: o .!: 10 .!: o.!: o .!:
<0 .!: IO.!:
"I.!: ('I) .!: 0 0 <0 0 NO lOT"" <OT"" 0<0T""o mT""
co,... <00 T""N ('1)<0
Number Number °co lOCO
~m ~m
T""~
~N ~N t::('I) ~~ ~~ ~('I) :'!::~
00 <ON
~~
OT""
<0-
10 T""
T""-
0-
"I""
10-
"1 m
10- 10
NT"" IO~ 0 lOa; lO-
<0 0
co~ 0<0
ON ,...,... - co
0,...
"1 m ~IO ,...0 0T"" ('1)('1) lOT""
('1)_ ~S ('I)T""
""T"" 10 _
NT""
"Ie "Ie "IS ('I)S ('I)S ('1)_
~-
72 127877- 004 005 006 007 008 009 010 011 012 013
90 121762- 004 005 006 007 008 009 010 011 012 013
Note: The second dash number is the same as the truck's inside straddle dimension
863 through 1550 mm (34 through 61 in).
INDEX 73 - Mast Spring

5030 198 2260 89 122399 Bronze 119031 Gray

5335 210 2415 95 119031 Gray 119031 Gray
6100 240 2720 107 119031 Gray 119031 Gray
6860 270 3025 119 119031 Gray 119031 Gray
7620 300 3325 131 128010 Bronze 122422 Green
8155 321 3555 140 128010 Bronze 122422 Green
8660 341 3785 149 122422 Green 122422 Green
9300 366 4065 160 122422 Green 122422 Green
10160 400 4370 172 122422 Green 122422 Green
10695 421 4520 178 122422 Green 122422 Green
Crown 2009 PF17825-14 Rev. 7110 07.2-1457-113

04 Rev. 7/10
851
Mast - TT 184 mm (7.25 in) Channel l!J\OWI'
~-(a)
97-_:
~
, 116
1 I
90-
110-~~/
~: \
~ 117
~'i
'-:[) i
),i
(
/
! I Lj
105 . . . . . . . ~.:::::115! 1,/ I
~
107
,I
I"/1'" / ~< ~/ 'i
ii
(c)
95 i
i
106-
~
-108
//114 r 1//Lj
iii
Ii
i
IW-(b)
><J!IfY
/1
I
-109
(
1
:(t'
1
: /// t
1
1 : $,/'(e)
,) 1
91 (f) • 1// ",,_117

96 i" 98- ~
\/
e
I
I
/ / / 116
I
'"
\
(a) Yoke e"

113
(b) Free Lift Cylinder /
96 1 /
(c) Install clamps with the cut edge to the outside of the bend 1 '@
(d) Reach Carriage
91 (f)
,
;::::::115 '0- 112
(e) Mast Chain
(f) Torque 40 - 50 Nm (30 - 35 ft Ib)
1'''-114
94
I
~~--93
91---\J
Figure 19269-02
Crown 2009 PF17825-15 Rev. 7/10

07.2-1457-114
04 Rev. 7/10
852
CJ\OWrl Mast· TT 184 mm (7.25 in) Channel
90. . . .. . 3rd Stage Mast, refer to chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

91 121738 Guard 1
92 060017-032 Screw 2
93. . . . . 060005-009. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
94 060021-011 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
95. . . . . 132466 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
97. . . .. . Carriage Chain, refer to chart 2
98 075385-004 Chain Anchor 2
99 123316-003 Switch (Includes switch, leads, terminals and JC label) 1
108306 . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
100 060061-005 Screw 2
101 060030-012 Flatwasher. 2
102 . . . . 060005-005. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
103 084985 Pin 2
104. . . . 060017-050 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
105. . . . 103270 . . . . . . . . . . . Poly Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
106 128016 Spring Ram 2
107 . . . . 060000-080. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
108 122919 Rod 2
109. . .. . Carriage Spring, refer to chart 2
110 075385-003 Chain Anchor 2
111 060095-001 Set Screw 2
112 . . .. 123400 . . . . . . . . . . . Roller Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
113 060030-130 Shim AR
114 060038-003 Cotter Pin 6
115 060021-028 Nut. 2
116 060000-055 Roll Pin 8
117 086499 Pin 8
061003-004 Cable Tie 140 mm (5.6 in) AR

061003-005 Cable Tie 290 mm (11.4 in) AR
Crown 2009 PF17825-16 Rev. 7/10

07.2-1457-115
04 Rev. 7/10
853
Mast - TT 184 mm (7.25 in) Channel Cl\OWI'
90-
105 . . . . . . .
107
106-
-.j
-108
~I
il
102 i 112
100-~ 8l..~ '.
-109
101/ lU ii,
t:l ' --,'
1
/
99
.....
1
)
FLS 91 (f) •
96
\"
e
112-(/)'@
113/ "
(a) Yoke e" 1
/ 1 113
(b) Free Lift Cylinder 1 1 /
96 1 1 '@
(c) Install clamps with the cut edge to the outside of the bend 112
91 (f) ..
(d) Reach Carriage : ;:::;;115'0-
1 .....
(e) Mast Chain
1 1..... "-114
(f) Torque 40 - 50 Nm (30 - 35 ft Ib) 1 94
: I
~~--93
91---\/
Figure 19269-02
Crown 2009 PF17825-17 Rev. 7/10

07.2-1457-116
04 Rev. 7/10
854
Mast - TT 184 mm (7.25 in) Channel
INDEX 97 - Carriage Chain
Collapsed Minimum Order Quan-

Required Part tity
Lift Height Height
(When Cutting From Bulk) Number
Length Box Length
5030 198 2260 89 1390 54.75 73 073991-122 3 10
5335 210 2415 95 1465 57.75 77 073991-122 3 10
6100 240 2720 107 1620 63.75 85 073991-123 4.5 15
6860 270 3025 119 1770 69.75 93 073991-123 4.5 15
7620 300 3325 131 1925 75.75 101 073991-123 4.5 15
8155 321 3555 140 2040 80.25 107 073991-123 4.5 15
8660 341 3785 149 2155 84.75 113 073991-123 4.5 15
9300 366 4065 160 2305 90.75 121 073991-124 6 20
10160 400 4370 172 2460 96.75 129 073991-124 6 20
10695 421 4520 178 1535 99.75 133 073991-124 6 20
Note: Replace both mast chains at the same time. When ordering the chain, order the number of feet
required for your particular truck. The appropriate minimum order quantity is listed in the above chart. Cut
the chain to the length required for your truck. Refer to the Lifting Mechanism Maintenance section for the
chain cutting procedure.
INDEX 109 - Carriage Spring

5030 198 2260 89 122398 Red 119031 Red
5335 210 2415 95 122398 Red 119031 Red
6100 240 2720 107 122398 Red 122421 Bronze
6860 270 3025 119 122398 Red 122421 Bronze
7620 300 3325 131 122398 Red 122421 Bronze
8155 321 3555 140 122421 Bronze 122421 Bronze
8660 341 3785 149 122421 Bronze 122421 Bronze
9300 366 4065 160 122421 Bronze 122421 Bronze
10160 400 4370 172 122421 Bronze 122421 Bronze
10695 421 4520 178 122421 Bronze 122421 Bronze
Crown 2009 PF17825-18 Rev. 7/10 07.2-1457-117

04 Rev. 7/10
855
TT· Drive In Rack Mast CJ\OWI'

21 (b) ECR2 (Height Sensor) is standard on col-
lapsed heights more than 3025 mm (119 in)
and optional on 3025 mm (119 in) and below;
HGTRS2 is not required if ECR2 is present.
(c) HGTS1 and HGTS2 are optional
(d) Cover used on trucks with a collapsed height
of 3325 mm (131 in) or more
"'OiI-14
(e) On RRIRD 5700S trucks
(f) On RRIRD 5700 trucks
(d) (g) Torque 190 -215 Nm (140 -160 ft lb)

(e) Torque 305 - 340 Nm (225 - 250 ft lb)
(A g
7\
8"
rdtJ-S
I
I
=lI (e){g)
•
I
6-~~/ I I
~/",
(a) 9
=lI (f){g)
8
Figure 22009
07.2-1457-200 Crown 2009 PF1n22-1 Rev. 2110
03 Rev. 2110
856
cnowr. TT • Drive In Rack Mast
1 , 060021-049 Nut 4
2 , 060005-046 Lockwasher 4
3. . . . . 060023-009 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 (1) Mainframe 1
5 060019-076 Set Screw 2
6 060042-001 Nut. 2
7. . ... 060030-260 Flatwasher ............................................... 2
8 , 121681-006 Shim 1.5 mm (0.06 in) Thick AR
121681-012 Shim 3 mm (0.12 in) Thick AR
9. . . . . 060020-048* Screw 190 mm (7.50 in) Long 5700/5700. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
060020-047* Screw 255 mm (10.0 in) Long 5700S/5700S RH Side 1
060020-048* Screw 190 mm (7.50 in) Long 5700S/5700S LH Side 1
10 123316-001 Limit Switch Assembly 2260 & 2415 mm (89 & 95 in) Collapsed Height 1
123316-002 Limit Switch Assembly 2720 & 3025 mm (107 & 119 in) Collapsed Height. 1
108306 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 , 143985-001* Proximity Sensor Enhanced Display with CDM(2) 1
143985-002* Proximity Sensor Enhanced Display with CDM(3) 1
143985-003* Proximity Sensor Enhanced Display with CDM(4) 1
12 060014-090 Screw 2
13 , 128901 Shim 1.6 mm (0.06 in) Thick AR
14 060061-008 Screw 2
15 060020-015 Screw 4
16 060005-014 Lockwasher 4
17 ,. 060015-016 Screw 2
061004-026 Thread Locking Adhesive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. AR
18 092747-001 Poly Stop 2
19. . . . . 107563-001 Bracket 2
20. . . . . 080069 . . . . . . . . . . . Block Stop 2
21 074481-001 Shim Stop AR
23 , 123400 Column Roller 2
24 060015-123 Screw 2
(1)See Charts 1 & 2

(2)36 V and 2260 - 2720 mm (89 - 107 in) Collapsed HeighU5025 - 6100 mm (198 - 240 in) Lift Height
(3)36 V and 3025 - 3555 mm (119 - 140 in) Collapsed HeighU6860 - 8155 mm (270 - 321 in) Lift Height
(4)3785 - 4520 mm (149 -178 in) Collapsed HeighU8660 to 10695 mm (341 - 421 in) Lift Height

Crown 2009 PFl7722-2 Rev. 2110 07.2-1457-201

03 Rev. 2110
857
TT • Drive In Rack Mast CROWl'

21
(b) ECR2 (Height Sensor) is standard on col-
lapsed heights more than 3025 mm (119 in)
and optional on 3025 mm (119 in) and below;
HGTRS2 is not required if ECR2 is present.
(c) HGTS1 and HGTS2 are optional
(d) Cover used on trucks with a collapsed height
""0-14 of 3325 mm (131 in) or more
(e) On RRIRD 5700S trucks
(f) On RRIRD 5700 trucks
(d)
(g) Torque 190 - 215 Nm (140 - 160 ft Ib)
(e) Torque 305 - 340 Nm (225 - 250 ft Ib)
8"", I
7\ ~{J I
I
6-~~/ I I
;/",
(a) 9
={I (f)(g)
Figure 22009
Crown 2009 PFl7722-3 Rev. 2110

07.2-1457-202
03 Rev. 2110
858
CJ\OW~ TT - Drive In Rack Mast
Chart 1 - RR 5700/57005 2040 kg (4500 Ib) Capacity
Load Wheel Size First Dash Number Collapsed Height/Lift Height
E
E E E E E E EE
Index
E
E'-
c E~ E
E·-
c E~ E
E .-c EE c.- E E E-::: E-::: E E-::: E-:::
E-:::
E
Number
Part Number ION
0"":
Eeo
O~
ION
0"":
Eeo
O~
ION
0"":
IO~
T"""~
IOc
N.-
IO c
("') .-
o .!:
00
oo!:
COo
o
N c .-
lOo!:
lOT"""
o.!:
o .!:
COT"""
°co
°
co c
T"""o
.-
("')0 T"""~ eo,.... coo T"""N ("')co 00
T"""~
x x
,....N
x x
T"""~
x x
,....N
x x
T"""~
x X
T"""X °eo
~O> ~T""" ~~ ~N 1:::: 0 se~ ~~ ~~ ~~
XIO OT""" ION 0,.... 10- IO~ 10 ina> 10 0 ON
00
o . 100 100
N . 00
10 . 00 10 .
coO CO-
NO> T"""-
~IO
NO>
NO 0T""" NT""" 0
IO~ eo~ COco
,....,....
N· 10·
~~ ~~ ~~ ~~ ~~
("') ("')
T"""::! T"""~ T"""!!? T"""~ T"""~ N~ N~ N~ ("')~ ("')T"""
Non-Removable
4
Outrigger Ends
129309- X 304 305 306 307 308 309
129309- X 204 205 206 207 208 209 210 211 212
129309- X 404 405 406 407 408 409 410 411 412
129309- X 504 505 506 507 508 509
129310- X 109 110 111 112
129310- X 209 210 211 212
Non-Removable
Outrigger Ends
(Tapered with
Sideshift Only)
129309- X 804 805 806 807 808 809
129309- X 704 705 706 707 708 709 710 711 712
129309- X 904 905 906 907 908 909 910 911 912
129310- X 310 311 312
129310- X 410 411 412
Removable
Outrigger Ends
129291- X 304 305 306 307 308 309
129291- X 204 205 206 207 208 209 210 211 212
129291- X 404 405 406 407 408 409 410 411 412
129310- X 610 611 612
129310- X 710 711 712
Crown 2009 PFl7722-4 Rev. 2110 07.2-1457-203

03 Rev. 2110
859
TT - Drive In Rack Mast CJ\OWI'
Chart 1 - RR 5700/57005 2040 kg (4500 Ib) Capacity (cont'd)
E
E c E E E E E E E E
Index
E c
E·- E~ E c
E·- E~ E c
E·- E·- E E E..-::- E
E--:- E-= E-::
E
E-=
Part Number Eco Eco O.~ o c
O£ 10£ O.~ °
co c
o£
Number ION ION ION IO~ IO c IO c
N·- .-
0"": 0CX! 0"": 0CX! 0"": T"""'t N.- C"> .-
C">o
COo coo
° 0
T"""'t
COr--.
lOT""
T""N
COT"" T""o
°co
C">co
00
T"""'t
>< ><
r--.N
>< ><
T"""'t
>< ><
r--.N
>< ><
T"""'t
>< ><
°co
T"">< ~O'l lOT"" seN t:: 0
se~ ~~ ~~ ~~ ~~
0
><10 aT""
10 . CO-- LO~ 10--
Or--.IO~
NO'l NT"" 100 LOa> 100
ON
a 0. 100
N·
100
N . 0 0.
10 0 0.
10 COO NO'l T""IO NO
aT"" C">C"> l2"'t co"'t COco
~r--.
T""~ T""~ T""!:e T""~ T""~ N:S N!:£ ~~ ~~ C">:s C"> T"" C">:s ~~ ~~ "'t:S
Removable
Outrigger Ends
4
(Tapered with
Sideshift Only)
129291- X 804 805 806 807 808 809
129291- X 704 705 706 707 708 709 710 711 712
129291- X 904 905 906 907 908 909 910 911 912
129310- X 810 811 812
129310- X 910 911 912
75 129068- 004 005 006 007 008 009 010 011 012
105 129059- 004 005 006 007 008 009 010 011 012
Note: The second dash number is the same as the truck's inside straddle dimension 863 - 1550 mm (34 - 61 in).
07.2-1457-204 Crown 2009 PF1n22-5 Rev. 2110
03 Rev. 2110
860
CJ\OW" 11 • Drive In Rack Mast
Chart 2 - RD 5700/57005 1360 kg (3000 Ib) Capacity
E
E E E E E E E E E
Index E~ E--E c E~
~~ E~ E'2E-- E E E-= E-= E E-= E--:: E-= c
Part Number Eco I.O N Eco I.O N Eco I.O N I.O c 1.0'2 o.!: o .!: 0'2 I.O.!: o .!: oo!: °<0.-
Number (") .- 00 <0 0 <00 N .- 1.0...- <0...-0<0
0CiC! ...-oq-
0"'": 0CiC! ...-oq- 0"'": N.- (")0
0"'": 0CiC! ...-oq- (")<0 "'-0
00
"N "N "N
X X X X X X X X X X X X 0"'-
°co
~O> ~...-
"'-oq- co"
~~ ~N 1:::: 0 "'-N
f!2(") ~~ ~(") ~~
NO> I.O~
I.ON 0" 1.0- 1.0- 1005 lO-
00 00 1.00 1.00 00 00 <0- ...-- ~O 0"'- (") N ...- 1.0 0 <0 0 ON
COoq- 0<0
o . o
...-~ ...-~
. N . N . 10 • 1.0 . NO> oq-I.O
...-!e ...-~ ..... ~ ...-~ N~ N~ N~
(")
(")~ (") ...-
l.Ooq-
(")~ ~~ ~~ oq-~ ~"
Non-Removable
4 Outrigger Ends
(Tapered)
129077- X 104 105 106 107 108 109
129077- X 304 305 306 307 308 309
129077- X 204 205 206 207 208 209 210 211 212
129077- X 404 405 406 407 408 409 410 411 412
129311- X 310 311 312
129311- X 410 411 412
Removable
Outrigger Ends
(Tapered)
129077- X 604 605 606 607 608 609
129077- X 804 805 806 807 808 809
129077- X 704 705 706 707 708 709 710 711 712
129077- X 904 905 906 907 908 909 910 911 912
129311- X 810 811 812
129311- X 910 911 912
75 129068- 004 005 006 007 008 009 010 011 012
105 129059- 004 005 006 007 008 009 010 011 012
Note: The second dash number is the same as the truck's inside straddle dimension 863 - 1550 mm (34 - 61 in).
Crown 2009 PF1n22~ Rev. 2110 07.2-1457-205

03 Rev. 2110
861
TT - Drive In Rack Mast CJ\OWI'
30 . 32
I
~,9.
I
-9i~ 33
U" '-l ./
/ 1 ~
31 I
34
(a)-
-(c)
y I
I ~
I I
I
I
\
....
I
I
/
"

(b) Mainframe
Figure 22010
07.2-1457-206 Crown 2009 PF17722-7 Rev. 2110
03 Rev. 2110
862
CJ\owr. TT - Drive In Rack Mast
30 060042-006 Nut. 2
31 124010* Guide Freezer/Corrosion 1
32 121679 Guide 1
33 123281 Clamp 1
34 060015-015 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35 (1) Mast Chain 1
36 086499 Pin 2
37 060000-055 Roll Pin 4
38 075385-001 Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
39 076470-025 Clevis Pin 2
40 060030-191 Flatwasher 2
41 121667 Guide 1
42 121679 Guide 1
43 060021-028 Nut 4
44. . . . . 060038-003 Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 060038-017 Cotter Pin 2
(1) See Chart 3

Chart 3 - Index 35 - Mast Chain

I
Collapsed Required Part Number Minimum Order Quantity

Lift Height
Height Length (When Cutting From Bulk) Quantity Box Length
5030 198 2260 89 2115 83.25 111 073991-123 1 4.5 15
5335 210 2415 95 2265 89.25 119 073991-123 1 4.5 15
6100 240 2720 107 2572 101.25 151 073991-124 1 6 20
6860 270 3025 119 2875 113.25 151 073991-124 1 6 20
7620 300 3325 131 3180 125.25 167 073991-125 1 7.5 25
8155 321 3555 140 3410 134.25 179 073991-125 1 75 25
8660 341 3785 149 3640 143.25 191 073991-125 1 7.5 25
9300 366 4065 160 3945 155.25 205 073991-123 2 4.5 15
10160 400 4370 172 4210 167.25 221 073991-123 2 4.5 15
Note: Replace both mast chains at the same time. When ordering chain, order the number of feet required for
your particular truck. The appropriate minimum order quantity is listed in the above chart. Cut the chain to the
length required for your truck. Refer to Lifting Mechanism Maintenance for cutting chain procedure.
Crown 2009 PF17722-8 Rev. 2110 07.2-1457-207

03 Rev. 2/10
863
TT - Drive In Rack Mast CJ\OWr\
63-~""""',
t 2
61-~
64-~
~-63
~-65 '"
'"
"
70
I
~-60
59-% -70
~ 60 68 69 61 64 63
59 _ %9> - 56 I I I I Q'L I
~ I r:1L ~+~-+-m-~ +-
57-iJ\~-58 ~+-O--I W +1 W I I
I
66 67 59
I
56 63
~
65
~--74
~--56 62
~-I ~'
75-
70
I
72-~@
/
71
71
78_
-79
80::::::::: •
, -81
82-
Figure 22011
Crown 2009 PF17722-9 Rev. 2110

07.2-1457-208
03 Rev. 2110
864
CJ\OWI' 11 - Drive In Rack Mast
55 060019-071 * Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
060019-061 * Screw Load Sense & Freezer/Corrosion or Tilt Position Assist 1
56. . . . . 060030-332 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
57 . . . . . 127874-003* Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
127874-004* Shaft Load Sense & Freezer/Corrosion or Tilt Position Assist 1
58 128883* Pulley Load Sensor & Freezer/Corrosion 1
59 060030-192 Flatwasher 3
60. .... 119655-001 Pulley .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
62. .... 117556-001 Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
64 065081-045 Ball Bearing , 2
65. .... 117557-001 Pulley Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
66 060019-071 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
67 127874-001 Shaft 1
68 127513-001 Pulley Cable 1
69. .... 127791 Pulley Hose 1
70 060019-076 Set Screw 4
72. . . . . 123400 . . . . . . . . . . . Column Roller 4
73 060015-043 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
74. . . . . 060042-006 Nut ..... ... ... .. ... .. ... ... ... ..... ............ ... 2
75 (1) . • . . • • . • . . . . . . . Second Stage Mast 1
76 (2) . • . . . . . . . . . . . . . Mast Spring 2
063002-025 Lubricant AR
77 128014* Ram Spring(3) 2
128013* Ram Spring(4) 2
78 060009-101 * Retaining Ring (5) : 2
060009-045* Retaining Ring (6) . • . . . . . . . • • • . • . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . 2
79. . . . . 121622 Lower Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
80 060030-277 Flatwasher 0.78 mm (0.031 in) Thick AR
81 124019 Bumper 2
82 060017-056 Screw 2
(1) See Charts 1 & 2
(2) See Chart 4
(3) 2260 - 3025 mm (89 -119 in) Collapsed HeighU5025 - 6860 mm (198 - 270 in) Lift Height
(4) 3325 - 4520 mm (131 - 178 in) Collapsed HeighU7620 - 10695 mm (300 - 421 in) Lift Height
w @

Crown 2009 PF1n22-10 Rev. 2110 07.2-1457-209

03 Rev. 2/10
865
TT· Drive In Rack Mast CAOWI\
t
o,
62 63-~ ""
~-65 ",
64-~ ",
~-63
61-Q)
~-60
59-% -70
~ 60 68 69 61 64 63
59 - %~ - 56 I II I Q"L I
~ I rYL + -t- +- %- w +--
r:1t.
\~-58 ~+-o-W +1 W I I I ~-74
57--,1 I I 56 63 65
66 59 67 ~
<i-56 62
~-I ~'
75-
70
I
72-@@
/
71
71
78_
~
-79
80::::::::: •
-81
82-
Figure 22011
Crown 2009 PF17722-11 Rev. 2110

07.2-1457-210
03 Rev. 2110
866
CJ\OWI' TT· Drive In Rack Mast
Chart 4 - Index 76 - Mast Spring
Lift Height Collapsed Height One Each Required

5030 198 2260 89 122399 Bronze 119031 Gray
5335 210 2415 95 119031 Gray 119031 Gray
6100 240 2720 107 119031 Gray 119031 Gray
6860 270 3025 119 119031 Gray 119031 Gray
7620 300 3325 131 128010 Bronze 122422 Green
8155 321 3555 140 128010 Bronze 122422 Green
8660 341 3785 149 122422 Green 122422 Green
9300 366 4065 160 122422 Green 122422 Green
10160 400 4370 172 122422 Green 122422 Green
Crown 2009 PF17722·12 Rev. 2110 07.2-1457-211

03 Rev. 2/10
867
(C)~~
~ ". "'- 103"
'Qf"iiQ~
,
~ 0 • '.
99
i : ;
~: :II t : (t; ~
• lOr : ~"!
:1 ; I
-101
A.! ;,98
'1d' ,! 'i 97
92 ~t1~~iI
/
~',
'-
.....,<., .'......
!
iI 99
'"
,)
I
93
,
'"
1 [\,
)'"
I 98
FLS 94 ~~~ '@/" 118
95/~
I
YlJ-97
~
96
97-(/)'@
/
98 .-
v
/ I 98
(a) Yoke 118 I /"
(b) Free Lift Cylinder I '@ "i'ift - 97

;::::::110 \V
(c) Reach Carriage
"'",,-111
I 114
I I
~~--115
116---\j
Figure 22012-01
Crown 2009 PF1IT22-13 Rev. 2110

07.2-1457-212
03 Rev. 2110
868
CROWl' TT • Drive In Rack Mast
90 060061-005 Screw 2
91 060005-005 Lockwasher 2
92 060030-012 Flatwasher 2
93 123316-003 Limit Switch Assembly 1
108306 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
94 (1) Carriage Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
95 084985 Pin 1
96. . . . . 060000-055 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
97 . . . . . 123400 Column Roller 6
99 060000-080 Roll Pin 4
100 (2) Carriage Spring 2
101 122919 Rod 2
102 128016 Ram Spring 2
103 . . . . 103270 Poly Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
104 060017-050 Screw 2
105 (3) Third Stage Mast 1
106 060019-076 Set Screw 4
107 . . . . 075385-003 Anchor Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
108 086499 Pin 2
109 132466 Clamp 2
110 060021-028 Nut 8
111 . . . . 060038-003 Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
112 (4) . . . . . . . . • • . . . . . Mast Chain 1
113 . . . . 075385-004 Anchor Chain ......................................... 2
114 060021-011 Nut 2
115 . . . . 060005-009 Lockwasher 2
116 129088 Guard 1
117 060017-032 Screw 2
118 060042-018 Nut 4
061003-004 Cable Tie 140 mm (5.6 in) Length AR

061003-005 Cable Tie 290 mm (11.4 in) Length AR
(1) See Chart 5

(2) See Chart 6
(3) See Charts 1 & 2
(4) See Chart 3
Crown 2009 PFl7722-14 Rev. 2/10 07.2-1457-213

03 Rev. 2/10
869
~-(a)
--106 ~
"",=::!==r::;s
~ 94-~ I 1
96
105-
107-t~/
~: \
;~ 108
1~1
! 'I
!
103 . . . . . . .
99
102-
~
-101
118
\v
97-(/)
'@
98/
v I
(a) Yoke
/ I
I /98
118 I
(b) Free Lift Cylinder 1 '@
~::::::110'0-97
1
1
(c) Reach Carriage 1
1
I'
1
1
'-111
1 114
1 I
~~--115
116--\j
Figure 22012..Q1
07.2-1457-214 Crown 2009 PF1n22-15 Rev. 2110
03 Rev. 2110
870
CJ\OWI' TT • Drive In Rack Mast
Chart 5 • Index 94 - Carriage Chain
Collapsed Required Part Number Minimum Order Quantity

Lift Height
Height Length (When Cutting From Bulk) Box Length
5030 198 2260 89 1390 54.75 73 073991-122 3 10
5335 210 2415 95 1465 57.75 77 073991-122 3 10
6100 240 2720 107 1620 63.75 85 073991-123 4.5 15
6860 270 3025 119 1770 69.75 93 073991-123 4.5 15
7620 300 3325 131 1925 75.75 101 073991-123 4.5 15
8155 321 3555 140 2040 80.25 107 073991-123 4.5 15
8660 341 3785 149 2155 84.75 113 073991-123 4.5 15
9300 366 4065 160 2305 90.75 121 073991-124 6 20
10160 400 4370 172 2460 96.75 129 073991-124 6 20
Note: Replace both mast chains at the same time. When ordering chain, order the number of feet required
for your particular truck. The appropriate minimum order quantity is listed in the above chart. Cut the chain
to the length required for your truck. Refer to Lifting Mechanism Maintenance for cutting chain procedure.
Chart 6 - Index 100 - Carriage Spring
Lift Height Collapsed Height One Each Required

5030 198 2260 89 122398 Red 122398 Red
5335 210 2415 95 122398 Red 122398 Red
6100 240 2720 107 122398 Red 122421 Bronze
6860 270 3025 119 122398 Red 122421 Bronze
7620 300 3325 131 122398 Red 122421 Bronze
8155 321 3555 140 122421 Bronze 122421 Bronze
8660 341 3785 149 122421 Bronze 122421 Bronze
9300 366 4065 160 122421 Bronze 122421 Bronze
10160 400 4370 172 122421 Bronze 122421 Bronze
Crown 2009 PFl7722-16 Rev. 2110 07.2-1457-215

03 Rev. 2110
871
Load Wheel CJ\own
100 mm (4 in) 0.0. Tandem Load Wheels
Figure 13101-03
07.4-1452-001 Crown 2001 PF13126-1 Rev. 9/09
06 Rev. 9/09
872
CJ\OWI' Load Wheel
1 073962-006* (1) Axle 75 mm (2.88 in) Load Wheel Width 4

073962-003* (1) Axle 105 mm (4.12 in) Load Wheel Width 4
2 060030-068 Flatwasher 0.8 mm (0.03 in) Thick, 40 mm (1.62 in) 0.0. . . . . . . . . . . .. AR
3 060030-109 Flatwasher 3.0 mm (0.12 in) Thick, 60 mm (2.25 in) 0.0 8
4 060030-110 Flatwasher 1.5 mm (0.06 in) Thick, 30 mm (1.19 in) 0.0 AR
5 083585-xxx-88(2) Poly Wheel Assembly 100 mm x 75 mm (4 in x 2.88 in) 4
088628-xxx-88(2) Poly Wheel Assembly 100 mm x 105 mm (4 in x 4.12 in) 4
6 083585-xxx(2) Poly Wheel 100 mm x 75 mm (4 in x 2.88 in) 4
088628-xxx(2) Poly Wheel 100 mm x 105 mm (4 in x 4.12 in) 4
8. . . . . 060000-030. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9 122451-001 PivotPlateAssembly75mm(2.88in)&105mm(4.12in) 2
10 065084-013 Bearing 2
11 122451-002 Pivot Plate Assembly 75 mm (2.88 in) & 105 mm (4.12 in) 2
12 065084-013 Bearing 2
13 111859-002 Sleeve 4
(1) 100 mm (4 in) 0.0. Tandem Load Wheels

(2) Choice of dash no. depends on load wheel application. When ordering load wheels, refer to Field Appli-
cation Guide and complete the part no. with the correct dash no.

Crown 2001 PF13126-2 Rev. 9/09

07.4-1452-002
06 Rev. 9/09
873
Load Wheel CROWl'
39
Figure 13102-03
Crown 2001 PF13126-3 Rev. 9/09

07.4-1452-003
06 Rev. 9/09
874
CJ\owr. Load Wheel
25 073962-006* (1) Axle 75 mm (2.88 in) Load Wheel Width 4

26 060030-127 Flatwasher 0.8 mm (0.03 in) Thick, 50 mm (2 in) 0.0 8
27 060030-278 Flatwasher 3 mm (0.12 in) Thick, 75 mm (3 in) 0.0 8
30. . . .. 115032-xxx-88(2) Poly Wheel Assembly 125 mm x 75 mm (5 in x 2.88 in) 4
31 115032-xxx(2) Poly Wheel 125 mm x 75 mm (5 in x 2.88 in) 4
115033-xxx(2) Poly Wheel 125 mm x 105 mm (5 in x 4.12 in) 4
32 065081-057 Ball Bearing 8
33 060000-030 Roll Pin 4
35 065084-015 Bearing 2
37 065084-015 Bearing 2
38. . . . . 111858-002 Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


Crown 2001 PF13126-4 Rev. 9/09 07.4-1452-004

06 Rev. 9/09
875
Load Wheel CJ\OWf\
63
50 55 54
-
i<
L --
....... -"
.~. i
-~-. \
Figure 13103-03
07.4-1452-005 Crown 2001 PF13126-0 Rev. 9/09
06 Rev. 9/09
876
l!J\OWr. Load Wheel
*50 074659-006* (1) Axle 75 mm (2.88 in) Load Wheel Width 4

54 125069-xxx-88(2) Poly Wheel Assembly 150 mm x 75 mm (6 in x 2.88 in) 4
55 125069-xxx-<2) Poly Wheel 150 mm x 75 mm (6 in x 2.88 in) 4
125070-xxx-(2) Poly Wheel 150 mm x 105 mm (6 in x 4.12 in) 4
56 065081-008 Ball Bearing 8
57 060000-051 Roll Pin 4
58 125205 Pivot Plate Assembly 75 mm (2.88 in) & 105 mm (4.12 in) 2
59 065084-015 Bearing 2
60 125204 Pivot Plate Assembly 75 mm (2.88 in) & 105 mm (4.12 in) 2
61 065084-015 Bearing 2
62. . . . . 111858-002 Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Crown 2001 PF13126-6 Rev. 9/09

07.4-1452-006
06 Rev. 9/09
877
Load Wheel CJ\OWI)
265 mm (10.5 in) 0.0. Load Wheels
72
Figure 13104-03
07.4-1452-007 Crown 2001 PF13126-7 Rev. 9/09
06 Rev. 9/09
878
CJ\OWI' Load Wheel
70 074659-004* (1) Axle 100 mm (4 in) Load Wheel Width .. ' 2

71 060030-111 Flatwasher 3.2 mm (0.12 in) Thick, 75 mm (3 in) 0.0 AR
74 060030-085 Flatwasher 0.8 mm (0.03 in) Thick, 50 mm (2 in) 0.0. . . . . . . . . . . . . . .. AR
75 113018-060* Wheel Assembly 265 mm x 100 mm (10.5 in x 4 in) 2
113019-060* Wheel Assembly 265 mm x 115 mm (10.5 in x 4.5 in) 2
76 065081-008 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
77 105090-060* Tire Assembly 265 mm x 100 mm (10.5 in x 4 in) 2
105091-060* Tire Assembly 265 mm x 115 mm (10.5 in x 4.5 in) 2
105088-060-01* Tire 265 mm x 100 mm (10.5 in x 4 in) 2
105089-060-01* Tire 265 mm x 115 mm (10.5 in x4.5 in) 2
78 105086 Hub 265 mm x 100 mm (10.5 in x 4 in) 2
105087 Hub 265 mm x 115 mm (10.5 in x 4.5 in) 2
79 060000-051 Roll Pin 2
(1) 265 mm (10.5 in) 0.0. Load Wheels

Crown 2001 PF13126-8 Rev. 9/09 07.4-1452-008

06 Rev. 9/09
879
Load Wheel - Field Application Guide l!J\C1WI'
Application Type
Composition Wet/Freezer Dock Boards Heavy Loads Floor Debris
"c ..
::::I Q) ce=
Q) Q)
Resistant to Rough Floors Long Runs Resistant to
0.0 .. c
Wheel Series c.E Chunking Floor Debris Resistant to Flat Spotting
0"E
E ::::I J: Resistant to Extreme Heat
oz 0 Zlll
(J Chunking
100 Series
101 93A polyether • •
Light Duty 102 9SA polyester • •
201 83A polyester • •
200 Series
Mid-Range
205 87A polyether • • •
301 95A polyether • • • •
302 95A polyester • • • •
300 Series
303 9SA polyester • • • •
High Capacity 304 9SA polyester • • • •
400 Series 401 93A vulkollan
Heavy Duty 402 99A polyether
100 Series Light Duty wheel compounds are best suited for light loads and intermittent use.
200 Series Mid-Range wheels are designed for light to medium loads and short to medium runs.
300 Series High Capacity are for the typical demands of most applications. High capacity wheels feature compounds designed for high
capacities and long runs.
400 Series Heavy Duty wheels are designed for maximum capacities and extreme runs.
Shore A Hardness Scale

I I I I I I I I I I I
o 10 20 30 40 50 60 70 80 90 100
30A is comparable to a rubber band. Typically more cut and tear resistant and provide a smoother ride.
60A is comparable to a car tire. Provide improved travel speeds (less rolling resistance) and generate less heat.
Polyester vs. Polyether
These elements of polyurethane chemical composition can be found in each compound series.
Polyester - provides greater cut and tear resistance and overall durability.
Polyether - provides greater load bearing capacity and heat resistance.
07.4-0000-001 Crown 2009 PF17762-1
880
CJ\owr.
Notes:
881
Yoke CJ\OWr\
(
"
Figure 21638
07.5-1452-250 Crown 2001 PF13127-1 Rev. 4109
01 Rev. 4/09
882
CJ\owr. Yoke
o. . . . . 121802 Yoke Assembly , 1

124013-001 * Yoke Assembly with Freezer/Corrosion and Load Sense 1
1 121628 Yoke 1
2 123183-002 Shaft 1
4 123181-003 Shaft 1
6 123401-001 * Shaft with Freezer/Corrosion and Load Sense , 1
8 117575-003 Pulley Assembly , 1
9. . . . . . . . .. 117576-003 Pulley 1
10 065081-027 Ball Bearing 2
11 060030-329 Flatwasher 4
12 119655-002 Pulley Hose 2
13 127583-001 Pulley Wire 1
14 060000-112 Roll Pin , 1
15 060000-067* Roll Pin with Freezer/Corrosion and Load Sense 1
16 127513-002* Pulley Wire with Freezer/Corrosion and Load Sense , 1
17 060030-192* Flatwasher with Freezer/Corrosion and Load Sense 1
18 060009-011 * Retaining Ring with Freezer/Corrosion and Load Sense 1

Crown 2001 PF13127-2 Rev. 4109 07.5-1452-251

01 Rev. 4/09
883
Load Backrest CJ\OWrl
"C"
2
~''(1./ / 1
"B"
~
..-
..-
(
..-
., '(J.
..-/ 4
~-3
)
..- ..-
(a) Top of Fori<

(b) Fori< Carriage ..- ..-
Figure 21639
Crown 2001 PF13128-1 Rev. 4/09

07.8-1452-001
01 Rev. 4/09
884
CJ\owr. Load Backrest
1 060019-019 Screw 2
3 060019-031 Screw 2
4. . . . . 060005-029 Lockwasher 2
5 *(1) Load Backrest 1
(1) See Chart 1 - Load Backrest
• To select appropriate part number, refer to truck data number.

The truck data number represents truck features.
Refer to Introduction.
Chart 1 • Load Backrest
Index 5 Overall Dimension Dimension "A" Dimension "B" Dimension "C"

Series
Load Backrest mm in mm in mm in mm in
RR&RD 125608-036 825 x 915 32.5 x 36 215 8.5 810 31.88 915 36
RR&RD 125608-042 825 x 1070 32.5 x 42 370 14.5 960 37.88 1070 42
RR&RD 125608-048 825 x 1220 32.5 x 48 520 20.5 1115 43.88 1220 48
RR&RDwith
125367-036 825x915 32.5 x 36 215 8.5 810 31.88 915 36
Sideshift
RR&RDwith
125367-042 825 x 1070 32.5 x 42 370 14.5 960 37.88 1070 42
Sideshift
RR&RDwith
125367-048 825 x 1220 32.5 x 48 520 20.5 1115 43.88 1220 48
Sideshift
Crown 2001 PF13126-2 Rev. 4109 07.8-1452-002

01 Rev. 4/09
885
Fork CJ\OWI'
I
I
/
~4
..-
1 3/ " 2
088228-xxx
Fork Assembly
I
I
/
t
I
1
094182-xxx
Fork Assembly
I
I
/
1
1
Figure 14309
07.9-08.0-004 Crown 2004 PF13823-1 Rev. 5/09
05 Rev. 5/09
886
r-------------------

CROWl' Fork
1 . . . . . 103442 Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

103443 Pin 1
2 104329 Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 060000-061 Roll Pin 1
4 075248 Handle 1
Fork Assemblies noted in Charts include Index 1 through 4
Crown 2004 PF13823-2 Rev. 5109 07.9-08.0-005

05 Rev. 5/09
887
Fork CJ\OWI'
075324-xxx
Fork Assembly
I
I
/
....
....
....~4
1 3/ 2
088228-xxx
Fork Assembly
I
I
/
....
/
t 4
I
1 3~ . . ~
2
094182-xxx
Fork Assembly
I
I
/
Figure 14309
Crown 2004 PF13823-3 Rev. 5109

07.9-08.0-006
05 Rev. 5/09
888
CROWl' Fork
Model, Fork Designation Chart
Fork Assembly Base Part Number

Series Capacity Polished Fork Full Taper
075324-xxx 094182-xxx
088228-xxx
W 1815 kg (4000 Ibs) X
455 - 1360 kg (1000 - 3000 Ibs) X
WB
1815 kg (4000 Ibs) X
WR 910 - 1360 kg (2000 - 3000 Ibs) X
RC
1360 kg (3000 Ibs) X X
RC 3000
1585 -1815 kg (3500 - 4000 Ibs) X X
RC 5500
SC 1360 kg (3000 Ibs) X X
SC 4000,4500 1585 - 1815 kg (3500 - 4000 Ibs) X X
RR 3000, 3500
RR 5000, 5200 1585 - 2040 kg (3500 - 4500 Ibs) X X
RR 5700
RS 3000,3500 1815 kg (4000 Ibs) X X
RD 3000, 3500
RD 5000, 5200 1360 kg (3000 Ibs) X X X
RR 5700
SH 1815 kg (4000 Ibs) X X
1130 - 1360 kg (2500 - 3000 Ibs) X X
SHR
1585 kg (3500 Ibs) X X
Fork Length Chart
Fork Length Fork Assembly Part Number

Polished Fork Full Taper
mm in 075324-xxx 094182-xxx
088228-xxx
760 30 -001 -001 -001
915 36 -002 -002 -002
990 39 -006 -006 -006
1065 42 -003 -003 -003
1145 45 -005 -005 -005
1220 48 -004 -004 -004
Following Part Numbers Not Used on RR, RS, & RD Series Trucks
1370 54 -007 -007 -007
1525 60 -008 -008 -008
Crown 2004 PF13823-4 Rev. 5109 07.9-08.0-007

05 Rev. 5/09
889
CJ\OW"
Notes:
890
mown
CYLINDER PARTS
891
CYLINDER PARTS
TT Lift Cylinder
-
~10
.-
~10
1
I
( 1
('
I I I
I
I
~9
rn I 9
I
I
I
I 8 ~8
I
I
7 7
I
I
I
I
I
I
1 I
I
(c) I
1
I
I
I
I
(d) ,
I
I
I
I
I
,
I
I
I I
I I
I
6 I
6
I I
I 1
I 1
I I
I I
I I
I I
I I
10 9 I 1
I 1
1 I
8 I I
I I
7 I I
~e I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I (a) LH Drive In Rack Cylinder I
I I
I (b) RH Drive In Rack Cylinder I
I I
I (c) LH Lift Cylinder
I
I I
(d) RH Lift Cylinder
I 1
I I
I I
1 I
11~
I I 0
5
1
,
I
11 !
~
$::4 5
'~ 4
: Q
~5
"'~4 \',
'
'-'I
4
Figure 21697-01
Crown 2010 PF25118-1

08.3-1452-005
892
CYLINDER PARTS
l!I\OWrl TT Lift Cylinder
o. . ... (1)* RH Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

(1)* LH Cylinder Assembly 1
(2)* RH Drive In Rack Mast Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . .. 1
(2)* LH Drive In Rack Mast Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . .. 1
1 (1)* RH Cylinder Tube 1
(1)* LH Cylinder Tube 1
(2)* RH Drive In Rack Mast Cylinder Tube 1
(2)* LH Drive In Rack Mast Cylinder Tube .. " 1
2 060015-078 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 074240 Seal 1
4 060009-067 Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 073975-004 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 (1)* Ram 1
(2)* Ram, Drive-In Rack Mast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 081161-018 Collar 1
8 064132-046 Packing Rod 1
9 149265 Cap 1
10 064017-017 Wiper Ring 1
11 124251-003 Velocity Fuse (LH Cylinder Only) 1
149335 Seal Kit (Includes Index 2,3,8,9 & 10) 1

091240-004 Poly Pak Tool (Used for Seal Installation) 1
(1) See Chart 1 - TT Mast

(2) See Chart 2 - Drive-In Rack Mast

Crown 2010 PF25118-2 08.3-1452-006
893
CYLINDER PARTS
TT Lift Cylinder CJ\OWI)
... -I o
~10
...
~10
I
( I r
I I I
1
I 9 I 9
~8
I
I
I
I
~8
I
I
7 7
I
I
I
I
I
I
1 I
I
(c) I
1
I
(d)
I
I
I
I
I
I
I
I
6 6
I
1
I
I
I
I
I
I
9 I
I
I
8 I
I
7 I
I
I
I
I
I
I
I
I
I
I I
I I
1 I I
I (a) LH Drive In Rack Cylinder I
I I
I (b) RH Drive In Rack Cylinder I
6 I I
I (c) LH Lift Cylinder I
I I
(d) RH Lift Cylinder
1 I
I I
I I
11~
I o I
I I
11 i
~
~4
~5 !\', ~4
Q. 5
"'~4 ',J ~4
Figure 21697-01
08.3-1452-007 Crown 2010 PF25118-3
894
CYLINDER PARTS
CROWl' TT Lift Cylinder
Chart 1 - TT Mast
Collapsed LH Cylinder RH Cylinder LH Cylinder RH Cylinder

Lift Height Ram
Height Assembly Assembly Tube Tube
Index 6
mm in mm in Index 0 Index 0 Index 1 Index 1
2260 89 5025 798 121676-004 121663-004 121677-004 121664-004 121672-004

2415 95 5335 210 121676-005 121663-005 121677-005 121664-005 121672-005
2720 107 6100 240 121676-006 121663-006 121677-006 121664-006 121672-006
3025 119 6860 270 121676-007 121663-007 121677-007 121664-007 121672-007
3325 131 7620 300 121676-008 121663-008 121677-008 121664-008 121672-008
3555 140 8155 321 121676-009 121663-009 121677-009 121664-009 121672-009
3785 149 8660 341 121676-010 121663-010 121677-010 121664-010 121672-010
4065 160 9300 366 121676-011 121663-011 121677-011 121664-011 121672-011
4370 172 10160 400 121676-012 121663-012 121677-012 121664-012 121672-012
4520 178 10695 421 121676-013 121663-013 121677-013 121664-013 121672-013
4825 190 11225 442 121676-014 121663-014 121677-014 121664-014 121672-014
Chart 2 - Drive-In Rack Mast
Collapsed LH Cylinder RH Cylinder LH Cylinder RH Cylinder

Lift Height Ram
Height Assembly Assembly Tube Tube
Index 6
mm in mm in Index 0 Index 0 Index 1 Index 1
2260 89 5025 798 129053-004 129056-004 129054-004 129057-004 131272-004

2415 95 5335 210 129053-005 129056-005 129054-005 129057-005 131272-005
2720 107 6100 240 129053-006 129056-006 129054-006 129057-006 131272-006
3025 119 6860 270 129053-007 129056-007 129054-007 129057-007 131272-007
3325 131 7620 300 129053-008 129056-008 129054-008 129057-008 131272-008
3555 140 8155 321 129053-009 129056-009 129054-009 129057-009 131272-009
3785 149 8660 341 129053-010 129056-010 129054-010 129057-010 131272-010
4065 160 9300 366 129053-011 129056-011 129054-011 129057-011 131272-011
4370 172 10160 400 129053-012 129056-012 129054-012 129057-012 131272-012
4520 178 10695 421 129053-013 129056-013 129054-013 129057-013 131272-013
4825 190 11225 442 129053-014 129056-014 129054-014 129057-014 131272-014
Crown 2010 PF25118-4 08.3-1452-008
895
CYLINDER PARTS
TT Carriage Cylinder l!J\OWI'
5
'"'-
I ....
I 13
') 12 __....u.m-
I 3
I
I
I 11 2
I
I f' ....
I I
I
I
6
I
I ')
1-- I I
I I 8
I
I
I 9
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
I
5- I 4
I
I I
I I
I I
I I
I I
I I
I I
I I
I
I
I
I 14-Q
Q-13
I I
I I
I I
I I
I I I
4-~
I I
I
I I
I I 12-Q
I I
0-
I
911--=-· I
\
I
11
I
I
I
I
I
I ~-8
I
I
I
\
9-cp (a) Torque 152 - 167 Nm (112 - 123 ft Ib)
(;)-10
I
I
....;
Figure 21640-01
Crown 2010 PF25119-1

08.3-1452-054
896
CYLINDER PARTS
l!J\OWf\ 11 Carriage Cylinder
o *(1) Cylinder Assembly 1

1 *(1) Cylinder Tube 1
2 060015-078 Screw 1
3 074240 Seal 1
4 064336 Flow Regulator 1
5 *(1) Ram 65 mm (2.625 in) 0.0. . 1
7 127489-002 Shutoff Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 084882-001 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 060009-096 Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 081161-020 .. , Collar 1
12 064132-042 Seal Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 149260 Cap 1
14 064017-016 Wiper Ring 1
149334 Seal Kit (Includes Index 2,3, 12, 13 & 14) 1

091240-009 Poly Pak Tool (Used for Seal Installation) 1
(1) See Chart 1 - Cylinder Assembly
Chart 1 • Cylinder Assembly
Collapsed Height Lift Height Cylinder Assembly Cylinder Tube Ram

mm in mm in Index 0 Index 1 Index 5
2260 89 5025 198 130395-004 130394-004 121725-004

2415 95 5335 210 130395-005 130394-005 121725-005
2720 107 6100 240 130395-006 130394-006 121725-006
3025 119 6860 270 130395-007 130394-007 121725-007
3325 131 7620 300 130395-008 130394-008 121725-008
3555 140 8155 321 130395-009 130394-009 121725-009
3785 149 8660 341 130395-010 130394-010 121725-010
4065 160 9300 366 130395-011 130394-011 121725-011
4370 172 10160 400 130395-012 130394-012 121725-012
4520 178 10695 421 130395-013 130394-013 121725-013
4825 190 11225 442 130395-014 130394-014 121725-014
Crown 2010 PF2511&-2 08.3-1452-055
897
CYLINDER PARTS
Reach Cylinder Cl\OWI'
I................
I
I
I
I
91 (a) •
I 3
I
/ 4
(@~
i, ,
I
I
I
I
I
, ~O: ,
5
,
I
\""
(a) Torque 298 ± 13.5 Nm (220 ± 10 ft Ib)
Figure 21644
08.5-1452-002 Crown 2004 PF13875-1 Rev. 4/09
02 Rev. 4/09
898
CYLINDER PARTS
CJ\OWrl Reach Cylinder
o *(1) Reach Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 065012-010 Bushing Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 *(1) Tube 1
3 060080-011 Flange Nut 1
4 132396 Piston 1
5 064216-005 Piston Seal 1
7 *(1) Piston Rod 1
8 064019-015 O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 064074-005 Back-Up Ring 1
10 132398 Guide Rod 1
11 064132-050 Packing Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 064135-019 Wiper Ring 1
13 133459-001 Retainer Wire 1
14 060021-040 Nut 1
15 136694 End Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
134137 Seal Kit (Includes Index 5,8,9,11,12 & 13) 1
(1) See Chart 1 - Reach Cylinder Assembly

Chart 1 - Reach Cylinder Assembly
Index 0 Index 2 Index 7

Series Orientation
Reach Cylinder Assembly Tube Piston Rod
RH 132419 132420 132397-001
RR
LH 133460 132421 132397-001
RH 132388 132389 132397-002
RD
LH 132393 132394 132397-002
Crown 2004 PF13875-2 Rev. 4/09 08.5-1452-003

02 Rev. 4/09
899
CYLINDER PARTS
Tilt Cylinder CROWl'
\
;'
;'
;'
;';';';';' 15-~ ~-17

;';' I I
16--~ ~---18
I I
/19 ~
'0 ;'
;'
13
.<@)<}--.... ~
\
12
11 \
10 \~;'
\ ~).
~)~
9
\
Figure 21651
Crown 2001 PF13132-1 Rev. 4/09

08.6-1452-001
01 Rev. 4/09
900
r-------~------- ---
CYLINDER PARTS
Tilt Cylinder
o 123399-001 Tilt Cylinder 1

1 088579 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 064135-002 Wiper Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 082305 Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 064074-012 Back-Up Ring 1
5 064019-040 a-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 064132-010 Packing Rod 1
7 064074-013 Back-Up Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 064019-041 a-Ring 1
9 105206 Piston 1
10 064216-002 Piston Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 060044-004 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 060043-004 Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 073981-003 Square Wire Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 122492-001 Cylinder Tube 1
15 064091-006 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 064019-031 a-Ring , 1
17 064091-002 Plug 1
18. . . . . . . . . . 064019-029 a-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 060009-030 Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 065012-004 Ball Bushing 1
089178 Seal (Includes Index 2, 4, 5, 6, 7, 8 & 10) 1
Crown 2001 PF13132-2 Rev. 4109 08.6-1452-002

01 Rev. 4/09
901
CYLINDER PARTS
Sideshift Cylinder CROWl'
f',
I
"
I....... ,
I
I
I
I
I
16- I
I
I
I
I
I
I I
@-11 :
12--~ i
13-0 i ~1
/
14-0 : I
I
o
, ,
'J
I
'..,J
Figure 21652
Crown 2001 PF13133-1 Rev. 5109

08.7-1452-050
01 Rev. 5/09
902
CYLINDER PARTS
CJ\owra Sideshift Cylinder
o 093559-002* Cylinder Assembly 100 mm (4.0 in) 1

093559-004* Cylinder Assembly 50 mm (2.0 in) 1
1 085130-002* Rod 100 mm (4.0 in) Sideshift 1
085130-004* Rod 50 mm (2.0 in) Sideshift 1
2 064069-007 Ring Wiper 1
3 083397 Adjustor Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 064132-011 Packing Rod 1
5 085262 Tube Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 073981-009 Ring Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 064074-004 Ring Back-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 064019-025 O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 064133-005 U-Cup Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 085132 Piston 1
11 060030-041 Flatwasher 1
12 060042-005 Nut Self-Locking 1
13 064019-006 O-Ring 1
14 064074-018 Ring Back-Up 1
15 093558 Chamber Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 088587* Spacer 50 mm (2.0 in) Sideshift 2
101343 Kit Seal (Includes Index 2, 4, 6, 7, 8, 9,13, & 14) 1

Crown 2001 PF13133-2 Rev. 5/09 08.7-1452-051

01 Rev. 5/09
903
CJ\OWI'
Notes:
904
mow"
REACH MECHANISM PARTS
905
Reach with Tilt - RR CJ\OWI'
Figure 23085
09.0-1457-005 Crown 2010 PF17979-1
906
PLATFORM PARTS
CJ\OWI' Reach with Tilt - RR
1 122273-002 Reach Support - 35 Models 1

122159-002 Reach Support - 45 Models 1
129292-002 Reach Support - 45 Models (drive in rack mast option) 1
2 074481-001 Shim AR
074481-004 Shim AR
074481-005 Shim AR
3 092746-001 Bracket 1
4 092747-001 Poly Stop 1
5 060015-068 Screw 1
6 060000-104 Roll Pin 2
7 113516 Pivot Shaft 2
8. . . . . 093680 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. . . . . 060000-029. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 060016-065 Screw 2
11 . . . . . 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 060016-088 Screw 2
13 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 060021-009 Nut. 2
15 122168 Hose Guide 1
16 , Reach Cylinder, refer to Cylinder Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 082579* Pivot Shaft 2
088892* Pivot Shaft (Freezer/Corrosion) 2
18 060000-090 Roll Pin 2
19 065012-007 Ball Bushing 2
20 124018 Poly Stop 2
21 060017-050 Cap Screw 2
22. . . . . 060030-279. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 123474-001 Pulley 1
24 060015-048 Screw : 2
25 060042-006 Lock Nut 2
26. . . . . 122927 . . . . . . . . . . . Mounting Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 065012-001 Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
28 122922-001 Inner Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 082381 Thrust Washer. 2
30. . . . . 076293 . . . . . . . . . . . Carriage Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
31 076143 Cap 2
32 060016-022 Screw 2

Always Specify Model, Data & SerIal Number
Crown 2010 PF1797~2 09.0-1457-006
907
~-----------------------------------------

Reach with Tilt· RR CJ\OW"
70
71
60
~---- 80
81
77---
Figure 23083
Crown 2010 PF17979-3

09.0-1457-007
908
PLATFORM PARTS
CJ\OWI' Reach with Tilt· RR
40 060030-085 Flatwasher. AR
41 074668-001 Column Roller , 2
42 065007-052 Bushing , 2
43 082381 Thrust Washer , 2
44. . . . . 082384 . . . . . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
46 060077-002 Roll Pin 2
47 100116-001 Outer Arm , 2
48 060015-050 Set Screw 2
061004-019 Thread Locking Adhesive , 1
50. . . . . 060015-064 Screw , 1
060015-069 Screw 1
51 . . . . . 123402 Guide , 1
52. . . . . 093680 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
53. . . . . 060000-029. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
54 129830-002 Cover , 1
55 060015-004 Screw 2
56. . . .. . Tilt Cylinder, refer to Cylinder Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
57 065007-018 Bearing Sleeve 2
58 065012-004 Ball Bushing , 1
60. . . . . 123393-001 Carriage , 1
61 060015-019 Screw 1
62. . . . . 060005-007. . . . . . . . Lockwasher , 1
63. . . . . 060021-006. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., 1
64 065007-017 Sleeve Bearing 4
65. . . . . 060016-035 Screw , 2
66 060005-008 Lockwasher 2
67 079564-001 Terminal Block , 1
079565-001 Marking Strip , 1
105605-406 TB Label , 1
68 060013-017 Screw , 2
69 060005-004 Lockwasher 2
70. . . . . 128003 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
71 060014-088 Hex Flange Screw , 2
72. . . . . 127842 Tilt Position Assist Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
73 060012-023 Screw 2
74 060005-048 Lockwasher 2
75. . . . . 127845 . . . . . . . . . . . Mounting Plate , 1
76 060015-117 Hex Flange Screw , 2
77 . . . . . 060000-066. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
78. . . . . 093736 Cylinder Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
79 060000-054 Roll Pin , 2
81 093560-002 Fork Plate 1
Crown 2010 PF179794 09.0-1457-008
909
Reach with Tilt & Sideshift - RR CROWl'
(a) Reach Cylinder, refer to Cylinder Parts
Figure 23087
09.0-1457-106 Crown 2010 PF17976-1
910
PLATFORM PARTS
l!J\OWr. Reach with Tilt & Sideshift - RR
1 122273-002 Reach Support - 35 Models 1

122159-002 Reach Support - 45 Models 1
129292-002 Reach Support - 45 Models (drive in rack mast option) 1
2 074481-001 Shim · .. AR
074481-004 Shim AR
074481-005 Shim AR
3 092746-001 Bracket 1
4 092747-001 Poly Stop 1
5 060015-068 Screw 1
6 060000-104 Roll Pin 2
8. . . . . 093680 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. . . . . 060000-029. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 060016-065 Screw 2
11 . . . . . 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
088892 Pivot Shaft (Freezer/Corrosion) 2
14 060000-090 Roll Pin 2
15 060016-088 Screw 2
16. . . . . 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 060021-009 Nut. 2
19 065012-007 Ball Bushing 2
20 124018 Poly Stop 2
21 060017-050 Cap Screw 2
22. .... 060030-279. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 123474-001 Pulley 1
24 060015-048 Screw 2
25 060042-006 Lock Nut 2
26. .... 122927 Mounting Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 065012-001 Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
28. .... 122922-001 Inner Arm .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 082381 Thrust Washer 2
30. .... 076293 . . . . . . . . . . . Carriage Roller . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
31 076143 Cap 2
32 060016-022 Screw 2
33 060030-085 Flatwasher AR
34 074668-001 Column Roller 2
35 065007-052 Bushing 2
37. . . . . 082384 . . . . . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
39 060077-002 Roll Pin 2
40. . . . . 100116-001 Outer Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
41 060015-050 Set Screw 2
Crown 2010 PFl7978-2 09.0-1457-107
911
Reach with Tilt & Sideshift • RR CJ\OWI'
TB406
67
Figure 23084
Crown 2010 PF17978-3

09.0-1457-108
912
PLATFORM PARTS
Reach with Tilt & Sideshift • RR
50 060015-064 Screw , 2
060015-069 Screw 1
51 123402 Guide 1
52. .... 093680 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
53 060000-029 Roll Pin 2
54. .... 129830-001 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
55 060015-004 Screw 2
56. . . .. . Tilt Cylinder, refer to Cylinder Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
58 065012-004 Ball Bushing 1
60. .... 123393-001 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
61 060015-019 Screw 1
62. .... 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
63 060021-006 Nut. 1
64 065007-017 Sleeve Bearing 4
65 060005-008 Lockwasher 4
66 060017-026 Screw 4
67 079564-001 Terminal Block 1
079565-001 Marking Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
105605-406 TB Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
68 060013-017 Screw 2
69 060005-004 Lockwasher 2
70. .... 128003 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
71 060014-088 Hex Flange Screw 2
72 127842 Tilt Position Assist Sensor 1
73 060012-023 Screw 2
74. .... 060005-048. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
75. .... 127845 Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
76 060015-117 Hex Flange Screw 2
77 . .... 082262 . . . . . . . . . . . Bracket :.............................. 2
Crown 2010 PF17978-4 09.0-1457-109
913
Reach with Tilt & Sideshift - RR CROWl'
94
93--~;r
Figure 23086
09.0-1457-110 Crown 2010 PF17978-5
914
PLATFORM PARTS
CROWl' Reach with Tilt & Sideshift· RR
85. . . . . 060000-066. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

86. . . . . 093736 Cylinder Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
87 060000-054 Roll Pin 2
89 093560-002 Fork Plate 1
90 060017-007 Screw 1
91 060005-009 Lockwasher 1
92 060030-078 Flatwasher 1
93 060019-039 Screw 4
94. . . . . 060005-029. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
95 085144 Lower Hanger 2
96. . . .. . Sideshift Cylinder, refer to Cylinder Parts. . . . . . . . . . . . . . . . . . . . . . . . . .. 1
97 085188 Slide 6
98 085143* Shaft 4
088910* Shaft Freezer/Corrosion 4
99. . . . . 060000-030. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
100 085137-001 Lower Support 2
101 085137-002 Upper Support 2
102 065007-026 Bushing 8
103 085142 Roller , 4
104. . . . 085239* Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
088909* Shaft Freezer/Corrosion 2
105 . . . . 060000-018. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
106 085152 Fork Carriage 1
107 076235-003* Pivot Shaft 1
088893-002* Pivot Shaft Freezer/Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Crown 2010 PF1797~ 09.0-1457-111
915
Reach With Tilt· RD CJ\own
14
I 14
~~ / /16
15 ~~~'(>'
17 __ ~ I 19 " "
8-~ ;~
10,-~ 1- 11
1
18
(b)
St/ ......
13
,
",
"I~I I~~
1 1 91 ./'
... '" /9
1 I l~J .. Q
d, d> 1 ''>---1/ IAl
... ~""12
o
... ... \ 21
... ... ~,
" @ . 20 <", IJl\
... ~ <q
\
22
1 1
1 1
23 fj)'['" /24: :
~tJ/ ' , C"".. /1 :
19 --........0 ... 1
-1 \ ......... :
18-%J¥ 1
. . ~)4 1
17-~ _/~ /15 :

16 ~~:
27-0ff/:;;) \:
28-~~~~
TB406
-l/
1
2
@~ 14 :
4 29 / V,,,,,
""'d'J)~
3
30 I
31
(a) Reach Cylinder
(b) Reach Manifold
Figure 21997
Crown 2009 PF1772G-1

09.0-1657-007
916
PLATFORM PARTS
CJ\OWrl Reach With Tilt· RD
1 . . . . . 122301 Reach Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

129090 Reach Support with Drive In Rack Mast Option 1
079565-001 Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
105605-406 TB Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3. . . . . 060005-004 . . . . . . . Lockwasher 2
4 060013-017 Screw 2
5. . . . . 060000-104 . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 113516 Pin 2
7. . . . . 093680* .. . . . . . . . . Pivot Shaft 2
093735* Pivot Shaft Freezer/Condition 2
8. . . . . 060000-029 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. . . . . 060005-008 Lockwasher 4
10 060016-065 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 060016-088 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 060021-009 Nut 2
060016-082 Screw 1
060042-010 Lockwasher 1
14. . . . . 060030-279 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15 123474-001 Pulley 2
16. . . . . 122927 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 060015-079 Screw 4
18. . . . . 060005-007 Lockwasher 4
19 060021-006 Nut 4
20 124018 Poly Stop 2
21 060017-050 Cap Screw 2
22 065012-001 Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 060000-079 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
24. . . . . 082579* . . . Pivot Shaft '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 065012-007 Ball Bushing 2
26. . . . . 122924-001 Primary Inner Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28. . . . . 060077-002 Groove Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
29 085161 Lock Nut 2
30 085158-002 Thrust Washer 2

Crown 2009 PF1772G-2 09.0-1657-008
917
Reach With Tilt - RD l!J\OWI'
48
a '~
I 58
@A@/
,,/", ~
(~"
, "'---44
59- (2 /
45-~ \
'0
60
61___ 61 "
62-_~~
~ / ,,'-A-64,,"
",,"
65", ~~~63
66 -@ll@) "
•
. -68
~.
I
67 40
~ I
'@
Figure 21998
Crown 2009 PFlm0-3

09.0-1657-009
918
PLATFORM PARTS
CROWr. Reach With Tilt· RD

41 . . . . . 100103-001 RH Outer Arm 1
100103-002 LH Outer Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
42. . . . . 060030-085 Flatwasher AR
45. . . . . 060077-002 Groove Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
46. . . . . 082384 . . . . . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47 065007-052 Bushing 2
48 085158-001 Thrust Washer. 4
49. . . . . 076293 . . . . . . . . . . . Carriage Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50 076143 Cap 2
51 060016-022 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
061004-019 Thread Locking Adhesive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
52. . . . . 100116-002 RH Outer Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
100116-003 LH Outer Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
53 065012-007 Bushing 2
076048-002 Lubrication Fitting 4
55. . . . . 060005-008 Lockwasher 4
56 060021-009 Nut 4
57 112943-001 Secondary Inner Arm 1
58. . . . . 065007-077 Bearing Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60 085161 Lock Nut , 2
61 060030-279 Flatwasher 2
62 123474-001 Pulley , 1
63. . . . . 122927 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
64 060015-079 Screw 2
65. . . . . 060005-007 Lockwasher 2
66 060021-006 Nut : 2
67 060016-019 Screw 4
68. . . . . 122926 . . . . . . . . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2009 PF17720-4 09.0-1657-010
919
Reach With Tilt - RD CJ\OWI'
96
~,
95 r.>!' t&
94-~ I
, , .::P
97-0
98----
!
108
I (a) Tilt Manifold

106 (b) Tilt Cylinder
Figure 21999
Crown 2009 PF1IT2G-5

09.0-1657-011
920
PLATFORM PARTS
CJ\OW" Reach With Tilt - RD
78 060014-088 Screw 2
79. . . . . 128003 . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
80 060012-023 Screw 2
81 060005-048 Lockwasher 2
82. . . . . 127842 Tilt Position Assist Sensor . . . . . . . . . . . . . . . . . . . . .. 1
83 060015-117 Screw , 2
84. . . . . 127845 Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
85 060015-064 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
060015-069 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
86. . . . . 123402 Guide 1
87 060015-019 Screw 1
88. . . . . 093680* . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
093735* Shaft Freezer/Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
89. .... 060000-029 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
90. .... 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
91 060021-006 Nut. 1
92. .... 129830-002 Cover .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
93 060015-004 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
94. .... 093736 . . . . . . . . . . . Cylinder Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
95. .... 060000-054 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
088891 * Pivot Shaft Freezer/Condition 2
97. . . . . 060005-008. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
98. . . . . 060016-035 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
99. . . . . 093560-002 Fork Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
100 060000-066 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
102 065012-004 Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
103 060009-030 Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
105. . . . 090440-004. . . . . . . . Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
106. . . . 123393-002 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
107 . . . . 060005-009. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
108 060017-007 Screw 4

Crown 2009 PF17720-6 09.0-1657-012
921
Reach With Tilt & Sideshift • RD CJ\OWI'
TB406
4
2-1 // /
"'-... ~J)""-
3
(a) Reach Cylinder

(b) Reach Manifold
Figure 21997
09.0-1657-108 Crown 2010 PF17976-1
922
PLATFORM PARTS
CJ\owr. Reach With Tilt & Sideshift· RD
1 122301 Reach Support 1

129090 Reach Support with Drive In Rack Mast Option 1
079565-001 Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
105605-406 TB Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3. . . . . 060005-004 Lockwasher 2
4 060013-017 Screw , 2
5 060000-104 Roll Pin 2
6 113516 Pin 2
7. . . . . 093680* . . . . . . . . . . Pivot Shaft 2
8 060000-029 Roll Pin 2
9. . . . . 060005-008 Lockwasher 4
10 060016-065 Screw 2
11 060016-088 Screw 2
12 060021-009 Nut 2
060016-082 Screw 1
060042-010 Lockwasher 1
14 060030-279 Flatwasher 4
15 123474-001 Pulley 2
16 122927 Shaft 2
17 060015-079 Screw 4
18. . . . . 060005-007 Lockwasher 4
19 060021-006 Nut 4
20 124018 Poly Stop 2
21 060017-050 Cap Screw , 2
22 065012-001 Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 060000-079 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 065012-007 Ball Bushing 2
26. . . . . 122924-001 Primary Inner Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28 060077-002 Groove Pin 2
29 085161 Lock Nut 2

Crown 2010 PF17976-2 09.0-1657-109
923
Reach With Tilt & Sideshift • RD CJ\OW"
61___ 61
62-~
65
/ ~-61/
~~ //
66-~~.
" ~_~:"-63
//
~ : -68
I
67
Figure 21998
09.0-1657-110 Crown 2010 PF17976-3
924
PLATFORM PARTS
l!J\OWrl Reach With Tilt & Sideshift· RD

41 100103-001 RH Outer Arm 1
100103-002 LH Outer Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
42. .... 060030-085 Flatwasher AR
45. .... 060077-002 Groove Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
46. .... 082384 . . . . . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47 065007-052 Bushing 2
49. .... 076293 . . . . . . . . . . . Carriage Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50 076143 Cap 2
51 060016-022 Screw 2
52 100116-002 RH Outer Arm 1
100116-003 LH Outer Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
53 065012-007 Bushing 2
54 076048-001 Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
076048-002 Lubrication Fitting 4
55. .... 060005-008 Lockwasher 4
56 060021-009 Nut 4
57 112943-001 Secondary Inner Arm 1
58. .... 065007-077 Bearing Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60 085161 Lock Nut 2
61 060030-279 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
62 123474-001 Pulley 1
63. .... 122927 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
64 060015-079 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
65. .... 060005-007 Lockwasher 2
66 060021-006 Nut : 2
67 060016-019 Screw 4
68. .... 122926 . . . . . . . . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2010 PF17976-4 09.0-1657-111
925
Reach With Tilt & Sideshift· RD CROWl'
I
99
(a) lilt Manifold

(b) lilt Cylinder
Figure 22001
09.0-1657-112 Crown 2010 PF17976-5
926
PLATFORM PARTS
CJ\owr. Reach With Tilt & Sideshift • RD
78 060014-088 Screw 2
79. . . . . 128003 . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
80 060012-023 Screw 2
81 060005-048 Lockwasher 2
82. . . . . 127842 Tilt Position Assist Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
83 060015-117 Screw 2
84. . . . . 127845 . . . . . . . . . . . Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
85 060015-064 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
060015-069 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
86. . . . . 123402 . . . . . . . . . . . Guide 1
87 060015-019 Screw 1
88. . . . . 093680* Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
89. . . . . 060000-029 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
90. . . . . 060005-007. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
91 060021-006 Nut. 1
92. . . . . 129830-002 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
93 060015-004 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
95 065012-004 Ball Bushing 1
98 090440-004 Spacer 2
99. . . . . 123393-002 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
100 . . . . 060005-009. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
101 060017-007 Screw 4

Crown 2010 PF17976-6 09.0-1657-113
927
Reach With Tilt & Sideshift - RD CJ\OWI'
0-119
/1
I A-
126 U 127
(a) Sideshift Cylinder
Figure 22002
Crown 2010 PF17976-7

09.0-1657-114
928
PLATFORM PARTS
CJ\OWI' Reach With Tilt & Sideshift • RD
110 . . . . 093736 . . . . . . . . . . . Cylinder Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

111 . . . . 060000-054 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
088891 * Pivot Shaft Freezer/Condition 2
113 . . . . 060030-078 Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
114 . . . . 060005-009 Lockwasher 1
115 060017-007 Screw 1
116 085152 Fork Carriage 1
117 060009-005 Retaining Ring , 2
118 . . . . 076235-003*. . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
088893-002* Shaft Freezer/Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
119 . . .. 085239* Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
120 060000-018 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
121 085188 Slide 6
122 085137-002 Upper Support 2
123 065007-026 Bushing 8
124 085142 Roller 4
125 085137-001 Lower Support 2
126 060000-030 Roll Pin 4
127 085143* Shaft 4
088910* Shaft Freezer/Condition 4
128. . . . 093560-002 Fork Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
129 085144 Lower Hanger 2
130. . . . 060005-029 Lockwasher 4
131 060019-039 Screw 4
132 060000-066 Roll Pin 1

Crown 2010 PF17976-8 09.0-1657-115
929
CJ\OWI'
Notes:
930
mow"
LABELS AND DECALS
931
LABELS AND DECALS
InfoLink Accessories CJ\OW"
Work Assist Assembly - -

o
See Section 04.9
~/10
I
Part of d>
Power Unit Top - -
7-lJ
Figure 16023
Crown 2007 PF15689-1 Rev. 9/09

10.0-1452-001
02 Rev. 9/09
932
LABELS AND DECALS
CJ\owr. InfoLink Accessories
o 140253-001* InfoLink Kit With Proximity Reader Includes Index 1 - 4 1

140253-002* InfoLink Kit Without Proximity Reader Includes Index 1 - 4 , 1
1 134791-001* lnfoLink Module With Proximity Reader Included in -001 Kit , 1
062872 Proximity Reader , 1
340064 Proximity Reader Cover. 1
134791-002* lnfoLink Module Without Proximity Reader Included in -002 Kit 1
062919 Antenna 1
2 060061-006 Screw 4
3 060005-005 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 139899 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 060062-038 Screw 2
6 140382 Impact Sensor Module , 1
7 145969 Bracket , 1
9 060042-016 Locking Nut. 2
10 140557 Impact Sensor Harness Extension , 1

Crown 2007 PF15689-2 Rev. 9/09 10.0-1452-002

02 Rev. 9/09
933
LABELS AND DECALS
Work Assist Tube
Terminal Bracket Kit 129572
RH Tube Kit 131414
8-7
8"",
12
"9
Terminal Tube and Mounting Kit 131416
o
o I
I
"'" 19
I
I
I
"' ... / 17 12" :

~
... ~ ...
... ' .....
' - - 18 RH Mast Guard
' " 15
Figure 16093
10.0-1452-050 Crown 2007 PF15708-1
934
LABELS AND DECALS
mowr. Work Assist Tube
o. . . . . 129572* Terminal Bracket Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

1 128846 Mounting Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 060017-047 Screw 2
3 129571 Mounting Plate 1
4 060017-006 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 060005-010 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 060016-068 Screw 4
7 060042-010 Locking Nut 4
8 128858 Adjusting Bar 1
0 131414* RH Tube Kit. 1

9 131236 Tube Bracket 1
10 060016-003 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11 060042-010 Locking Nut 3
12 124530 Tube Plug 2
13 069169 Operator Warning Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 069199 Platform Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
o 131416* Terminal Tube And Mounting Kit 1

15 131401 Tube 1
16 128362-002 Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
18 060062-012 Screw 2
19 124530 Tube Plug 2

Crown 2007 PF15708-2 10.0-1452-051
935
LABELS AND DECALS
Work Assist Tube Accessories CJ\OWI'
Terminal Mounting Kit

126236-001, -002 & -003 Universal Terminal Mounting Kit 131417
Terminal Mounting Kit 131418 Clip Pad and Hook Kit 130144
17 r"-.
! \.-'1 / Part of Tube
/
" ! I
,,~ I
/ I'
',I1............ ......
16 ;,
I
hi
v~
Figure 16094-01
10.0-1452-075 Crown 2007 PF1571o.1 Rev. 5/07
02 Rev. 5/07
936
LABELS AND DECALS
CJ\owr. Work Assist Tube Accessories
o. . . . . 126236-001 Terminal Mounting Kit for LXE Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

126236-002 Terminal Mounting Kit for Norand Terminal 1
126236-003 Terminal Mounting Kit for Telxon Terminal 1
1 128855-001 Mounting Plate for LXE Terminal 1
128855-002 Mounting Plate for Norand Terminal . . . . . . . . . . . . . . .. 1
128855-003 Mounting Plate for Telxon Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
128855-004 Mounting Plate for Janus Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 060017-047 Screw 2
3 060017-006 Screw 2
4 060005-010 Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 128858 Adjusting Bar 1
0 131417 Universal Terminal Mounting Kit , 1

6 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 060062-012 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. ... .. ....... .... ... 2
8 128362 Upper Clamp 1
9 131365 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 050003-014 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ..... ......... .... ... 4
0 131418 Terminal Mounting Kit , 1

11 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
12 060062-012 Screw 2
13 128362 Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 131366 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
15 060061-013 Screw 4
o 130144 Clip Pad and Hook Kit. 1

16 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17 060062-012 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
18 130154 Clip Pad and Hook Assembly 1
If truck is not equipped with Work Assist Tube see section 10.0 "Work Assist Tube" parts page.
Crown 2007 PFl571(}.2 Rev. 5/07 10.0-1452-076

02 Rev. 5/07
937
LABELS AND DECALS
Work Assist Tube Accessories CJ\OWrl
Universal Accessory Clamp Kit 130145 Storage Pocket Kit 130868
Part of Tube __ r
rv"
J
,
25
~
I ~~
26 __ ~~/I/
30
• .,e-
/1
J
/j[~ 24
&- . !
.J\U».. j r
~ \..Aj
27
~/
\ "'" 28
29
Clip Pad Kit 131415 Hanger Kit 131419
Part of Tube ""- (Jl 32

. I ~
" 1/I~"
i / "'"
~ / /1 31
Ii I!
--'1
i\..J-.--/
~-40
Figure 16095
Crown 2007 PF1571~ Rev. 5/07

10,0-1452-077
02 Rev. 5/07
938
LABELS AND DECALS
CJ\OWrl Work Assist Tube Accessories
o. . . .. 130145 Universal Accessory Clamp Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

20 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
21 060062-012 Screw ······ 2
22 128362 Upper Clamp 1
23 060061-013 Screw 4
o. . .. . 130868 Storage Pocket Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

24 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. 1
25 060062-012 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
26 128362 Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 125503-002 Pocket Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28 125502 Storage Pocket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29 060016-013 Screw 1
30 060042-010 Nut 1
o 131415 Clip Pad Kit 1

31 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
32 060062-012 Screw 2
33 132088 Clip Pad Assembly 1
0 131419 Hanger Kit 1

34 127697 Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
35 060062-012 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
36 128362 Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
37 130050-002 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
38 060062-015 Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
39 130071 Wire Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
40 130125 Round Vinyl Cap 2
41 130060 Clamp Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
42 060062-016 Screw 4
If truck is not equipped with Work Assist Tube see section 10.0 "Work Assist Tube" parts page.
Crown 2007 PFl57104 Rev. 5107 10.0-1452-078

02 Rev. 5/07
939
LABELS AND DECALS
Camera CJ\OW"
17
-2
I
1
I
-7
1
10
~
I -6)-11
- - (b) (a) 2nd Stage Mast

(b) 3rd Stage Mast
Figure 22456
10.0-1457-100 Crown 2009 PFl774D-1 Rev. 8110
01 Rev. 8/10
940
LABELS AND DECALS
l!J\OWI' Camera
1 147125-001 NTSC Heated Camera 1

147125-002 PAL Heated Camera 1
2 146837 Brace (1) . . . . . . . . . . . . . . . . . . . . . . . . . • • • . . . . . . • • . . . • • • . . • . . . . . . . 1
146838 . . . . . . . . . . . Brace (2) . . . . . . . . • . . . . • • . . . . . . . • . . . . . . . . . . . . . . . • . . . . . . . . . . . .. 1
3 146844 Plate 1
4 062749-001 Attachment Clip 1
5 089544 Extension Spring 90 mm (3.5 in) 1
122914 Extension Spring 355 mm (14 in) 1
6 060061-032 Screw 1
7 (3) . . . . . . . . . . . . . . . Mast Camera Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8 060015-019 Screw 2
9 061002-011 Hamess Clamp 2
10 060030-012 Flatwasher. 2
11 060042-006 Nut. 2
12 060019-022 Screw 1
13 060030-332 Flatwasher 1
14 127874-005 Shaft , 1
15 127513-001 Pulley 1
16 060030-192 Flatwasher. 3
17 . . . . . 060005-031. . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
18. . . . . 060059-065. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
061003-004 Cable Tie AR

143999 Camera Harness 1067 mm (42 in) 1
144000 Camera Harness 1219 mm (48 in) 1
(1) Used on a 140 mm (5.5 in) I-Beam Mast with a Lift Height of 6858 - 7620 mm (270 - 300 in) and a Col-
lapsed Height of 3023 - 3327 mm (119 - 131 in)
(2) Used on a 178 mm (7 in) I-Beam Mast with a Lift Height of 6858 - 11227 mm (270 - 442 in) and a Col-
lapsed Height of 3023 - 4826 mm (119 - 190 in)
(3) Refer to Chart 1 - Index 7 Mast Camera Cable Assembly
Crown 2009 PFl7740-2 Rev. 8110 10.0-1457-101

01 Rev. 8/10
941
LABELS AND DECALS
Camera CROWl'
'-28
I
o I
29--
I
I
I
I
I
I
I
I
(a)-- I
I
I
I
I
I
I
I
I
\
I
\ I
\ I
\ I
\ I
\ I
'\1
--30
\
\
\
31-~-U--- \
\
\
~-33
32-£
Figure 22457
Crown 2009 PF1774().3 Rev. 8110

10.0-1457-102
01 Rev. 8/10
942
LABELS AND DECALS
CJ\OWI' Camera
28 060042-006 Nut. 2
29 147124 Monitor 1
30. . . . . 146836 Monitor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
31 069603 Camera Display Label 1
869603-(1) Camera Display Label. 1
32 060063-024 Screw 2
33 060061-013 Screw 4
062897-006 Mini Blade Fuse 1
(1) Choice of dash number depends on language. Use the following dash numbers for the language indi-
cated: -001 German, -002 French, -003 Spanish, -004 Dutch, -005 Italian, -006 English.
Chart 1 - Index 7 Mast Camera Cable Assembly
Collapsed Height Lift Height

Part Number
mm in mm in
147145-007 3023 119 6858 270
147145-008 3327 131 7620 300
147145-009 3556 140 8153 321
147145-010 3785 149 8661 341
147145-011 4064 160 9296 366
147145-012 4369 172 10160 400
147145-013 4521 178 10694 421
147145-014 4826 190 11227 442
Crown 2009 PF17740-4 Rev. 8110 10.0-1457-103

01 Rev. 8/10
943
LABELS AND DECALS
Labels & Decals l!J\OWI'
, - - - - 69.85 mm
(2.75 in)
3
(a)
1
2 4.83 mm
(0.19 in)
4
(b)
25.4 mm
(1.0 in)
J-.-+*-I--+- 15.75 mm
9.65 mm (0.62 in)
(0.38 in)
(f)
7 (d)
50.8 mm 5
(2.0 in) (c)
(g)
(a) Center top and bottom on trucks with 5029.2 mm (198.0 in)
8 and 5334 mm (210.0 in) lift heights
(b) On carriage
12 9 (c) Center on carriage
(d) 76.2 mm (3.0 in) from bottom of cylinder
(e) 76.2 mm (3.0) from top of power unit center on front wall
10 On both sides
1320.8 mm (f)
(52.0 in) (g) Center on beam
1025.9 mm (h) Date stamp
(40.39 in)
(i) SIN stamp
Figure 21704-01
10.9-1457-001 Crown 2009 PF1747G-1 Rev. 12109
02 Rev. 12/09
944
LABELS AND DECALS
CJ\owr. Labels & Decals
1. . . .. . RR 5700 Capacity Plate Contact Factory 1

· RD 5700 Capacity Plate Contact Factory 1
· RR 5700 Australian (SAA) Capacity Plate Contact Factory . . . . . . . . . . . .. 1
· RD 5700 Australian (SAA) Capacity Plate Contact Factory . . . . . . . . . . . .. 1
2. . . . . 069863 Tilt Position Assist Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 069374-001 Crown.com Decal 1
4. . . . . 069009 Stand on Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
5 069105 No Hands - Text Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 069010 Stand Under Warning 2
7 069093* EE Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 069107 Battery Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 069112-027* Battery Size Warning (1) 1
069112-028* Battery Size Warning (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
069112-034* Battery Size Warning (3) • . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . 1
069112-043* Battery Size Warning (4) 1
10 069913-001 Patent Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 069310 Hydraulics Caution '. 1
12. . . .. 106158-001 Heavy Crown Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
(1) B Battery Compartment 337 x 892 mrn (13.25 x 35.12 in)

(2) B Battery Compartment 337 x 968 mm (13.25 x 38.12 in)
(3) C & D Battery Compartment 394 x 968 mm (15.50 x 38.12 in)
(4) E Battery Compartment 508 x 968 mm (20.0 x 38.12 in)

Crown 2009 PF1747o-2 Rev. 12109 10.9-1457-002

02 Rev. 12109
945
LABELS AND DECALS
Labels & Decals CJ\OWI'
(a) Center on top mainframe brace
(b) Center on carriage
(c) DC lift only
(d) AC lift only
(e) Centered
(d)(e)
28
19.05 mm ---l-.J~__-
76.71 ± 12.7 mm (0.75 in)
27
(3.02 ± 0.50 in) (d)
111tl""'""'tJ~:]U ~~---19.05 ± 12.7 mm

(0.75 ± 0.50 in)
26
(c)
(b)
50.8 mm 25
(2.0 in)
j
o:==:=:sJ
22 (a)
25
168.15 mm
(6.62 in)
1025.9 mm
(40.39 in) 24
31.75 mm
(1.25 in)
23
Figure 21705-01
Crown 2009 PF17470-3 Rev. 12/09

10.9-1457-003
02 Rev. 12/09
946
LABELS AND DECALS
CJ\OWrl Labels & Decals
22 106158-001 Heavy Crown Decal 1

23. . . . . 069887* .. ..... DC Control Component Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
069888* AC Control Component Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
24 069885* DC Power Component Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
069886* AC Power Component Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
25 069105 No Hands - Text Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
26. . . . . 069935* ACCESS 2 DC Label . . . . . . . . . . . . . . . . . . . . . . .. 1
27 069882* AC Pump Motor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28. . . . . 069593-002* AC Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2009 PF17470-4 Rev. 12109 10.9-1457-004

02 Rev. 12109
947
LABELS AND DECALS
(a) Center top and bottom on trucks with
6096 mm (240 in) lift heights 299.97 mm 64.77 mm
(11.81 in) (2.55 in)
(b) Required on all cross braces
(a)
(c) On bottom of brace 37
(d) 635 mm (25 in) without work assist;
1168.4 mm (46 in) with work assist and
41.91 mm I.. 25.4 mm
(1.65 in) (1.0 in)
3022.6 mm (119 in) and greater col-
lapsed height
(e) 127 mm (5 in) with work assist and 38
(b)
2260.6 mm (89 in) collapsed height;
25.4 mm (1.0 in) with work assist and
2413 mm (95 in) and 2717.8 mm
(107 in) collapsed height
25.4 mm
(f) SIN stamp to power unit (1.0 in)
(g) Door shown open
(h) Inside momentum oval inline with
inside of vent hole
(i) DC lift only
39
(c) (d)(e)
0) AC lift only 40
(h)
41
6.35 mm (d)(e)
(0.25 in)
2.54 mm
(0.10 in)
(d)
21.34 mm
(0.84 in) -----j+--++-~ ~-=+-I
9.65 mm
(0.38 in)
12.7 mm
1.:f===~=(0.50 in)
60.96 mm----++-~
(2.40 in)
42
22.35 mm
43
(0.88 in)
6.35 mm
(0.25 in)
(f)
222.25 mm ----+----.-j
(8.75 in) 1025.9 mm
(40.39 in)
Figure 21706-01
10.9-1457-005 Crown 2009 PF17470-5 Rev. 12/09
02 Rev. 12109
948
LABELS AND DECALS
CJ\OWI) Labels & Decals

38 069105 No Hands - Text Warning 2
39 069111 * UL Label, EE Trucks Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
40 069169 Operator Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
41 069199 Platform Warning 1
42 069047 Charger Hook Up Caution 1
43 069168 Articulation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
44 069177 Brake Adjustment Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
45 069881* DC Pump Motor Map 1
46. . . . . 069883* DC Traction Motor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
069884* AC Traction Motor Map 1
47 069372-054* RR 5700 Momentum Decal 1
069372-065* RD 5700 Momentum Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
48 069864* Danger Electrical Additions Label, EE Trucks Only 2
49 069985* AC Motor Power Cable Torque Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Crown 2009 PF1747~ Rev. 12109 10.9-1457-006

02 Rev. 12109
949
LABELS AND DECALS
Labels & Decals l!J\OWI'
4.83mm 44.45 mm
(0.19 in) (1.75 in)
I L-f.-I-------l1I;--161.8 mm
(6.37 in)
57
58
II
28.96 mm ---Jj1!---!1l----lH-----n-_
59
(a)
(1.14 in)
'--~- 25.4 mm
(1.0 in)
65 60
~ 00 00
(b)
63
63.5 mm 152.4 mm
(2.50 in) (6.0 in) ±
6.35 mm
(0.25 in)
62 (a) Affix to back side of cover

(b) Faces RH side of truck
(c) Centered
66
(c) (d) AC lift only
Figure 21707-01
10.9-1457-007 Crown 2009 PF1747Q-7 Rev. 12/09
02 Rev. 12/09
950
LABELS AND DECALS
CROWl) Labels & Decals
57 069932 Fuse Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

58. . . .. . Data Plate Contact Factory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
59. . . . . 069889 . . . . . . . . . . . Electrical Control Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
60 069012 Electrical Additions Warning 2
62. . . . . 069933 . . . . . . . . . . . Distribution Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
63 069766 Protect Yourself Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
65 069864* ., Danger Electrical Additions Label, EE Trucks Only 2
66. . . . . 069593-002* AC Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2009 PF1747o-a Rev. 12109 10.9-1457-008

02 Rev. 12109
951
LABELS AND DECALS
3o.
23mm
(1.19 in)
l 74
J=~~~tr
~:;;;\;;;;;;;;;;f,,"
20.57 mm (a) -1"""--
20.57 mm
(0.81 in) (0.81 in)
74 20.57 mm
~~9il=t=* (0.81 in)
20.57 mm 20.57 mm
(0.81 in) (0.81 in)
(d) (e)
75 75
(b) (b)
(g)
(f)
74.93 mm
(2.95 in)
34.54 mm
(1.36 in)
75j20.57mm
(0.81 in)
1I1/t~~~
(a) 6096 mm (240.0 in) and greater lift heights
20.57 mm
(b) 5029.2 mm (198.0 in) and 5334 mm
20.57 mm (0.81 in)
(210.0 in) lift heights
(0.81 in) (b)
(b) (c) 6096 mm (240.0 in) and greater lift heights _-J"'-I---L---20.57 mm
75 dimensions same as without wor!< light (0.81 in)
(h) (d) Left side 184.15 mm (7.25 in) I-beam without wor!< light
(i)
(c) (e) Right side 184.15 mm (7.25 in) I-beam without wor!< light (c)
(f) Left side 184.15 mm (7.25 in) I-beam with wor!< light
(g) Right side 184.15 mm (7.25 in) I-beam with wor!< light
75 (h) Left side 144.53 mm (5.69 in) I-beam without wor!< light
(i) Right side 144.53 mm (5.69 in) I-beam without wor!< light
(b) 0) Left side 144.53 mm (5.69 in) I-beam with wor!< light (b)
(k) Right side 144.53 mm (5.69 in) I-beam with wor!< light
(k)
(j)
-'-~- 100.33 mm
(3.95 in)
Figure 21708
10.9-1457-009 Crown 2009 PF17470-9 Rev. 12/09
02 Rev. 12109
952
LABELS AND DECALS
CJ\OWI' Labels & Decals
'INDEX PART NUMBER PART NAME NUMBER REQUIRED
74 106158-021 Crown Heavy Decal (1) 2

75 069372-001 * RR 5700 Momentum Decal 2
069372-066* . . . . . . . RD 5700 Momentum Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
147406-001-0S Warning Labels Kit 1

147407-001-0S Labels & Decals Kit 1
148045-001-02 Warning Labels Kit - ANSI - US French 1
148045-001-03 Warning Labels Kit - ANSI - US Spanish 1
(1) Used on trucks without mast mounted work lights, and on trucks with mast mounted work lights and a lift
height of 6096 mm (240 in) or greater.
* To select appropriate part number. use the data number

Crown 2009 PF1747().10 Rev. 12/09 10.9-1457-010

02 Rev. 12109
953
LABELS AND DECALS
Labels & Decals SAA CJ\OWI'
, - - - 69.85 mm
(2.75 in)
3
(a)
1
2 4.83 mm
(0.19 in)
4
(b)
25.4 mm -----l~ I~--,
(1 in)
j-..H--l--+-15.75 mm
(g)
9.65 mm (0.62 in)
(0.38 in)
(d)
50.8 mm 5
(2 in) (c)
(a) Center top and bottom on trucks with 5029.2 mm (198 in)
and 5334 mm (210 in) lift heights
7 (b) On carriage
(f)
(c) Center on carriage
9
(d) 76.2 mm (3 in) from bottom of cylinder
(e) 76.2 mm (3 in) from top of power unit center on front wall
(f) Center on beam
E!)
8 C) (g) Date stamp
C)
1025.9 mm 1199.39 mm (h) SIN stamp
(40.39 in) (47.22 in)
Figure 22709
Crown 2009 PF1775~1

10.9-1457-100
954
LABELS AND DECALS
mow" Labels & Decals SAA
1 . . . .. . RR 5700 Australian (SAA) Capacity Plate Contact Factory 1

................. RD 5700 Australian (SAA) Capacity Plate Contact Factory 1
2 069863 Tilt Position Assist Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4. . . . . 069009 Stand on Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 069010 Stand Under Warning 2
7 . . . . . 069107 . . . . . . . . . . . Battery Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
8. . . . . 069310 . . . . . . . . . . . Hydraulics Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Crown 2009 PF17759-2 10.9-1457-101
955
LABELS AND DECALS
(c) DC lift only
(d) AC lift only
(e) Centered
(d)(e)
28
19.05 mm ----<1-1 f-o_

76.71 ± 6.35 mm (0.75 in)
27
(3.02 ± 0.25 in) (d)
111h~mrit:fiOt::l..--_--19.05 ± 6.35 mm
(0.75 ± 0.25 in)
26
(c)
(b)
50.8 mm 25
(2 in)
1
w:::=4J
22 (a)
25
168.15 mm
(6.62 in)
1025.9 mm
(40.39 in) 24
31.75 mm
(1.25 in)
23
Figure 22710
Crown 2009 PF17759-3

10.9-1457-102
956
LABELS AND DECALS
CJ\OWI' Labels & Decals SAA
22 106158-001 Heavy Crown Decal . . . . . . . . . .. 1

23 069887* DC Control Component Map 1
24. . . . . 069885* . . . . . . . . . . DC Power Component Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26. . . . . 069935* ACCESS 2 DC Label . . . . . . . . . . . . . . . . . . . . . .. 1
27 069882* AC Pump Motor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28 069593-002* AC Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2009 PF1n59-4 10.9-1457-103
957
LABELS AND DECALS
6096 mm (240 in) lift heights
299.97 mm-+--~ 64.77 mm
(b) Required on all cross braces (11.81 in) (2.55 in)
(c) On bottom of brace (a)
(d) 635 mm (25 in) without work assist; 37
1168.4 mm (46 in) with work assist and 41.91 mm t-----25.4 mm
1.....
3022.6 mm (119 in) and greater col- (1.65 in) (1 in)

lapsed height
(e) 127 mm (5 in) with work assist and
38
(b)
2413 mm (95 in) and 2717.8 mm
(f) SIN stamp to power unit -++---\~ ..J I I - - - - 25.4 mm
(g) Door shown open
(1 in)
(h) Inside momentum oval in line with
inside of vent hole
(i) DC lift only
0) AC lift only (d)(e)
----39
(h)
40
6.35 mm -+tll--r- (d)(e)
(0.25 in)
(g)
2.54 mm
(0.10 in)
(d)
21.34 mm
(0.84 in) -----++---fl+------'~I ~=f_I
9.65 mm
(0.38 in)
12.7 mm
1.:f===~=(0.50 in)
60.96 mm-----++-~
(2.40 in) ~.-..19.05 mm
(0.75 in)
41
22.35 mm 42
(0.88 in)
6.35 mm
(0.25 in)
(f)
222.25 mm --f-e_--.J
(8.75 in) 1025.9 mm
(40.39 in)
Figure 22711
10.9-1457-104 Crown 2009 PF1 nS9-5
958
LABELS AND DECALS
CJ\owr. Labels & Decals SAA

38 069105 No Hands - Text Warning 2
39 . . . . . 069293 . . . . . . . . . . . Moving Vehicle Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
40. . . . . 069496 8M Platform Warning , 1
41 069047 Charger Hook Up Caution , 1
44 069881* DC Pump Motor Map , 1
45. . . . . 069883* DC Traction Motor Map , 1
069884* AC Traction Motor Map , 1
46 . . . . . 069372-054*. . . . . . . RR 5700 Momentum Decal , 1

Crown 2009 PF1775~ 10.9-1457-105
959
LABELS AND DECALS
4.83 mm 44.45 mm
(0.19 in) (1.75 in)
I ~.-I-------'\\--161.8 mm
(6.37 in)
57
28.96 mm -tl/--il't---m-----"lif-..,.
(1.14 in)
(b)
63
152.4 mm
(6 in) ±
6.35 mm
(0.25 in)
(a) Affix to back side of cover

62
(c) Centered
66 (d) AC lift only
(c)
Figure 22712
Crown 2009 PF1 n59-7

10.9-1457-106
960
LABELS AND DECALS
57 069932 Fuse Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

58. . . .. Data Plate Contact Factory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
59. . . . . 069889 . . . . . . . . . . . Electrical Control Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
62 069933 Distribution Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
63. . . . . 069766 . . . . . . . . . . . Protect Yourself Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
65 069864* Danger Electrical Additions Label, EE Trucks Only . . . . . . . . . . . . . . . . . . . 2
66. . . . . 069593-002* AC Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
•

Crown 2009 PF1 nS9-8
10.9-1457-107
961
LABELS AND DECALS
Labels & Decals SAA CROW"
3o.
23mm
(1.19 in)
l 74
20.57 mm (a) 20.57 mm

(0.81 in) (0.81 in)
74 20.57 mm
(0.81 in)
20.57 mm
(0.81 in)
(d) (e)
(c) (c)
75 75
~100.33mm
(b) (b)
(3.95 in)
(g)
(f)
74.93 mm
(2.95 in)
34.54 mm
(1.36 in)
75j20.57mm
(0.81 in)
~~~=* (a) 6096 mm (240 in) and greater lift heights
(b) 5029.2 mm (198 in) and 5334 mm 20.57 mm
(210 in) lift heights (0.81 in)
20.57 mm
(0.81 in) (c) 6096 mm (240 in) and greater lift heights (b)
(b) dimensions same as without work light -,r-I-...L---20.57 mm
75 (0.81 in)
(d) Left side 184.15 mm (7.25 in) I-beam without work light
(h) (i)
(e) Right side 184.15 mm (7.25 in) I-beam without work light
(c) (c)
(f) Left side 184.15 mm (7.25 in) I-beam with work light
(g) Right side 184.15 mm (7.25 in) I-beam with work light
(h) Left side 144.53 mm (5.69 in) I-beam without work light
75 (i) Right side 144.53 mm (5.69 in) I-beam without work light
OJ Left side 144.53 mm (5.69 in) I-beam with work light
(b) (b)
(k) Right side 144.53 mm (5.69 in) I-beam with work light
(k)
OJ
~"r-- 100.33 mm
(3.95 in)
Figure 22713
10.9-1457-108 Crown 2009 PF17759-9
962
LABELS AND DECALS
74. . . .. 106158-021 Crown Heavy Decal (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

75 069372-001 * RR 5700 Momentum Decal 2

Crown 2009 PF177S9-10 10.9-1457-109
963
LABELS AND DECALS
Labels & Decals China CJ\OWI'
--- 6.35 mm
(0.25 in)
r---- 69.85 mm
(2.75 in)
13
3
(a)
4.83 mm
2 (0.19 in)
4
(b)
9.65 mm
(0.38 in)
11--11-0--.1-11+--+-15.75 mm
(0.62 in)
(g)
8 (d) 5
(c)
12 9 (a) Center top and bottom on trucks with 5029.2 mm
(198 in) and 5334 mm (210 in) lift heights
(b) On carriage
11 (c) Center on carriage

1320.8 mm (d) 76.2 mm (3 in) from bottom of cylinder
(52 in) (e) 76.2 mm (3) from top of power unit center on front
(1 in) 1025.9 mm wall
25.4 mmM+-----.J (40.39 in)
(f) On both sides
(g) Center on beam
(h) Date stamp
(i) SIN stamp
15
149.4 mm -...-11""--12.7 mm
(5.88 in) (0.50 in)
Figure 22723
10.9-1457-200 Crown 2009 PF17761·1
964
LABELS AND DECALS
l!J\owra Labels & Decals China
1. . . .. . RR 5700 China Capacity Plate Contact Factory 1

................. RD 5700 China Capacity Plate Contact Factory 1
2. . . . . 069863 Tilt Position Assist Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
4 069009 Stand on Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 069010 Stand Under Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. . . . . 069093* .. . . . . . . . . EE Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 069107 Battery Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 069112-027* Battery Size Warning (1) . . . . . . . . . . . • • . • . . . • . . . . . . . . . . . . . . . . . . • . . 1
069112-028* Battery Size Warning (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
069112-034* Battery Size Warning (3) 1
069112-043* Battery Size Warning (4) . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . 1
10 069913-001 Patent Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 069310 Hydraulics Caution 1
13. . . . . 122857 . . . . . . . . . . . Data Plate Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
14 069862 Capacity Load Curve Plate 1
15 069101 Lift Here Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(3) C & D Battery Compartment 394 x 968 mm (15.50 x 38.12 in)
(4) E Battery Compartment 508 x 968 mm (20 x 38.12 in)

Crown 2009 PF1IT61-2 10.9-1457-201
965
LABELS AND DECALS
Labels & Decals China CROWl'
(c) DC lift only
(d) AC lift only
(e) Centered
(d)(e)
28
19.05 mm--l-.l~--
76.71 ± 12.7 mm (0.75 in)
27
(3.02 ± 0.50 in) (d)
VUU",,~ 1-.1f------19.05 ± 12.7 mm

(0.75 ± 0.50 in)
26
(c)
(b)
50.8 mm 25
(2 in)
j
(a)
22 25
S=1I'i'I~---~-I-168.15 mm
(6.62 in)
1025.9 mm
(40.39 in) IL----.....J, 24
~~'-'W--31.75 mm
~~~~b~~ (1.25 in)
23
Figure 22724
Crown 2009 PF17761-3

10.9-1457-202
966
LABELS AND DECALS
CAOWr. Labels & Decals China

23. . . . . 069887* . . . . . . . DC Control Component Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
24. . . . . 069885* . . . . . . . DC Power Component Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26. . . . . 069935* ACCESS 2 DC Label . . . . . . . . .. 1
27 069882* AC Pump Motor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28. . . . . 069593-002* AC Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
29 069101 Lift Here Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Crown 2009 PF17761-4 10.9-1457-203
967
LABELS AND DECALS
Labels & Decals China CAOWI'
6096 mm (240 in) lift heights
299.97 mm-+--~ 64.77 mm
(b) Required on all cross braces (11.81 in) (2.55 in)
(c) On bottom of brace (a)
(d) 635 mm (25 in) without work assist; 37
1168.4 mm (46 in) with work assist and 41.91 mm ------25.4 mm
3022.6 mm (119 in) and greater col- (1.65 in) (1 in)
lapsed height
(e) 127 mm (5 in) with work assist and
38
(b)
2413 mm (95 in) and 2717.8 mm
(f) SIN stamp to power unit -++---+~~ I f - - - - 25.4 mm
(g) Door shown open (1 in)
(h) Inside momentum oval in line with
inside of vent hole
(i) DC lift only
39
0) AC lift only (c) (d)(e)
----40
41
(h)
6.35 mm -Hlf-o-r- (d)(e)
(0.25 in)
(g)
2.54 mm
(0.10 in)
(d)
21.34 mm
(0.84 in) ----++----H---'l~~'"<::::f-I
9.65 mm
(0.38 in)
12.7 mm
1.::f===~:=(0.50 in)
60.96 mm----++--~
(2.40 in) ..-l1~19.05 mm
(0.75 in)
22.35 mm 43
(0.88 in)
6.35 mm
(0.25 in)
(f)
222.25 mm-----t-o-~
(8.75 in) 1025.9 mm
(40.39 in)
Figure 22725
10.9-1457-204 Crown 2009 PF1n61-5
968
LABELS AND DECALS
CJ\owr. Labels & Decals China

39 069111* ULLabel, EETrucksOnly 1
40. . . . . 069169 Operator Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
41 069199 Platform Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
42. . . . . 069047 . . . . . . . . . . . Charger Hook Up Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
45 069881* DC Pump Motor Map 1
46. . . . . 069883* . . . . . . . . . . DC Traction Motor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
069884* AC Traction Motor Map 1
47 069372-054* RR 5700 Momentum Decal 1
069372-065* RD 5700 Momentum Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Crown 2009 PF1776Hl 10.9-1457-205
969
LABELS AND DECALS
4.83 mm 44.45 mm
(0.19 in) (1.75 in)
~-+-------\\--161.8 mm
(6.37 in)
57
58
59
28.96 mm ---Ht----ilft----itt-----"liI- (a)
(1.14 in)
60
CJC) 00 00
(b)
63
152.4 mm
(6 in) ±
12.7 mm
(0.50 in)
(a) Affix to back side of cover

62
(c) Centered
66 (d) AC lift only
(c)
Figure 22726
10.9-1457-206 Crown 2009 PF1n61·7
970
LABELS AND DECALS
CJ\owr. Labels & Decals China
57 069932 Fuse Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

58. . . .. . Data Plate Contact Factory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
59. . . . . 069889 . . . . . . . . . . . Electrical Control Map... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
61 069168 Articulation Warning 1
63 069766 Protect Yourself Warning 1
64 069937 Distribution Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
66. . . . . 069593-002* AC Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Crown 2009 PFl7761-8

10.9-1457-207
971
LABELS AND DECALS
20.57 mm (a)
20.57 mm
(0.81 in) (0.81 in)
74 20.57 mm
94.49 mm
(3.72 in) (0.81 in)
20.57 mm 20.57 mm
(0.81 in) (0.81 in)
(d) (e)
(c) (c)
75 75
(b) (b)
(g)
(f)
74.93 mm
(2.95 in)
34.54 mm
(1.36 in) Y~~\f
75j20.57mm
(0.81 in)
JJ~~~~ (a) 6096 mm (240 in) and greater lift heights
(b) 5029.2 mm (198 in) and 5334 mm 20.57 mm
(210 in) lift heights (0.81 in)
20.57 mm
(0.81 in) (c) 6096 mm (240 in) and greater lift heights
(b) dimensions same as without work light 20.57 mm
75 (0.81 in)
(d) Left side 184.15 mm (7.25 in) I-beam without work light
(h) (i)
(e) Right side 184.15 mm (7.25 in) I-beam without work light
(c) (c)
(f) Left side 184.15 mm (7.25 in) I-beam with work light
(g) Right side 184.15 mm (7.25 in) I-beam with work light
(h) Left side 144.53 mm (5.69 In) I-beam without work light
75 (i) Right side 144.53 mm (5.69 In) I-beam without work light
0) Left side 144.53 mm (5.69 in) I-beam with work light
(b) (b)
(k) Right side 144.53 mm (5.69 in) I-beam with work light
(k)
0)
-'-,)"'\--- 100.33 mm 100.33 mm
(3.95 in) (3.95 in)
Figure 22713
10.9-1457-208 Crown 2009 PF17761-9
972
LABELS AND DECALS
CJ\OWI' Labels & Decals China
74 106158-021 Crown Heavy Decal (1) 2

75 069372-001 * RR 5700 Momentum Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
069372-066* RD 5700 Momentum Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2009 PF17761·10 10.9-1457-209
973
CJ\OW"
Notes:
974
RRIRD 5700 AC Series
Customer
PF17419-00C
REV. A
mfg 20101101

Cl/OWI': RR/RD 5700 Series

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{JQS5 ced~ J3/1

Crown 2009 PF17419 6109 Printed In U.SA

HOW TO ORDER SERVICE PARTS

1. Address all orders to your local Crown dealer.

3. List the quantity needed.

5. Show billing and shipping address.

6. Suggest fastest routing.

Our Local Crown Dealer Is

Crown 1986 PF7609 Rev. 4101 Printed In U.SA

• Hydraulic Motors, Valves & Pumps • Motors

• Drive Units • Cylinders

OF1795 Rev 4/10 Pmted In USA

Limited Supplemental Warranty

Crown Equipment Corporation ("Crown") makes this limited Supplemental Warranty

• Standard and Enhanced Display Module (Access 1)

Applicable Crown Models:

• RR & RD 5200(S) • SR5285H .

OF14276 Rev 4/10 Printed In USA

SVT ... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :::

DRIVE UNIT PAGE

Event Code 370

Event Code 371

Event Code 375 .................................... 381

HYDRAULIC SCHEMATIC PAGE

POWER UNIT PARTS PAGE

DRIVE UNIT PARTS PAGE

ELECTRICAL PARTS PAGE

BRAKE PARTS PAGE

LIFTING MECHANISM PARTS PAGE

CYLINDER PARTS PAGE

REACH MECHANISM PARTS PAGE

LABELS AND DECALS PAGE

General Maintenance Instructions 5. Before starting to operate truck-

- Remove key. 10. All parts of lift mechanisms shall be inspected to

Crown 1976 PF2821-1 Rev. 10/06 MA..Q4.0-001

• All trucks except Series B and Tow Tractors, refer

• Series B trucks, refer to current ASME B56.10.

• Tow Tractors, refer to current ASME B56.9.

MA-04.0-002 Crown 1976 PF 2821-2 Rev. 10/08

Cleaning of Material Handling operation or immediate failure could be the resultant of

Crown Cleaning Products Chart

Cleaner Type Part Number Package Quantity

Crown 2000 PFll969-1 Rev. 6110 MA-114Q-050

Do not bring any type of flame, spark, etc., near the

Crown 2008 PF17657-1 MA-1457-100

When maintenance is to be performed and the battery

MA-1457-101 Crown 2008 PF17657-2

Crown 2008 PF17657-3 MA-1457-102

Applying the Brakes

MA-1457-103 Crown 2008 PF17657-4

Mechanical Brake Release Method

Crown 2008 PF17657-5 MA-1457-104

Crown 2008 PF17657~

Towing Device Requirements:

Towing by Lifting Truck and

Crown 2008 PF17657-7 MA-1457-106

MA-1457-107 Crown 2008 PF17657-8

Lifting and Blocking Equipment Capacities Required:

1 Lower forks and move towards center of truck if required

Move truck to a secure non-traffic maintenance

1 Raise forks 70 to 150 mm (3.0 to 6.0 in) from floor

Crown 2008 PF17657-9 MA-1457-108

• . . . tudt .. loufl(l1obllnnMdNlPorrn..,werUN.... OICXIn!l'tlu~.,unAteCD'llllion._manw.hdblltpOl1ed~lO