TSP 7000 SERIES

MAINTENANCE MANUAL

Order Number: 812596-006

Revision: A • Printed in Germany
 This master manual is subject to continual updates.
It is intended solely for companies authorized by Crown.
The transfer of the content or copies thereof to third parties is prohibited.

Crown Gabelstapler GmbH & Co. KG

– European Headquarters –
Moosacher Str. 52
80809 Munich
Germany

Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 133

All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2012
Crown Equipment Corporation
TABLE OF CONTENTS
I
Notes:

II
 TABLE OF CONTENTS

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Truck data number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Releasing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
To release the brakes through the Access 123 UTILITIES Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
To release the brakes using the Drive/Tow Switch (DTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
To release the brakes mechanically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Towing by Pulling in Power Unit First Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Towing by Pushing in Forks First Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Jacking and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Mast - TF & TN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Mast - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blocking Third Stage Mast Above Second Stage Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Platform - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Tool Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Platform and Load Handler Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Load Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Lubricants, Aerosols & Service Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SAE Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

COMPONENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Audible Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ALM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
HN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ED1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ECR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ECR7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ECR8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FU8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FU9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FU10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FU11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FU12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FU13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FU14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FU15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FU21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FU22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FU23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
LGT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
LGT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
LGT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LGT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LGT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LGT6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LGT7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LGT8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LGT9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
BRK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
EAC Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FAN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FAN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FAN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FSB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FSB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
JC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ACCESS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ACCESS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ACCESS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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ACCESS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
ACCESS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
POT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RES7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
RES8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
RES9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
RES10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
EACA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
EACA2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
EACB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
EACB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
GS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
GS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
EML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVF2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PVLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PVP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PVP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PVT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PVT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
SVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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SVML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SVMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Suppressor Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SB11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SB31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SB32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SB41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
APS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BRS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BRS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BRS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
BRS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CHS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CHS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CHS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CHS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CHS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CHS6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CHS7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CHS8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CTS (TF Mast Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
DTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
EMS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
EMS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FHSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FHSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FPS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FPS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FPS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FPS6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FPS7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FPS8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FPS9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
GTSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
GTSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
GUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
HGTRS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
HGTRS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
HPSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
HPSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
LGS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
LGS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
LGS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ORS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

TSP 7000 SERIES

VII
TABLE OF CONTENTS

PRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
RGSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
RGSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
RSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
SLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
TBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
TDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
TVRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ZSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Hydraulic Plumbing and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Reservoir and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Tank Top Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Drift Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Lift Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Lower Circuit (MVL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Load Handler Circuit through the Mainframe Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Mainframe Manifold - Auxiliary Circuit: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Auxiliary Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Auxiliary Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Traverse Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Traverse Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fork Extend Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Fork Retract Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Pivot Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Pivot Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Lift Pump Priming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Relief Valve (RV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Manifold Block O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Traverse Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Prepare the Traction Motor for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Traverse Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Traverse Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

TSP 7000 SERIES

VIII
 TABLE OF CONTENTS

DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Necessary Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Drive Tire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Drive Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Necessary Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Traction Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Traction Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Necessary Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Wire Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Access 1 2 3® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Static Return to Off (SRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Access 1 2 3® Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
LEVEL 1 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
LEVEL 2 and LEVEL 3 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
ANALYZER Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
When to Calibrate the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
CALIBRATION Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
FEATURES Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
HOUR METERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
HOUR METERS Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
EVENT CODES Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
PERFORMANCE Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
UTILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
UTILITIES Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Operation of the Wire Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Steer Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Line Driver Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

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End Aisle Control (EAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

EAC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
EAC in Wire Guidance Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
EAC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
EAC Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Emergency Disconnect Contactor (ED1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Logic Power Contactors (K2 & K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
How to Charge the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
How to Remove the Battery from the Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Event Code Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
No Event Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
ACCESS Module Listing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Locating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
When a Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
No Event Code? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Locate Malfunctioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Event Code Group 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Event Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Event Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Event Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Event Code 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Event Code 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

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Event Code 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Event Code 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Event Code 197 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Event Code 198 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Event Code Group 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Event Code 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Event Code 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Event Code 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Event Code 216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Event Code 217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Event Code 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Event Code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Event Code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Event Code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Event Code 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Event Code 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Event Code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Event Code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Event Code 237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Event Code 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Event Code 246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Code 278 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Codes 289, 291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Code 293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Event Code 298 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

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Event Code Group 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Codes 317, 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Event Codes 323, 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Event Code 327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Event Code 331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Event Code 373 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Event Code 378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Event Code Group 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Event Code 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Event Code 402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Event Code 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Event Code 406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Event Code 407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Event Codes 408, 409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Event Codes 411 - 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Event Code 436 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Event Code 437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Event Code 438 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Event Code 439 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Event Code 440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Event Code 441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Event Code 442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Event Code 443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Event Code 444 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Event Code 445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Event Code 446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Event Code 447 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Event Codes 491 - 499 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

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Event Code Group 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Event Code 502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Event Code 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Event Code 504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Event Code 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Event Code 507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Event Code 508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Event Codes 509, 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Event Codes 511 - 521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Event Codes 522, 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Event Codes 524, 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Event Codes 526, 527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Event Codes 528, 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Event Codes 530, 531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Event Codes 532, 533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Event Codes 534, 535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Event Code 536 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Event Code 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Event Codes 538, 539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Event Code 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Event Code 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Event Code 542 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Event Code 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Event Code 544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Event Code 545 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Event Codes 546 - 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Event Code 551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Event Codes 552, 553 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Event Code 554 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Event Codes 555, 556 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Event Code 557 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Event Codes 558 - 561 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Event Code 562 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Event Code 563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Event Code 564 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Event Code 565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Event Code 566 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Event Codes 567 - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Event Codes 571, 572 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Event Codes 576 - 581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Event Codes 582 - 585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Event Codes 586, 587 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Event Codes 588, 589 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Event Codes 590, 591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Event Codes 592, 593 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

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Event Code Group 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Event Code 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Event Codes 611, 612 &
Event Codes 621 - 628 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Event Code 631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Event Code 632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Event Code 633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Event Code 636 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Event Code 637 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Event Codes 638, 639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Event Codes 652 - 659 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Event Codes 660 - 663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Event Codes 664 - 667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Event Codes 668 - 671 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Event Code 672 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Event Code Group 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Event Code 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Event Code 701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Event Code 702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Event Code 707 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
Event Codes 708, 709 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Event Codes 711 - 720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Event Code 736 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Event Code 737 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Event Code 738 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Event Code 739 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Event Code 740 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
Event Code 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
Event Code 742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Event Code 743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Event Code 744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Event Code 745 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Event Code 746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Event Codes 747 - 749 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Event Code 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
Event Code 751 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Event Code 752 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Event Code 753 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Event Code 754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Event Code 755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Event Code 756 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Event Code 757 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Event Code 758 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Event Code 759 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Event Code 760 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Event Code 761 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Event Code 762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Event Code 763 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Event Code 764 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Event Code 765 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Event Code 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Event Code 768 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Event Code 769 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Event Code 770 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

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Event Code 771 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

Event Code 772 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Event Code 773 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Event Code 774 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Event Code 775 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Event Code 776 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Event Code 777 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Event Code 778 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Event Code 779 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Event Code 780 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Event Code 781 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Event Code 782 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Event Code 783 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Event Code 784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Event Code 785 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Event Codes 790 - 799 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Event Code Group 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Event Code 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Event Code 801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Event Code 802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Event Code 803 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Event Code 804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Event Code 805 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Event Code 806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Event Code 807 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Event Code 816 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Event Code 821 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Event Code 822 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Event Code 823 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Event Code 824 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Event Code 825 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Event Code 836 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
Event Code 837 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
Event Code 838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Event Code 839 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Event Code 840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Event Code 841 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Event Code 842 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Event Code 843 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Event Code 844 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Event Code 845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Event Code 846 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Event Code 847 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Event Code 848 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Event Code 849 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
Event Codes 850 - 852 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
Event Codes 853 - 855 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Event Codes 856 - 859 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Event Codes 860 - 863 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Event Codes 864 - 867 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Event Codes 868, 869 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Event Codes 870, 871 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Event Codes 872 - 874 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
Event Codes 875 - 877 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489

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Event Codes 878, 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Stopping the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Stopping Distance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Torque Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Special Tools and Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Special tools and equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Rotor and Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Special Tools and Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
To Assemble the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Special Tools and Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Steering Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Steering Feedback Encoder (ECR6) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Steering Feedback Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Replacing the Steer Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Steer Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Steering Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Steering Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
TN (Telescopic No Free Lift) Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
TF (Telescopic Full Free Lift) Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
TT (Triple Telescopic Full Free Lift) Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
New Truck Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Second Stage Mast Removal and Installation - TF and TN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Second Stage Mast Removal without Sufficient Overhead Clearance . . . . . . . . . . . . . . . . . . . . . . 520
Second Stage Mast Removal with Sufficient Overhead Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 523
Second and Third Stage Mast Removal - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Second Stage Mast Installation - TF and TN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
Second Stage Mast Installation without Sufficient Overhead Clearance . . . . . . . . . . . . . . . . . . . . . 534
Second Stage Mast Installation with Sufficient Overhead Clearance . . . . . . . . . . . . . . . . . . . . . . . 538
Second and Third Stage Mast Installation - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
Column Roller Replacement - TF, TN, and TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
Side Thrust Roller Adjustment - TF, TN, and TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
Hose Take-Up Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
Hose Take-Up Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
Load Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
Lathe Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552

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Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
Plates with Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Lift Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Lift Chain Tension that is Not Equal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
The Lift Components Do Not Align Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Chain Leaf Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
Blade Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
Hanger Bore Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562

CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
TF Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
Access to the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
To Replace the Seals in the Primary Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
Primary Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
Primary Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
Secondary Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
Secondary Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
To Bleed the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
TN Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
Access to the Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
To Replace the Seals in the Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
To Bleed the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
Auxiliary Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
To Replace the Seals in the Auxiliary Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
To Bleed the Auxiliary Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
Fork Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
To Bleed the Fork Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
Pivot Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
Pivot Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
Pivot Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
Assemble the Pivot Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
Pivot Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
Pivot Cylinders Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596

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PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Column Roller Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Overhead Guard Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Lower Platform Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Mast Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
GTSL & GTSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Gate Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Chain Anchor and Platform Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Side Thrust Roller Adjustment - Platform (TF, TN and TT Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Traverse Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Seat Pivot Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Seat Rotate Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Seat Power Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Seat Up/Down Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Mirror Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Mirror Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
Height Sensor Assembly - ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Height Sensor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Height Sensor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
Height Sense Encoder (ECR5) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627

Introduction to Diagram Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
Schematic - Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
Schematic - Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
Platform Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
Platform Distribution Panel w/InfoLink® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
Power Unit Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
Lights & Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
ACCESS 1, PS1, ZSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
Platform Chain Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
ACCESS 4 (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
Platform Seat Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
Platform Floor Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
ACCESS 3 (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
ACCESS 5 (SCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
Traction Motor & Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645

TSP 7000 SERIES

XVIII
 TABLE OF CONTENTS

ACCESS 2 (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646

Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
PS3, PS4, CAN Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
ACCESS 8 (OCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
Left Armrest - Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
ACCESS 6 (EAC/GCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
PDS, FSB1, FSB2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
ACCESS 7 (ACM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
Power Cables P/N’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661

TSP 7000 SERIES

XIX
TABLE OF CONTENTS

Notes:

TSP 7000 SERIES

XX
INTRODUCTION
1
Notes:

2
 INTRODUCTION
IMPORTANT INFORMATION

Important Information Manual structure

This maintenance manual outlines the maintenance The manual is divided into the following sections:
work necessary for TSP 7000 Series trucks.

Service personnel qualification Section

To maintain the safety and functionality of the Table of Contents

truck, maintenance and repair work must only be
Introduction
performed by service engineers who have been au-
thorised by Crown. Safety
Contact Crown if you wish to have your engineers Lubrication & Adjustment
trained.
Componentry
Ordering spare parts Hydraulic System
To order spare parts, use the spare parts catalog sup- Drive Unit
plied separately. Always quote the following numbers
when ordering spare parts: Electrical System
• Truck data number Brake System
• Serial number Steering
These numbers can be found on the truck data plate.
For details of your truck's technical specifications refer Lifting Mechanism
to the Technical Specifications chapter in the operator Cylinders
manual.
Platform
Note: Always use original Crown spare parts.
Schematic Diagrams
Ordering documentation Hydraulic Schematic
Parts manuals, operator manuals, specification sheets
etc. can be obtained from: Conventions
Crown Gabelstapler GmbH & Co. KG Text mark-ups in the manual
Moosacher Str. 52 The following symbols and mark-ups are used in the
80809 Munich manual:
Germany 1., 2., 3. denote work steps to be taken.
 This arrow indicates the consequences of an ac-
Tel.: +49 (0)89 / 93 002 -0
tion.
Fax: +49 (0)89 / 93 002 -175 or 133
www.crown.com  This arrow indicates action to be taken to avoid haz-
ards contained in a warnings.
(1), (2), (3) etc. indicate text references to item num-
bers in illustrations.
• Indicates the first level in a list.
– Indicates the second level in a list.
Note: Where the word "Note" appears before text, this
indicates important additional information.

Crown 2011 PF25308-1 TSP 7000 SERIES ITD-1970-001

3
INTRODUCTION
IMPORTANT INFORMATION

Data plate
The data plate for the TSP 7000 series truck is located
on the platform post below the switch panel and in-
cludes information on the battery weight, hour rating,
type, voltage and maximum amp hour rating. It also in-
cludes truck weight less battery, maximum grade with
maximum fork height, load tire width, maximum tilt
back degrees, fork length, truck model number, serial
number and data number.

Figure 20785-01

Truck data number

The truck data number provides you and your Crown
dealer with a wealth of information to insure selection
of proper parts for your Crown truck. You may simply
provide this number to your Crown dealer, or use the
following breakdown if selecting your own part num-
bers or service information from this manual.

ITD-1970-002 TSP 7000 SERIES Crown 2011 PF25308-2

4
 INTRODUCTION
IMPORTANT INFORMATION

Guidance System Battery Compartment Size

End Aisle Control (EAC) Freezer Packages
1 = Wire w/o Stabilizer Bars A = A 627 mm (24.69 in)
- = No EAC 0 = Normal Operations
2 = Rail B = B 714 mm (28.12 in)
N = EAC North Sensing 1 = Standard Freezer without cab
3 = Wire/Rail C = C 857 mm (33.75 in)
S = EAC South Sensing 3 = Low Temp. Freezer without cab
4 = Wire with Stabilizer Bars D = D 1024 mm (40.31 in)
5 = Standard Freezer with cab
6 = Low Temp. Freezer with cab

Load Handler Length

584, 686 Thru 1372 mm
(23, 27 Thru 54 in)
Voltage
In 76.2 mm (3.0 in) Increments
72 = 72 volts
--No Load Handler
80 = 80 volts
**Special Load Handler
Fork Type
Mast Type T = Telescopic
TN = No Telescopic Free Lift 4 = Fixed 102 mm (4.0 in) Offset
TF = Telescopic Full Free Lift 5 = Fixed 127 mm (5.0 in) Offset
TT = Triple Telescopic Full Free Lift 6 = Fixed 152 mm (6.0 in) Offset
* = Fixed with Special Offset

C TN 207 72 1 01 N 56 B 0 27 52 T
Standard/Custom/Special Traverse Frame Width
- = Standard 1220 Thru 1753 mm (48 Thru
C = Custom 69 in) In 25.4 mm (1.0 in) Incre-
S = Special Load Wheel Overall Width ments
(OAW) Value --No Traverse Frame
Lift Height **Special Traverse Frame
193 = 4900 mm (193 in) 447 = 11350 mm (447 in)
207 = 5255 mm (207 in) 459 = 11655 mm (459 in) Guide Wheel Spread (Beyond Load Wheel OAW)
219 = 5560 mm (219 in) 471 = 11960 mm (471 in) Dash mm (in) Dash mm (in)
231 = 5865 mm (231 in) 483 = 12265 mm (483 in) -- None
243 = 6170 mm (243 in) 495 = 12570 mm (495 in) 01 31.75 (1.25) 17 133.35 (5.25)
255 = 6475 mm (255 in) 507 = 12875 mm (507 in) 02 38.10 (1.50) 18 139.70 (5.50)
267 = 6780 mm (267 in) 519 = 13180 mm (519 in) 03 44.45 (1.75) 19 146.00 (5.75)
279 = 7085 mm (279 in) 531 = 13485 mm (531 in) 04 50.80 (2.00) 20 152.40 (6.00)
291 = 7390 mm (291 in) 543 = 13790 mm (543 in) 05 57.15 (2.25) 21 158.75 (6.25)
303 = 7695 mm (303 in) 555 = 14095 mm (555 in) 06 63.50 (2.50) 22 165.10 (6.50)
315 = 8000 mm (315 in) 567 = 14400 mm (567 in) 07 69.85 (2.75) 23 171.45 (6.75)
327 = 8305 mm (327 in) 579 = 14705 mm (579 in) 08 76.20 (3.00) 24 177.80 (7.00)
339 = 8610 mm (339 in) 591 = 15010 mm (591 in) 09 82.55 (3.25) 25 184.15 (7.25)
351 = 8915 mm (351 in) 603 = 15315 mm (603 in) 10 88.90 (3.50) 26 190.50 (7.50)
363 = 9220 mm (363 in) 615 = 15620 mm (615 in) 11 95.25 (3.75) 27 196.85 (7.75)
375 = 9525 mm (375 in) 627 = 15925 mm (627 in) 12 101.60 (4.00) 28 203.20 (8.00)
387 = 9830 mm (387 in) 639 = 16230 mm (639 in) 13 107.95 (4.25) 29 209.55 (8.25)
399 = 10135 mm (399 in) 651 = 16535 mm (651 in) 14 114.30 (4.50) 30 215.90 (8.50)
411 = 10435 mm (411 in) 663 = 16840 mm (663 in) 15 120.65 (4.75) 31 222.25 (8.75)
423 = 10740 mm (423 in) 675 = 17145 mm (675 in) 16 127.00 (5.00) ** Special Guide Wheel Spread
435 = 11045 mm (435 in)

Crown 2011 PF25308-3 TSP 7000 SERIES ITD-1970-003

5
Notes:

6
SAFETY
7
Notes:

8
 SAFETY
Safety Notices

Safety Notices
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:

DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death will result.
 Follow all instructions indicated by this symbol in or-
der to avoid injury or death.

WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death may result.
 Follow all instructions indicated by this symbol in
order to avoid injury or death.

CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury may result.
 Follow all instructions indicated by this symbol in
order to avoid injury.

CAUTION
This signal word without a symbol warns of
material damage.
Damage to the truck, tools and mechanisms may
result.
 Follow all instructions indicated by this signal word
in order to avoid damage.

TSP 7000 SERIES

9
SAFETY
Basic Safety Notices
Basic Safety Notices
Organisational measures
• Repair work must only be carried out by service en-
gineers approved by Crown.
• Work on electrical equipment must only be carried
out by specialist electricians in accordance with
electrical regulations.
• Note the basic and action-specific safety notices in
the respective chapters of this manual. Refer also
to the truck operator manual, in particular the Safety
chapter.
• Service personnel must also observe statutory and
other binding accident and environmental protec-
tion regulations.
• The legal minimum age for performing repair work
must be observed.
• Service personnel must be trained and authorised
to operate industrial trucks and must be able to
demonstrate their competence.
Personal safety equipment
• Always wear safety equipment such as safety
shoes and goggles when carrying out maintenance
and repairs. Depending on requirements you may
also need to wear safety gloves and ear muffs.
• When carrying out work on the hydraulic system,
e.g. bleeding the system, wear suitable protective
clothing such as safety gloves, goggles or a face
mask.
• When handling batteries wear acid protective cloth-
ing such as safety gloves, goggles and an apron.
• Long hair, loose clothing and jewellery are prohib-
ited. They could get caught or drawn in, resulting in
injury. Do not wear jewellery especially when work-
ing on electrical systems, as a short circuit could
cause burning.
• Always use insulated tools when working on electri-
cal systems.
TSP 7000 SERIES
10
Protecting the hazardous area
• When carrying out repair work that could be hazard-
ous to yourself and other people, seal off a large
part of the hazardous area with suitable marker
tape.
• Before carrying out repair work, service personnel
must ensure that there is no one in the hazardous
area.
• Service personnel must stop work immediately if
any unauthorised persons enter the hazardous
area. These persons must be removed immedi-
ately.
Hazards from stored energy
• High pressure hydraulic oil can cause severe inju-
ries. Depressurise the hydraulic system before
opening any sections of it.
• A 15 minute discharge time must be observed for
the electrical energy stored in the capacitors and
coils. Alternatively, these components can undergo
a controlled discharge through an electrical resistor.
• When carrying out work near the battery, always
cover the battery terminals with a suitable insulating
material (e.g. plywood board) to prevent short cir-
cuits.
• Before carrying out work underneath and on raised
components (e.g. fork carriages, extended mast
stages, the truck itself), attach suitable safety de-
vices and supports with sufficient capacity.
• Springs and gas pressure dampers must be
checked and slowly discharged before removing
them.
Repair work
• Always carry out repair work in accordance with the
test and maintenance schedule contained in this
manual and any applicable service bulletins.
• Before carrying out repair work prepare the truck as
follows:
– Park the truck on a level surface
– Lower the forks to the ground
– Switch off the truck and prevent it from being
switched on again
– Disconnect the battery and prevent the connector
from being attached by unauthorised personnel.
• When carrying out work that requires battery sup-
ply, jack up the truck until the drive wheel is clear of
the ground.

• Do not use a naked flame near the truck or to check
fluid levels or for leaks.
• Always have suitable fire protection equipment to
hand when carrying out work.
• Keep the truck clean; this makes it easier to find
loose or missing components.
• Welding work must only be carried out after prior
consultation with Crown.
• Keep the work area clean and well lit. An untidy or
poorly lit work area can lead to accidents.
• Modifications to the original condition of the truck
must be examined and approved in writing by
Crown beforehand.
• Only use original Crown spare parts and accesso-
ries.
• Never install or commission damaged components.
Restoring the truck to service after
repair work
• After carrying out repairs refit any safety mecha-
nisms that have been removed and make sure they
are working correctly.
• The truck may only be restored to service after re-
pair work once all the truck functions have been
successfully tested, in particular on the following
components:
– Brakes
– Speed control
– Direction switches
– Steering
– Lifting mechanism
– Warning devices (horn, warning indicator)
• To avoid endangering other people, always test the
truck in an open area where there are no other peo-
ple or obstacles.
Cleaning work
Particular care is required when cleaning the truck and
components that have been removed.
Handling batteries
• Batteries may only be charged, serviced or re-
placed by trained personnel. Observe the instruc-
tions contained in the operator manual, as well as
the instructions of the battery and charger manufac-
turers.
TSP 7000 SERIES
SAFETY
Basic Safety Notices
• The charger must be appropriate to the battery volt-
age and capacity. First connect the battery, then
switch the charger on.
• When handling batteries wear acid protective cloth-
ing such as safety gloves, goggles and an apron.
• Do not use a naked flame and do not smoke when
handling batteries.
• Do not touch battery terminals with metal objects.
Cover the battery terminals with a suitable insula-
tion (such as a plywood board) if you have to work
in this area.
• Always charge batteries in designated charging ar-
eas and make sure the area is well ventilated.
• Remove battery acid stained clothing immediately.
• If acid comes into contact with the skin, rinse imme-
diately with plenty of clean water. If it comes into
contact with the eyes, rinse immediately with clean
water for several minutes and then seek medical at-
tention.
• Immediately neutralize and thoroughly rinse any
spilled battery fluid.
Warning and instruction decals on
the truck
• In accordance with the test and maintenance inter-
vals check that the warning and instruction decals
on the truck are complete and legible.
• Clean any dirty decals and replace any damaged or
missing ones.
Note: The spare parts manual gives details of the la-
belling and position of the warning and instruction de-
cals on the truck.
Lifting gear and slings
• Always use suitable hoist devices and lifting gear
with sufficient capacity.
• Attach lifting gear to the designated strap points
and prevent it from slipping. Make sure the lifting
gear cannot touch other components during lifting.
• Do not stand under a swinging load.
• Repair work can only be performed under a raised
truck if the truck has been protected against acci-
dental lowering.
• Work may only be performed on the chassis, fork
carriage or mast if they have also been protected
against accidental lowering.
• Lifting gear such as load slings routed around sharp
edges must be protected from cuts.
11
SAFETY
Basic Safety Notices

Environmental protection
• Any work that involves environmentally hazardous
substances being released must only be performed
in designated areas, to allow hazardous chemicals
and oils to be separated.
• All substances released during maintenance and
repair work must be collected in the proper manner
and disposed of in accordance with national regula-
tions. Oil filters and dehumidifying inserts must be
treated as special waste.
• Always act responsibly when carrying out repairs to
avoid damaging the environment.

TSP 7000 SERIES

12
 SAFETY
CONTROL OF HAZARDOUS ENERGY

Control of Hazardous Energy • If you must repair the battery, follow the battery
manufacturer instructions for the applicable repair
procedures.
Lockout/Tagout
In the interest of safety and to ensure compliance with Battery Maintenance
EU Machinery Directives, Crown has developed guide-
lines for proper energy control when performing ser-
vice and maintenance on the truck. Before performing CAUTION
any service or maintenance on the truck, review the ap-
propriate sections in this service manual for additional Only personnel that have experience with batteries can
procedures to be followed. do maintenance and repair on batteries.
Also, Crown recommends that all technicians wear ap-  Make sure that the battery charger you use agrees
plicable protective items when they do the servicing on with the voltage and amperage of the truck battery.
Crown equipment. Some examples of these protective This voltage is on the truck serial plate.
items are:  Before you connect or disconnect a battery to a bat-
• Safety glasses tery charger, make sure that the battery charger is
• Work gloves OFF. If you do this and the battery charger is ON,
an injury can occur to you, the battery, and the bat-
• Steel-toed shoes. tery charger.
Battery  Do not use explosive materials (for example, a
lighter). The battery fumes are explosive.
Safety Rules  Make sure that the battery you use agrees with the
• Wear protective items when you do the mainte- weight, dimension, amperage, and voltage specifi-
nance on the batteries. Some examples of these cations of the truck (refer to the serial plate). Do not
protective items are: operate a truck without the correct battery.
– A rubber apron
– Gloves Battery Charging
– Boots
– A full-face shield.
Do not let the battery acid touch the eyes, skin, cloth- CAUTION
ing, or floor. If the battery acid touches the eyes, you
Gas made while you charge a battery is very explosive
must flush them immediately with clean water. Get
and can cause injury.
medical aid immediately. If the battery acid touches the
skin, you must clean it immediately with clean water  Do not smoke or use a flame near the battery.
and soap. If you spill the battery acid on the floor or on
a different surface, use a Battery Spill Kit (300035) to Consult the battery charger manual for instructions on
make the battery acid neutral and clean it up. Follow operation and maintenance.
the manufacturer directions to use the kit.
• Keep the vent plugs tightly in position at all times,
but not when you add water or use a hydrometer.
• Do not let flames or sparks near the battery. Gas
made while the battery charges is very explosive.
This gas stays in the cells after you charge the bat-
tery.
• Do not put metal or conductive objects on the bat-
tery because they can cause a short circuit.
• Do not let contamination, solution, or other un-
wanted material into the cells. Contamination will
make the battery acid neutral and will lower the
available battery charge.

Crown 2011 PF25484-1 TSP 7000 SERIES MA-1970-100

13
SAFETY
CONTROL OF HAZARDOUS ENERGY
Battery Removal
CAUTION
When removing the battery, move truck to area in-
tended for battery care. Floor must be level.
 Turn key switch or toggle switch to OFF position
and remove key.
 Disconnect battery and lockout or tagout truck as
described in Lockout - Tagout in this section. Never
move battery partially from truck without roller stand
in place.
 Lower load engaging means completely.
 If battery is removed with load engaging means
raised, use hoist attached to mast to provide tip
over protection.
 Do not allow any metallic object to come in contact
with the top of the battery cells. This may cause a
short circuit when removing, transporting the bat-
tery. Use an insulator (such as plywood) to cover
the top of the battery before and during removal.
Figure 8251
MA-1970-101 TSP 7000 SERIES
14
CAUTION
When installing the battery, move truck to area in-
tended for battery care. Floor must be level.
 Turn key switch or toggle switch to OFF position
and remove key.
 Lockout or tagout truck as described in Lockout -
Tagout in this section.
 If battery was removed with load engaging means
raised, use hoist attached to mast to provide tip
over protection.
 Do not allow any metallic object to come in contact
with the top of the battery cells. This may cause a
short circuit when transporting or installing the bat-
tery. Use an insulator (such as plywood) to cover
the top of the battery before and during installation.
CAUTION
Make sure the battery that you use agrees to the
weight, capacity, amperage, and voltage requirements
of the truck (refer to serial plate). NEVER operate the
truck with a battery that does not agree with the re-
quirements.
Lockout/Tagout
Always turn the truck OFF, remove the key, and apply
a tag to the steering wheel to let other personnel know
that the truck is down for maintenance.
Figure 12723
When you do maintenance on the truck and the battery
will be left in the truck, disconnect the battery, remove
the primary power fuses and install a commercially
available lockout device on the battery connector.
When you do maintenance on the truck and the battery
is out of the truck, remove the primary power fuses and
install a lockout device on the battery connector if pos-
sible. Or, if possible, install a tag with a cable tie on the
Crown 2011 PF25484-2

trucks battery connector to tell other personnel that the
truck is not available for operation.
Capacitance
Because of capacitance voltage in the ACCESS 2 and
ACCESS 3 modules, release the capacitors when you
do maintenance that may cause you to touch the bus
bars or power cables.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Turn the truck OFF and remove the key.
3. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
4. Wait for 2 minutes after you disconnect the battery
for the capacitors to release.
5. To make sure that the capacitors are released, put
a volt-meter across the B+ and B- terminals of the
ACCESS 2 and ACCESS 3 modules.
Figure 26141
Crown 2011 PF25484-3 TSP 7000 SERIES
SAFETY
CONTROL OF HAZARDOUS ENERGY
Hydraulic
WARNING
Avoid high pressure fluids.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
 Relieve pressure before disconnecting hydraulic
lines.
 Tighten all connections before applying pressure.
 Keep hands and body away from pinholes which
eject fluids under high-pressure.
 Use a piece of cardboard or paper to search for
leaks. Do not use your hand.
Consider any fluid injected into the skin under high-
pressure as a serious medical emergency despite an
initial normal appearance of the skin. There is a de-
layed onset of pain, and serious tissue damage may
occur. Seek medical attention immediately by a spe-
cialist who has experience with this type of injury.
When you do maintenance on the hydraulic system,
make sure the hydraulic system is not pressurized by:
• Move the truck to a maintenance area that has a flat
and level floor.
• No load on forks.
• Fully lower the mast(s) or, if necessary for mainte-
nance, block the mast. Refer to SAFETY>Control of
Hazardous Energy>Jacking and Blocking.
• Lockout/tagout the truck. Refer to SAFETY>Control
of Hazardous Energy>Lockout/Tagout.
• Lift/Lower System. Open the power unit top and the
rear door. Then find the manual lower valve on the
right edge near the top of the power unit.
• Open the manual lower valve to remove the hydrau-
lic pressure.
• Traverse System. Read and follow the warning
about high pressure fluids. Carefully loosen the fit-
ting at the sideshift hydraulic motor to release the
pressure.
MA-1970-102
15
SAFETY
CONTROL OF HAZARDOUS ENERGY
Located in Power Unit
Figure 26021
Releasing the Brakes
There are several procedures to release the brakes in
a maintenance situation. Each of the procedures has
different degrees of operator control. If the truck will not
move and has to be towed, follow one of the proce-
dures that are shown below to release the brakes.
Note: The preferred procedure to release the brakes is
through the Access 123® UTILITIES Menu.
To release the brakes through the
Access 123 UTILITIES Menu
This is the preferred procedure to release the brakes in
a maintenance situation. Use this procedure only if the
truck is electronically functional and an operator is on
the truck. Refer to SAFETY>Control of Hazardous En-
ergy>Towing the Truck for the proper towing proce-
dures.
1. Lower the mast(s) fully.
2. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
3. Put chocks against the wheels of the truck to pre-
vent unwanted movement of the truck when the
brakes are released.
4. When you tow the truck, make sure that the oper-
ator knows of the procedures to apply the brakes.
5. Connect the battery and start the truck in the "Ser-
vice" mode of ACCESS 1 and put in the password.
MA-1970-104 TSP 7000 SERIES
16
6. Scroll the display of ACCESS 1 using the down ar-
row to the "UTILITIES" Menu and push the ENTER
key.
7. Use the up/down arrows to scroll to U2 "Active Tow
Mode" and push the ENTER key.
8. The operator can release the brakes at this time by
closing the gates and then sit or stand-up with 2
feet on the presence pedals (DMS) and having the
right hand on the right Multi-Task Handle.
WARNING
When the brakes are released the truck will be free to
move.
9. The truck can be towed and the operator can steer
the truck. (NOTE: If the operator opens a gate, re-
moves a foot or the right hand, the brakes will ap-
ply.)
10. Move the truck to a maintenance area that has a
flat and level floor.
11. Turn the truck off to disable tow mode.
To release the brakes using the Drive/Tow
Switch (DTS)
If the electrical system of the truck is non-functional,
the brakes can be released by using the Drive/Tow
Switch (DTS) during a maintenance situation. For this
procedure, the truck key can be on or off. When you
use this procedure to release the brakes, the truck will
not have brakes for stopping. Also, the truck will not
have traction control or a steering system that works.
Refer to Towing the Truck in this section for the proper
towing procedures.
WARNING
Use precaution when you use the Drive/Tow Switch
(DTS) to release the brakes. The truck will be free to
move and the brake pedal in the operator compartment
will have no effect on the brakes. Also, the steering
system will not operate. The brakes will only be applied
when the Drive/Tow Switch (DTS) is moved from the
Tow position to the Drive position.
1. Lower the mast(s) fully.
2. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
Crown 2011 PF25484-4

3. Put chocks against the wheels of the truck to pre-
vent unwanted movement of the truck when the
brakes are released.
4. When you tow the truck, make sure that all the op-
erators and other personnel know the trucks
brakes do not operate correctly.
5. Disconnect the brake harness from the primary
harness at connector PC407 and connect the
brake harness to the distribution panel at CA203.
6. Connect the battery and move the Drive/Tow
Switch (DTS) from the Drive position to the Tow
position.
7. Remove the wheel chocks and move the truck to a
level area that is used for maintenance.
8. Move the Drive/Tow Switch (DTS) from the Tow
position to the Drive position.
9. Disconnect the battery.
10. Disconnect the brake harness from the distribution
panel and connect the brake harness to its first
connection, CA407.
Figure 17675
1 Drive/Tow Switch DTS
2 Brake Harness PC407
To release the brakes mechanically
If the truck fails and you cannot release the brake elec-
trically by one of the above procedures, release the
brake mechanically.
Crown 2011 PF25484-5 TSP 7000 SERIES
SAFETY
CONTROL OF HAZARDOUS ENERGY
WARNING
Be careful when you use the manual brake procedure
to release the brake. The truck will be free to move and
the brake pedal in the operator compartment will have
no effect on the brakes. With the truck OFF, the truck
will not have traction or steering control. It is not neces-
sary to have an operator on the truck.
1. Lower the mast(s) fully.
2. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
3. Put chocks against the wheels of the truck to pre-
vent unwanted movement of the truck when the
brakes are released.
4. Use a wrench, a punch or a screwdriver to turn the
torque adjuster plate. This will remove the spring
preload.
5. Remove the wheel chocks and move the truck to a
maintenance area. When you tow the truck, make
sure all the operators and other personnel are told
of the problem with the truck's brake operation and
steering. Refer to SAFETY>Control of Hazardous
Energy>Towing the Truck for the proper towing
procedures.
6. To reapply the brake, turn the torque adjuster plate
back to its first position to get the correct spring
load.
WARNING
The truck will not have braking if you do not put the
adjuster plate in its original position.
7. Put a thin layer of lubricant on the top surface of the
adjuster plate to decrease the likelihood of bending
the compression springs.
8. Refer to Torque Gap Adjustment in the Brake sec-
tion of this manual for the factory adjustments.
Towing the Truck
Refer to the instructions below when you tow the truck:
MA-1970-106
17
SAFETY
CONTROL OF HAZARDOUS ENERGY
Towing by Pulling in Power Unit First Di-
rection
WARNING
• The towed truck must always have 3 points touch-
ing the floor and/or the towing device.
• The maximum travel speed while you tow the truck
is 1.6 km/h.
• Do not make sharp turns when you lift and tow this
truck.
• The floor must be flat, level, and clean.
Preparing the Truck For Towing:
• Forks must be empty, raised no more than 305 mm
from the floor. The load handler and forks must be
in the down position (make repairs if needed to get
forks in this position).
• The total truck weight must not be more than
12,250 kg. Refer to data plate for the total truck
weight; include the battery weight if it is in truck
when you tow it.
• Power must be on if the steering works.
• Release the brakes. Refer to SAFETY>Control of
Hazardous Energy>Releasing the Brakes.
• The operator can be on the towed truck if the steer-
ing works.
MA-1970-106 TSP 7000 SERIES
18
Towing Device Requirements:
Note: Too much acceleration by the towing truck, or the
resistance caused by the towed truck (i.e., brake resist-
ance, drive unit resistance, wheel resistance) will in-
crease the requirements to pull or push a truck.
Note: Drawbar pull tests are necessary to get a rea-
sonable multiplication factor for the total truck weight.
• To calculate the force that is necessary to pull the
truck on a flat and level surface, multiply the total
truck weight by 20% (i.e., total truck weight x 0.20).
• Tow strap/chains must be sufficient in length to sup-
ply a safe distance for towed truck to come to a
stop.
Attaching a Tow Device to the Towed Truck:
• Use the holes in the skirt and install eyelets.
Note: Use the pull force requirements found below
Towing Device Requirements (see above) to determine
the specifications of the tow strap.
• When you tow the truck, use a strap or chain that is
made for the pulling requirements.
Holes in skirt for lifting eyelets
Figure 26147
Towing Truck Minimum Requirements:
• Use the pull force requirements calculated in Tow-
ing Device Requirements to find the traction force.
This traction force must be in the towing specifica-
tions of towing truck.
• Release the brakes. Refer to SAFETY>Control of
Hazardous Energy>Releasing the Brakes.
Crown 2011 PF25484-6
 SAFETY
CONTROL OF HAZARDOUS ENERGY

Towing Operation Guidelines: • Use a different truck and push against the skirt of
• The maximum travel speed while you tow the truck the disabled truck in the forks first direction. Refer
is 1.6 km/h. to Figure 26148.
• Steering towed truck: if the steering works, a sec-
ond operator must be on the towed truck to steer
the truck. If there is no steering, tow the truck in a
straight line out of the aisle with no operator on the
towed truck. When the truck is out of the aisle,
make the necessary repairs to get steering operat-
ing, and then follow the instructions in the previous
sentence.
• The towed truck must always keep all the wheels on
the floor.
• Let sufficient distance for the truck to coast to a stop
at its destination.
Skirt
Towing by Pushing in Forks First Direction
NOTE: This procedure can be followed if the aisle lay- Figure 26148
out/position of the truck in the aisle does not let you pull Pushing Truck Minimum Requirements:
the truck by the power unit skirt. When the truck is out • Use the pull force requirements calculated in Tow-
of the aisle, pull the truck in the power unit first direc- ing Device Requirements to find the traction force.
tion. This traction force must be in the towing specifica-
tions of towing truck.
• Release the brakes. Refer to SAFETY>Control of
WARNING Hazardous Energy>Releasing the Brakes.

• The towed truck must always have 3 points touch-

ing the floor and/or the towing device.
• The maximum travel speed while you tow the truck
is 1.6 km/h.
• Do not make sharp turns when you lift and tow this
truck.
• The floor must be flat, level, and clean.

Preparing the Truck For Towing:

• Forks must be empty, raised no more than 305 mm
from the floor. The load handler and forks must be
in the down position (make repairs if needed to get
forks in this position).
• The total truck weight must not be more than
12,250 kg. Refer to data plate for total truck weight;
include the battery weight if its in the truck during
towing.
• Power must be on if the steering works.
• Release the brakes. Refer to SAFETY>Control of
Hazardous Energy>Releasing the Brakes.
• The operator can be on the towed truck if the steer-
ing works.
Pushing Disabled Truck:

Crown 2011 PF25484-7 TSP 7000 SERIES MA-1970-107

19
SAFETY
CONTROL OF HAZARDOUS ENERGY

Towing Operation Guidelines:

• The maximum travel speed while you tow the truck
is 1.6 km/h.
• Steering towed truck: if steering works, a second
operator must be on towed truck to steer truck in a
straight line to get it out of aisle. When the truck is
out of the aisle, follow the procedure for towing the
truck by pulling it in the power unit first direction. If
there is no steering, tow the truck in a straight line
out of the aisle with no operator on the towed truck.
When the truck is out of the aisle, make the neces-
sary repairs to get steering operating, then follow
the procedure for towing the truck by pulling it in the
power unit first direction.
• The towed truck must always keep all the wheels on
the floor.
• Let sufficient distance for the truck to coast to a stop
at its destination.

Jacking and Blocking

Special Tools and Equipment:
• Hydraulic Jack Capacity: 4500 kg
Figure 26149
– Crown Part Number: 122599
1 Load Wheel
– Collapsed Height Minimum: 60 mm
2 Hydraulic Jack
– Raised Height Maximum: 400 mm 3 Cutout for Hydraulic Jack
• 100 x 100 mm Hardwood Block 4 Hardwood Block
• Wheel Chocks
1. Move the truck to a maintenance area that has a
flat and level floor.
2. No load on forks. View “A”

3. Lockout/tagout the truck. Refer to SAFETY>Con-

trol of Hazardous Energy>Lockout/Tagout.
4. To lift the mainframe, refer to Figure 26149. To lift
the power unit, refer to Figure 26150.

See View “A”

Figure 26150
1 Wheel chock both load wheels
2 Hardwood Block
3 Cutout for hydraulic jack - both sides of power unit

MA-1970-108 TSP 7000 SERIES Crown 2011 PF25484-8

20
 SAFETY
CONTROL OF HAZARDOUS ENERGY

5. Put chocks against the load wheels if the power

unit is being lifted.
6. Put the hydraulic jack in the cutout of the compo-
nent being lifted.

Rear of
WARNING Truck

Do not raise the operator platform component

more than 450 mm from the floor.

WARNING
Truck stability decreases dramatically if the load
wheels are raised more than 13 mm.

WARNING
Do not put hardwood blocks at the back of the
power unit between the jack notches. Doing so can
result in damage to the guidance sensor.

7. Use the hydraulic jack and lift the truck enough to

put a hardwood block below the mainframe or the
Figure 26151
power unit. Then lower the truck onto the hard-
wood block.

WARNING
Before you raise the steer-wheel end of the truck,
make sure that the jack does not hit the guidance
sensor.

Note: When rail guides, stabilizer bars, or skid bars are

on the truck, the hydraulic jack must come in at an an-
gle to access the power unit jack notches.

Crown 2011 PF25484-9 TSP 7000 SERIES MA-1970-110

21
SAFETY
CONTROL OF HAZARDOUS ENERGY

Main Mast - TF & TN Main Mast - TT

Tools and Equipment:
• (2) 100 x 100 mm Hardwood blocks of appropriate
length
• Wheel Chocks
• Strap or Clamp.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Put chocks against the wheels of the truck to pre-
vent movement of the truck. Refer to
SAFETY>Control of Hazardous Energy>Jacking
and Blocking.
3. Connect the battery.
4. Raise the main mast to get the necessary second
stage height and then put the applicable length
blocks in each mainframe rail.
5. Hold the blocks on the mainframe with a strap or
clamp.
6. Lower the mast onto the blocks and make sure the
platform is against the stops.
7. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
Blocking the Mast with the Locking Tube Tool
Special Tools and Equipment:
• Locking Tube Tool (144009)
• (2) Screws (060115-040)
• (2) Nuts (060059-010)
• Wheel Chocks.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Put chocks against the wheels of the truck to pre-
vent movement of the truck. Refer to
SAFETY>Control of Hazardous Energy>Jacking
and Blocking.
3. Connect the battery.
4. Remove the screw and nut from one end of the
locking tube tool and put the tool through the first
stage mast. Then install the screw and nut back
through the locking tube tool to secure it in position.
5. Lower the mast until the second stage is on the
locking tube tool and the platform is fully lowered.
6. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.

Figure 20176
1 Locking Tube Tool 144009
Figure 26276 2 Screw 060115-030
1 Mainframe 3 Nut 060059-010
2 Second Stage
3 Strap

MA-1970-111 TSP 7000 SERIES Crown 2011 PF25484-10

22
 SAFETY
CONTROL OF HAZARDOUS ENERGY

Blocking Third Stage Mast Above Second

Stage Mast
(To service the mast hoses)
Special Tools and Equipment:
• (2) 100 x 75 x 355 mm Hardwood Blocks
• (2) 100 x 75 x 1219 mm Hardwood Blocks
• Wheel Chocks
• Straps or Clamps.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Put chocks against the wheels of the truck to pre-
vent movement of the truck. Refer to
SAFETY>Control of Hazardous Energy>Jacking
and Blocking.
3. Connect the battery.
4. Refer to Figure 26153. Raise the mast until there is
a sufficient distance to install the two 100 x 75 x
355 mm hardwood blocks into the second stage
mast rails (I-beams) and the two 100 x 75 x
1219 mm hardwood blocks into the third stage
mast rails (I-beams).
5. Refer to Figure 26153. Attach the hardwood blocks
to the mast rails with clamps or straps. Figure 26153
1 Second Stage Mast
2 Third Stage Mast
3 Hardwood Blocks, 100 x 75 x 355 mm
4 Hardwood Blocks, 100 x 75 x 1219 mm
5 Straps

6. Refer to Figure 26153. Lower the mast so the third

stage mast is on the two 355 mm long blocks and
the platform is on the two 1219 mm long blocks.
Note: Make sure the second stage is fully lowered to its
bottom position. The second stage I-beams should
lower into the mainframe pockets and stop.
7. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.

Crown 2011 PF25484-11 TSP 7000 SERIES MA-1970-112

23
SAFETY
CONTROL OF HAZARDOUS ENERGY

Auxiliary Mast Platform - TT

Special Tools and Equipment:
• (2) 100 x 100 mm (4 x 4 in) Hardwood Blocks of ap-
propriate length
• Wheel Chocks
• Straps or Clamps.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Put chocks against the wheels of the truck to pre-
vent movement of the truck. Refer to
SAFETY>Control of Hazardous Energy>Jacking
and Blocking.
3. Connect the battery.
4. Raise the fork carriage to get the correct height and
then put the correct length blocks in each of the
mast rails.
5. Hold the hardwood blocks on the mast rails with a
strap or clamp.
6. Lower the fork carriage so the carriage is on the
blocks.
7. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
Special Tools and Equipment:
• (2) 100 x 100 mm Hardwood Blocks of the correct
length or (2) Jack Stands
• Wheel Chocks
• Strap or Clamp.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Put chocks against the wheels of the truck to pre-
vent movement of the truck. Refer to
SAFETY>Control of Hazardous Energy>Jacking
and Blocking.
3. Connect the battery.
4. Raise the platform enough in free lift to put the jack
stands or hardwood blocks in the channels of the
mast.
CAUTION
If hardwood blocks are used, hold them in position
with a strap or clamp across the two hardwood
blocks.
5. Lower the platform onto the jack stands or hard-
wood blocks.
6. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.

Figure 26277

MA-1970-113 TSP 7000 SERIES Crown 2011 PF25484-12

24
 SAFETY
CONTROL OF HAZARDOUS ENERGY

Figure 17667
1 4.8 mm (0.1875 in) Diameter Rod
Figure 20178
2 Grind Flat
1 Platform
3 Screwdriver
2 Main Frame
4 Cut and Weld at 90o
3 Jack Stands
Spring Removal
1. Remove the height sensor from the truck and lock
Height Sensor the sensor in a vice.

WARNING WARNING
Personal injury is possible if you do not use ex- Personal injury is possible if you do not use ex-
treme caution. treme caution.
The spring is reverse wound and if it is not kept re-
 When you remove the last screw, turn the cover ap-
strained, it will unwind fully and then wind in the oppo-
proximately 5 revolutions to release the spring
site direction.
force.
 Wear safety glasses and gloves when you remove
the spring.
2. Remove the four screws from the reel cover and let
the spring force release through cover rotation.
Tool Fabrication
3. Pull the cover approximately 25.4 mm from the
A tool for moving the spring in the reel can be made as housing. Then, using a screwdriver, slowly remove
shown in Figure 17667. the arbor off the square shaft of the cover.
4. Remove the cover from the spacer. Remove the
grease.
5. Carefully pull the arbor from the spring using a nee-
dle nose pliers.
6. Move the opening in the inner spacer around until
you have access to the spring retainer screws.
7. Remove the spring retainer screws.

Crown 2011 PF25484-13 TSP 7000 SERIES MA-1970-114

25
SAFETY
CONTROL OF HAZARDOUS ENERGY

WARNING
Personal injury is possible if you do not use ex-
treme caution.
The spring is reverse wound and if it is not kept re-
strained, it will unwind fully and then wind in the oppo-
site direction.
 Wear safety glasses and gloves when you remove
the spring.

8. Use a fabricated rod or screwdriver, start to re-

move the spring approximately 12.7 mm out of the
reel.
Figure 17681
1 Spring
2 Vise Grip
3 Vice

10. Carefully put cable ties around the spring so the

locking pliers can be removed. Discard the spring.

Spring Installation
1. When the height sensor is ready to have the spring
installed, put a locking pliers carefully on the reel
shaft and secure the locking pliers to keep the reel
from turning. Put a bolt through the reel housing to
lock the reel.

Figure 17680
1 Reel Locking Bolt
2 Spring
3 Arbor
4 Reel Cover

9. Hold the spring with locking pliers near the end of

the spring on the outside diameter. While you hold
the locking pliers with one hand, remove the spring
from the reel with the fabricated tool.

Figure 17636
1 Spring
2 Shipping Rod

MA-1970-116 TSP 7000 SERIES Crown 2011 PF25484-14

26
 SAFETY
CONTROL OF HAZARDOUS ENERGY

2. The new spring is shipped with a rod wrapped par- Platform and Load Handler Lifting
tially around the circumference of the spring and is
tied with cable ties. Make sure the rod is in the Load Handler
center of the spring and then remove the cable ties.
The platform weighs approximately 1360 kg and the
3. Move the shipping rod around the circumference of load handler weighs approximately 1000 kg. Be sure
the spring so the end of the spring extends out be- the equipment used to lift and hold the load handler
tween the ends of the rod. and platform is of sufficient capacity to safely handle
this load.
4. Assemble the hook of the spring retainer in the
hole of the spring. The retainer mounting tab must 1. Move the truck to a maintenance area that has a
be on the opposite side of the spring as the diago- flat and level floor.
nally cut corner at the end of the spring.
2. Lower the main and auxiliary masts fully. No load
5. Put the inner spacer between the spring and the on forks.
spring retainer so the raised portion of the spacer
3. Lockout/tagout the truck. Refer to SAFETY>Con-
is away from the spring.
trol of Hazardous Energy>Lockout/Tagout.
6. Put the assembly into the reel, spring retainer first,
4. Put chocks against the wheels of the truck to pre-
and work the shipping bar to the outer edge of the
vent movement of the truck. Refer to
spring.
SAFETY>Control of Hazardous Energy>Jacking
7. Move the assembly around until the holes in the and Blocking.
spring retainer and reel align. Start the screws to
5. Remove the top and bottom traverse stop blocks
hold the spring retainer to the reel.
from the left end of the top and bottom traverse
8. Carefully push the spring into the reel and let it ex- gear racks.
pand in the reel. Tighten the screws holding the
6. Put the display in "Shipping Mode".
spring retainer.
7. Connect a lift to the auxiliary mast and raise the
9. Fully soak the spring with lubricant 063001-009.
load handler enough to move the load handler
Use lubricant 063002-059 for trucks used for oper-
weight from the platform to the lift.
ation in a freezer.
8. Slowly power the load handler off the left end of the
10. Put the arbor into the center of the spring so when
traverse gear racks by requesting "traverse left"
the arbor is turned clockwise, the flat on the arbor
using the thumb ball on the right multi-task handle.
pulls the spring.
Use precaution to prevent damage to the gang
11. Put a layer of lubricant (063001-009) on the sur- hose and load handler wire harness.
faces of the end spacer and position it in the reel
9. Disconnect the load handler wire harness.
housing.
10. Disconnect the hoses and seal the hose ends to
12. Put the square shaft of the cover into the arbor and
prevent hydraulic system contamination.
put the cover against the housing.
11. Carefully move the load handler away from the
13. Turn the cover clockwise five revolutions. Then put
truck.
the screws in and tighten them.

CAUTION
When you install the load handler on the platform,
make sure the timing of the gear engagement to the
top and bottom gear racks is the same. If the timing
is incorrect, jerky traverse and premature compo-
nent wear can result.

Crown 2011 PF25484-15 TSP 7000 SERIES MA-1970-117

27
SAFETY
CONTROL OF HAZARDOUS ENERGY

Platform 1 Overhead Guard

1. Move the truck to a maintenance area that has a 2 Three Point Hookup
flat and level floor. 3 Hardwood Block

2. Lower all the masts fully. No load on forks.

3. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy>Lockout/Tagout.
4. Put chocks against the wheels of the truck to pre-
vent movement of the truck. Refer to
SAFETY>Control of Hazardous Energy>Jacking
and Blocking.
5. Remove the load handler.
6. Remove the spotlights and overhead fan from the
overhead guard, if applicable.
7. Put a 100 x 100 mm hardwood block below the
overhead guard, tight against the back of the plat-
form. Make sure the hardwood block is a minimum
of 305 mm longer than the overhead guard and is
on center.
8. Use a 3-point hook-up and attach a strap, chain,
etc. to the hardwood block and the back of the
overhead guard. Raise the platform to the neces-
sary height.
9. Block or remove the platform. Refer to PLAT-
FORM>Platform>Removing the Platform for pro-
cedures to remove the platform.

Figure 17670

MA-1970-118 TSP 7000 SERIES Crown 2011 PF25484-16

28
LUBRICATION & ADJUSTMENT
29
Notes:

30
 LUBRICATION & ADJUSTMENT
Cleaning the Truck and
Components
CAUTION
Health risk
Cleaning agents, lubricants and consumables can
damage your health.
 Observe the manufacturer’s safety instructions
when handling solvents and lubricants.
Effects of incorrect cleaning
Electrical components
Electrical components such as connectors, contacts,
distributor boards, controllers and wiring can be dam-
aged by water, cleaning agents and solvents.
Mineral and chemical residue that automatically re-
main on or in components after cleaning, are a cause
of corrosion. This corrosion results in malfunctions and
premature failure.
Roller and slide bearings
Steam cleaning and solvents damage the lubricant film
on bearing surfaces. This results in dry running and
rapid damage to the bearing elements.
Corrosion-protected surfaces
The brake lines, screw connections and shiny metal
surfaces in particular on cold store trucks are factory-
treated with an anti-corrosive agent (Anticorit
BW 366®). This protection can be washed off by sol-
vents and steam cleaning. The above-mentioned com-
ponents will corrode as a result.
Environmental protection
Cleaning must only be performed in specially desig-
nated areas to enable hazardous chemicals and oils to
be separated.
Collect any waste (such as oily cleaning cloths) and
dispose of them in accordance with local regulations.
TSP 7000 SERIES
Cleaning the Truck and Components
Cleaning the entire truck
1. Park the truck in an area with an oil separator.
2. Switch off the truck, disconnect and remove the
battery.
WARNING
Malfunctions when restarting the truck can cause
serious injury
Water can penetrate electrical components after steam
cleaning or hose washing. This can accidentally trigger
certain functions when the truck starts up again.
 Do not steam-clean the truck or wash it down with
a hose.
Cleaning the truck surface
3. Dry clean the truck. To do this use cloths, soft
brushes (not metal brushes) and if necessary
weak, dry compressed air.
Note: Local contamination that cannot be removed by
dry cleaning can be treated with a damp cloth and a
neutral cleaning agent. Make sure that neither water
nor cleaning agent get into electrical components or
bearings.
Cleaning lift chains
4. See page 32.
Cleaning electrical components
5. Clean electrical components only with each, dry
compressed air and a dry cloth.
Interior cleaning
6. Clean detachable rubber mats with water and a
neutral cleaning agent.
7. Allow the rubber mats to dry out fully before return-
ing them to the truck.
8. Damp-wipe plastic parts with a neutral cleaner.
Note: If necessary use a standard commercial plastic
cleaning agent to remove obstinate dirt.
After cleaning the truck
9. Wipe down the truck.
10. Remove any paint damage.
11. Add anti-corrosion agent if necessary.
Returning the truck to operation after cleaning
Normally no special measures are required.
Rev. 1, Feb 09
31
LUBRICATION & ADJUSTMENT
Cleaning the Truck and Components
If however there is a possibility that damp may have
penetrated electrical components, proceed as follows:
1. Clean the truck with weak, dry compressed air and
a cloth.
2. Leave the truck to stand for at least 30 minutes in
a dry environment.
3. Insert the battery but do not connect it yet.
4. Jack up the truck so that the drive wheel is clear of
the ground.
WARNING
Malfunctions when restarting the truck can cause
serious injury
Water or cleaning agent residue in electrical compo-
nents can cause malfunctions when the truck is
switched on.
 You must be prepared to switch off the truck imme-
diately with the Emergency Disconnect when the
battery is connected and the truck is powered up.
 Make sure that nobody can be injured by compo-
nents accidentally starting up (lift mechanism, side-
shifter etc.).
5. Connect the battery.
6. Switch on the truck.
 If a function automatically starts, apply the
Emergency Disconnect immediately.
Note: If possible, apply compressed air to the respec-
tive switch or connector. Repeat steps 1 to 6.
 Is the starting pattern is normal, proceed to
step 7.
7. Check all functions.
Rev. 1, Feb 09 TSP 7000 SERIES
32
Cleaning removed components
Cleaning lift chains
WARNING
Improper cleaning can cause chains to crack
A cracked chain can result in fatal injuries.
Never clean lift chains with steam cleaners, cold clean-
ing agents or corrosive, acid-based agents. This can
cause direct chain damage through hydrogen embrit-
tlement.
 Clean the chain surfaces only with paraffin deriva-
tives such as cleaning petroleum or cleaning petrol.
 Apply an approved chain oil immediately after
cleaning (see page 34).
1. Remove persistent dirt with cleaning petroleum or
cleaning petrol. Apply a thin layer of the cleaning
agent with a hard bristle brush and wipe with a lint-
free cloth.
2. Apply an approved chain oil immediately after
cleaning (see page 34).
Cleaning other mechanical components
With the exception of lift chains, components that have
been removed can be steam-cleaned under certain
conditions.
CAUTION
Steam-cleaning can damage electrical compo-
nents and bearings
 Mechanical components may only be steam-
cleaned if no electrical components or bearings are
affected.
1. Components that have been removed should be
cleaned by hand, ideally with warm water and a
mild neutral cleaning agent.
2. If steam-cleaning cannot be avoided, it should be
done without a cleaning agent. If grease needs to
be removed, use a mild neutral cleaning agent.
Note: Steam-cleaning can remove anti-corrosion
agent and paint from surfaces.
3. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
4. Leave the cleaned components to dry thoroughly.
 LUBRICATION & ADJUSTMENT
Cleaning the Truck and Components

Note: Cleaned components must be dry and free of

cleaning agent residue before being refitted, lubricated
or painted.
5. Re-lubricate, paint or apply anti-corrosion agent to
the components as required.
6. Refit the components.
7. For cold store trucks apply Anticorit BW 366® as
an anti-corrosion agent for screw connections and
shiny metal surfaces.

TSP 7000 SERIES Rev. 1, Feb 09

33
LUBRICATION & ADJUSTMENT
LUBRICANTS, AEROSOLS & SERVICE SUPPLIES

Lubricants, Aerosols & Service

Supplies
Refer to the Lubrication Identification Chart or the Alter-
nate Lubricants & Fluids Chart in this section for the
recommended list of lubricants, aerosols and service
supplies to use when you do planned maintenance on
Crown Lift Trucks.

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
363514-001 1 Quart
AAAA Synthetic Gear Oil 75W-90
363514-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
063002-025 14.5 oz Cartridge
BBBB Grease (Multi-Purpose) Premium
063002-026 5 Gallon
C Oil (SAE 40)
363500-001 1 Quart
Engine Oil (10W30)
363500-012 (12) 1 Quart
CC
063041-001 1 Quart
JD Turf Guard (10W30)
063041-012 (12) 1 Quart Cans
363504-101 1 Gallon
D (1) Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon

DDD (2) Hydraulic Oil - Mobil DTE24 063001-021 1 Gallon

DDDD (3) Hydraulic Oil - Mobil Univis HVI 13 063001-035 5 Gallon

Note: Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
(1) Normal operation (temperatures of 0.6°C and above (33°F and above))
(2) Standard temperature freezers (-18°C to 4°C (0°F to 40°F))
(3) Low temperature freezers (-40°C to -12°C (-40°F to 10°F)) Do not blend with any other oil.

M1.0-04.0-050 TSP 7000 SERIES Crown 2011 PF25240-1 Rev. 4/12

01 Rev. 4/12
34
 LUBRICATION & ADJUSTMENT
LUBRICANTS, AEROSOLS & SERVICE SUPPLIES

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
363143-001 10.5 oz Can
EE Channel Slide Lubricant
363143-012 (12) 10.5 oz Cans
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
063002-039 1 lb
I Grease (Lift Pump Coupling)
127801S 1 oz
063004-002 12 oz
J Brake Fluid - Dot 5
063004-003 1 Gallon
063002-034 14.5 oz Cartridge
K Grease (Wheel Bearing)
063002-045 (40) 14.5 oz Cartridges
L Metal Assembly Spray 063002-021 11 oz Spray
LL Sprayon 500727 PTFE Freezer Lube 063002-059 9 oz. Can
M Silicone Grease (Clear) 063002-020 5.3 oz Tube
363102-001 14 oz Can
Brake & Parts Cleaner
363102-012 (12) 14 oz Cans
363103-001 14 oz Can
N Low VOC Brake & Parts Cleaner
363103-012 (12) 14 oz Cans
363116-001 19 oz Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 19 oz Cans
363104-001 20 oz Can
O Penetrating Lubricant
363104-012 (12) 20 oz Cans
363108-001 11 oz Can
P Premium Formula Multi-Purpose Grease
363108-012 (12) 11 oz Cans
363110-001 11 oz Can
Q White Lithium Grease
363110-012 (12) 11 oz Cans
363109-001 15 oz Can
R Choke & Carburetor Cleaner
363109-012 (12) 16 oz Cans

Crown 2011 PF25240-2 Rev. 4/12 TSP 7000 SERIES M1.0-04.0-051

01 Rev. 4/12
35
LUBRICATION & ADJUSTMENT
LUBRICANTS, AEROSOLS & SERVICE SUPPLIES

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

363106-001 10 oz Can
Contact Cleaner - Non-Flammable
363106-012 (12) 10 oz Cans
S
363128-001 11 oz Can
Contact Cleaner
363128-012 (12) 11 oz Cans
T Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc
363124-001 18 oz Can
U Battery Cleaner
363124-012 (12) 18 oz Cans
363125-001 15 oz Can
V Battery Protector
363125-012 (12) 15 oz Cans
363127-001 12 oz Can
W Food Grade Machine Lubricant
363127-012 (12) 12 oz Cans
363126-001 11 oz Can
X Food Grade Silicone Spray
363126-012 (12) 11 oz Cans
363509-101 1 Gallon
Coolant
363509-106 (6) 1 Gallon
Y
363511-101 1 Gallon
Extended Life Coolant
363511-106 (6) 1 Gallon

M1.0-04.0-052 TSP 7000 SERIES Crown 2011 PF25240-3 Rev. 4/12

01 Rev. 4/12
36
 LUBRICATION & ADJUSTMENT
LUBRICANTS, AEROSOLS & SERVICE SUPPLIES

Alternate Lubricants & Fluids Chart

Manufacturer/
Type of Lubricant Product Name
Distributor
A Gear Lube 80W-90 (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
AAA Universal Hydraulic & Transmission Fluid Crown Crown
AAAA Synthetic Gear Oil 75W-90 Crown Crown
Mobilgrease XHP 222 Special Mobil
Union Unoba EP No 2 Union 76 Co.
B Grease (Multi-Purpose) Retinax A (1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease (Low Temp) (2) Alvania RA (1) Shell
Helveum O (1) Burmah Castrol

BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
Mobilux EP2 64127-4 Mobil
Retinax AM 71119 Shell
BBBB Grease (Multi-Purpose) Premium
Chevron RPM Heavy Duty LC Chevron
Grease EP
C Oil (SAE 40)

D (2) Hydraulic Oil Crown Crown

DD Hydraulic Oil (Low Temp) Crown Crown

DDD (3)(5) Hydraulic Oil - Mobil DTE24 Mobil DTE 24 Mobil

DDDD (4) Hydraulic Oil - Mobil Univis HVI 13 Mobil Univis AVI 13 Mobil
E Channel Grease Factran #2 Standard Oil Co.
EE Channel Slide Lubricant Crown Crown
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
Note: Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
(1) Denotes allowable substitutes, contact factory if unavailable.
(2) Normal operation (temperatures of 0.6°C and above (33°F and above))
(3) Standard temperature freezers (-18°C to 4°C (0°F to 40°F))
(4) Low temperature freezers (-40°C to -12°C (-40°F to 10°F)) Do not blend with any other oil.
(5) Premium antiwear hydraulic oil used in blending with low temp oil.

Crown 2011 PF25240-4 Rev. 4/12 TSP 7000 SERIES M1.0-04.0-053

01 Rev. 4/12
37
LUBRICATION & ADJUSTMENT
LUBRICANTS, AEROSOLS & SERVICE SUPPLIES

Alternate Lubricants & Fluids Chart

Manufacturer/
Type of Lubricant Product Name
Distributor
I Grease (Lift Pump Coupling) Nyogel 774F-MS NYE Lubricants
J Brake Fluid - Dot 5 Q2-1141 Silicon Brake Fluid Dow Corning
Mobilgrease XHP 222 Special Mobil
K Grease (Wheel Bearing) Unirex EP-2 Exxon
Lubriplate No. 1242 (1) Fiske Bros. Refining Co.
L Metal Assembly Spray Dow Corning Dow Corning
LL Sprayon 500727 PTFE Freezer Lube Sprayon 500727 Sherwin Williams
M Silicon Grease (Clear) Dow Corning 111 Compound Dow Corning
Brake & Parts Cleaner Crown Crown
N Low VOC Brake & Parts Cleaner Crown Crown
Non-Flammable Brake & Parts Cleaner Crown Crown
O Penetrating Lubricant Crown Crown
P Premium Formula Multi-Purpose Grease Crown Crown
Q White Lithium Grease Crown Crown
R Choke & Carburetor Cleaner Crown Crown
S Contact Cleaner Crown Crown
Electrical Connector Oxidation &
T Nye Grease NYE Lubricants
Corrosion Inhibitor
U Battery Cleaner Crown Crown
V Battery Protector Crown Crown
W Food Grade Machinery Lubricant Crown Crown
X Food Grade Silicone Spray Crown Crown
Y Extended Life Coolant
(1) Denotes allowable substitutes, contact factory if unavailable.

M1.0-04.0-054 TSP 7000 SERIES Crown 2011 PF25240-5 Rev. 4/12

01 Rev. 4/12
38

Planned Maintenance
To make sure that your truck continues to move mate-
rials safely and quickly, you must do regular mainte-
nance on your truck.
CAUTION
Injury or material damage can occur.
If you operate a truck for which repair is necessary or
that is not in a safe condition, it can cause injury or ma-
terial damage.
If repair is necessary on the truck, or the truck is not in
a safe condition:
 Do not operate the truck until it is safe.
 Immediately make a report of the condition to the
applicable authority.
 Do not make repairs or adjustments to the truck un-
less you are approved to do them.
CAUTION
Injury or material damage can occur.
If you do not correctly prepare the truck for mainte-
nance, it can cause injury or material damage.
 Complete all lockout/tagout procedures. Refer to
Safety > Control of Hazardous Energy.
 Obey all safety instructions. Refer to Safety.
Do a visual inspection of the truck
1. Complete the Operators Daily Checklist. Refer to
INSPECTION AND LUBRICATION > Operator’s
Daily Checklist.
2. Move the truck to a maintenance area with a level
floor.
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent the
movement of the truck. Refer to Safety > Control of
Hazardous Energy.
5. Disconnect the battery.
6. Apply a lockout/tagout device to the truck. Refer to
Safety > Control of Hazardous Energy.
7. Release the capacitance voltage in ACCESS 3.
Refer to Safety > Control of Hazardous Energy.
8. Blow off the truck with low pressure air.
9. Look for unwanted material in or around the truck
components.
Crown 2012 PF25709-1 TSP 7000 SERIES
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE
10. Look for damaged components.
11. Look for loose or missing fasteners.
12. Look for damaged electrical wires or connectors.
Do the planned maintenance
1. Use the applicable interval chart in this section to
do the planned maintenance.
• 60 Day/250 Hour
• 12 Month/2000 Hour
Note: You must change the lubrication and inspection
intervals to decrease corrosion and wear on parts for
trucks operated in environments with low tempera-
tures, moisture, or other conditions that can cause con-
tamination or corrosion.
– Use the applicable Planned Maintenance Inspec-
tion Report (PF15039) to record maintenance.
– Consult your Crown dealer for Planned Mainte-
nance Inspection Reports.
– Figure 1 gives an example of PF15039. It is pos-
sible that it is not the newest report.
Annual inspection in accordance
with FEM 4.004
Guideline FEM 4.004 “Regular Inspection of Industrial
Trucks” requires the truck to be inspected by an expert.
This inspection must be carried out annually or in
intervals as specified by the owner's risk analysis.
National regulations must be taken into account.
Exact details of intervals should be discussed with a
Crown service engineer.
M1.0-1970-001
39
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

TSP 6000/6500/7000 Series Planned Maintenance

Inspection Report

Customer Dealer

Date Hr. Meter Reading(s) Make Serial No. Customer P.O. No.

I. VISUAL INSPECTION 10. Steering Gear 3. Chain Slack Switches

1. Oil Leaks 11. Battery Rollers 4. Lift Chains Condition - Wear
2. Overhead Guard 12. Auxiliary Hose Tracking Path 5. Lift Chain Adjustments
3. Mast Assembly 13. Lift Chains 6. Limit Switches (HGTRS1 & 2)
• Primary 14. Traverse Rack & Gears 7. Height Encoders
• Auxiliary 15. Door Hinges & Side Gates 8. Cylinder Condition & Leaks
4. Fork Carriage 16. Apply Armorall Sparingly to Mast 9. Power Unit Mounting Bolts
5. Forks Cables & Hoses 10. Control Cables & Tension
6. Platform Assembly III. HYDRAULIC PUMP & MOTOR 11. Pulleys
• Safety Shield(s) 1. Mounting Secure 12. Yoke
• Floor Mat 2. Cable Connections 13. Hose Take-up & Adj. (TF Mast)
• Gate(s) 3. Hoses & Fittings/Leaks 14. Column Roller Tracking Path
• Operator Harness (Belt & Tether) 4. Blow Dust From Motor XI. FREEZER CONDITION TRUCKS
• Fire Extinguisher (Optional) 5. Pump Operation & Leaks 1. Heater Operation (Circuitry)
• Operator Display IV. DRIVE UNIT & DRIVE MOTOR 2. Wiring Condition
• Switch Panel 1. Oil Level & Leaks XII. OPERATIONAL CHECK & TEST DRIVE
• Left & Right Armrest Controls 2. Motor Mounting Secure 1. Operator Display/Indicator Lights
• Seat 3. Motor Cable Connections 2. Hour Meter(s)
• Brake Pedals 4. Blow Dust From Motor 3. Horn
• Foot Presence Pedals 5. Mounting to Power Unit Secure 4. Power Disconnect (EDS)
7. Height Sensor(s) 6. Drive Tire Lug Nut(s) 5. Platform Switch Panel
8. Tire & Wheel Conditions V. CONTROL WIRING 6. Electronic Steering Operation
• Drive/Steer Tire 1. Power Cables Condition 7. Side Gate Operation LH & RH
• Load Wheels LH & RH 2. Power Cables Connection 8. Truck Settings
• Lug Nuts 3. Wiring Conditions 9. Lights & Fan(s)
• Aisle Guide Wheels, LH & RH 4. Wiring Connections 10. Flashing Light (Power Unit)
(Optional) 5. Wire Harnesses Condition 11. Flashing Lights (Platform - Optional)
9. Lift Chain & Yoke 6. Wire Harnesses Connector 12. Foot Presence Pedals
10. Hose(s) Mast & Auxiliary VI. CONTACTORS & RELAYS 13. Zone Select (Optional)
11. Traverse Rack & Gears 1. ED1 Tip Condition 14. EAC Operation (Optional)
12. Control Cable & Spring Condition 2. ED2 Tip Condition (Euro Trucks) 15. Wire Guidance Operation
13. Safety Decals & Data Plates in Place 3. K1 & K2 Tip Condition Calibration (Optional) (b)
14. Covers in Place & Secure 4. K3 Tip Condition (72/80 Volt Only) 16. Seat Operation
15. Manual Lowering System VII. ELECTRIC BRAKE 17. Directional Control Operation
16. Battery Retainer 1. Brake Pedal(s) Operation 18. Brake Pedals Operation
• Battery Retainer Switch (Optional) 2. Brake Adjustment (a) 19. Brake Stopping Distance (a)
17. Battery Spacers 3. Brake Pads 20. Plugging Distance (c)
18. Battery Cable Condition (Truck Side) 4. Brake Rotor 21. Rated Capacity
19. Battery Connector Condition VIII. ELECTRONIC STEERING SYSTEM 22. Raise - Main & Auxiliary
(Truck Side) 1. Steering Condition 23. Lower - Main & Auxiliary
20. Battery Roller Condition 2. Steering Tiller 24. Travel Alarm (Optional)
II. CLEAN & LUBRICATE 3. Steer Motor Mounting 25. Travel Speeds
1. Blow Off Truck 4. Brush & Armature Condition 26. Height Sensor (ECR5) Operation
2. Load Wheel Axles, Drive Unit Pivot, 5. Blow Dust From Motor 27. Performance Settings
Rail Guide Roller Linkage IX. HYDRAULIC SYSTEM 28. Pivot - Left - Right
3. Mast Assembly 1. Oil Level, Condition & Leaks 29. Traverse - Left - Right
4. Lubricate All Lubrication Fittings 2. Breather Cap 30. Extend/Retract (Optional)
5. Mast Channels & Column Rollers 3. Hoses & Fittings 31. Optional Attachments
6. Seat Telescopic Tube 4. Filters 32. Height Cable Tension
7. Upper Load Handler 5. Relief Valve(s) & Solenoid(s) 33. Skid Bar Adjustment
8. Multi-Task Handle X. MAST TF/TN/TT & AUXILIARY XIII. CUSTOMER CARE
9. Blow Off Brake 1. Mast Channel Wear 1. Wipe Off Truck
2. Poly Stops & Bumpers 2. Clean Area
IMPORTANT: Refer to Service Manual, Infopoint® Quick Reference Guide, Product
Information Bulletins for details on inspection, lubrication & adjustment. Repair Status
(a) See applicable service manual for brake adjustment procedures and recommended stopping distances. Codes Approved
(b) See applicable service manual for wire guidance adjustment/calibration procedures and specifications. 9= OK W.O.#
(c) See applicable service manual for plugging adjustment procedures and recommend plugging distances. A = Adjust Denied
Comments: R = Repair Quote Repairs
U = Urgent Follow-Up

Authorized Signature Service Technician

Crown 2005 PF15039 F Rev. 8/11 Printed in U.S.A.

Fig. 1 (27213)

M1.0-1970-002 TSP 7000 SERIES Crown 2012 PF25709-2

40
 LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Lubrication
The information that follows gives the correct intervals
for lubrication. Use high-grade lubricants and fluids.
Refer to the Lubricant Chart for the applicable lubri-
cants.
Note: You must change the lubrication and inspection
intervals to decrease corrosion and wear on parts for
trucks that operate in environments with low tempera-
tures, moisture, or that can cause contamination or cor-
rosion.
Apply rust preventative (078882) to all fasteners, wash-
ers, nuts, roll pins, retaining rings, etc. to prevent cor-
rosion.

Wire Guidance
On trucks that have Wire Guidance, do the wire guid-
ance planned maintenance. Refer to the "Wire Guid-
ance Planned Maintenance" check sheet.

Crown 2012 PF25709-3 TSP 7000 SERIES M1.0-1970-003

41
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Fig. 2 (27193)

M1.0-1970-004 TSP 7000 SERIES Crown 2012 PF25709-4

42
 LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Chart 1

Lubrication

Lube 60 Days 12 Months

Index Component Qty
Type 250 Hours 2000 Hours
L-1 Multi-Task Handle (Right) M AR Lubricate
L-2 Lift Chain C AR Lubricate
L-3 Side Gate Pivots C AR Lubricate
L-4 Seat Telescoping Tubes B AR Lubricate

Chart 2

Inspection And Adjustment

60 Days 6 Months
Index Component
250 Hours 1000 Hours
I-1 Multi-Task Handle (Left & Right) Check
I-2 Brake Operation Check
I-3 Brake Switch Check
I-4 Chain, Chain Anchors & Retainers Check
I-5 Chain Slack/Break Spring Collars & Switches Check
I-6 Gate Switches Check
I-7 Emergency Disconnect Check
I-8 Indicator Panel Lights & Switches Check
I-9 Floor Switches Check
I-10 Seat Switches Check
I-11 Steering Tiller Control Check
I-12 Key Switch Check
I-13 Electrical Connections Check
I-14 Height Sensor Check

Crown 2012 PF25709-5 TSP 7000 SERIES M1.0-1970-005

43
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Fig. 3 (27208)

M1.0-1970-006 TSP 7000 SERIES Crown 2012 PF25709-6

44
 LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Chart 3

Lubrication

Lube 60 Days 90 Days 6 Months 12 Months

Index Component Qty
Type 250 Hours 500 Hours 1000 Hours 2000 Hours
L-5 Battery Rollers B As Necessary Lubricate
L-6 Door Hinges C As Necessary Lubricate
L-7 Drive Unit Level A 7.1 liters Lubricate Change
L-8 Drive Unit Pivot B As Necessary Lubricate
L-9 Hydraulic Element As Necessary Change Change
L-10 Hydraulic Reservoir D(1) 56 liters Check Check Check Change
L-11 Hydraulic Breather As Necessary Change
L-12 Steering Gearbox D(1) 0.1 liters Lubricate
L-13 Steering Gears F As Necessary Lubricate
(1) Refer to the Notes on the Lubricants, Aerosols, & Service supplies charts to find the correct fluids to use in the environment in
which your truck operates.

Chart 4

Inspection And Adjustment

60 Days 6 Months
Index Component
250 Hours 1000 Hours
I-15 Battery & Battery Connectors Check
I-16 Brake Operation Check
I-17 Contactor Tips (EDI) Check
I-18 Drive Tire Check
I-19 Electrical Connections Check
I-20 Horn Check
I-21 Hydraulic Lines, Hoses & Fittings Check
I-22 Pump Motor (M2) Check
I-23 Steering Motor (M3) Check
I-24 Traction Motor (M1) Check
I-25 Power Unit & Mast Bolts - 8 Bolts Check
I-26 Power Unit Strobe or Flashing Light Check
I-27 Steering Gears Check

Crown 2012 PF25709-7 TSP 7000 SERIES M1.0-1970-007

45
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Fig. 4 (27209)

M1.0-1970-008 TSP 7000 SERIES Crown 2012 PF25709-8

46
 LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Chart 5

Lubrication

Lube 60 Days 12 Months

Index Component Qty
Type 250 Hours 2000 Hours
L-14 Load Wheel Axles B As Necessary Lubricate
L-15 Cylinder Yokes B As Necessary Lubricate
L-16 Hose Take-up Cables G As Necessary Lubricate
L-17 Hose Take-up Cam Rollers & Pulleys B As Necessary Lubricate
L-18 Hoses H As Necessary Lubricate
L-19 Lift Chain C As Necessary Lubricate
L-20 Mast Channels E As Necessary Lubricate
L-21 Mast Pulleys (Nylon) H As Necessary Lubricate
L-22 Mast Rollers E As Necessary Lubricate
L-23 Platform & Mast Column Rollers E As Necessary Lubricate
L-24 Rear Cover Hinge C As Necessary Lubricate
L-25 Turret Head Pivot (2 Lube Fittings) B As Necessary Lubricate

Chart 6

Inspection And Adjustment

60 Days 6 Months
Index Component
250 Hours 1000 Hours
I-28 Aisle Guide Wheels Check
I-29 Aisle Guide Switches Check
I-30 Load Wheels Check
I-31 Cable Tension Switches Check
I-32 Chain Anchors & Retainers Check
I-33 Column Rollers Check
I-34 Hose Take-Up Cables Check
I-35 Lift Chain Check
I-36 Lift Cylinder Check
I-37 Lift Cylinder Guides, Slides & Stops Check
I-38 Override Switches Check
I-39 Shock Absorbers Check

Crown 2012 PF25709-9 TSP 7000 SERIES M1.0-1970-009

47
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

TT MAST

TT Mast

Fig. 5 (27210)

M1.0-1970-010 TSP 7000 SERIES Crown 2012 PF25709-10

48
 LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Chart 7

Lubrication

Lube 60 Days 12 Months

Index Component Qty
Type 250 Hours 2000 Hours
L-26 Cylinder Yokes B As Necessary Lubricate
L-27 Hoses H As Necessary Lubricate
L-28 Lift Chain C As Necessary Lubricate
L-29 Mast Channels E As Necessary Lubricate
L-30 Mast Pulleys (Nylon) H As Necessary Lubricate
L-31 Mast Rollers E As Necessary Lubricate
L-32 Platform & Mast Column Rollers E As Necessary Lubricate
L-33 Chain Pulleys B As Necessary Lubricate

Chart 8

Inspection And Adjustment

60 Days 6 Months
Index Component
250 Hours 1000 Hours
I-40 Chain Anchors & Retainers Check
I-41 Column Rollers Check
I-42 Lift Chain Check
I-43 Lift Cylinder Check
I-44 Lift Cylinder Guides & Stops Check
I-45 Shock Absorbers Check
I-46 Chain Slack/Break Switches Check
I-47 Chain Couplers Check

Crown 2012 PF25709-11 TSP 7000 SERIES M1.0-1970-011

49
LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Fig. 6 (27211)

M1.0-1970-012 TSP 7000 SERIES Crown 2012 PF25709-12

50
 LUBRICATION & ADJUSTMENT
PLANNED MAINTENANCE

Chart 9

Lubrication

Lube 60 Days 12 Months

Index Component Qty
Type 250 Hours 2000 Hours
L-34 Cylinder Yoke B As Necessary Lubricate
L-35 Fork Slip Ring B As Necessary Lubricate
L-36 Lift Chain C As Necessary Lubricate
L-37 Mast Channels E As Necessary Lubricate
L-38 Mast Pulleys B As Necessary Lubricate
L-39 Mast Column Rollers E As Necessary Lubricate
L-40 Pivot Chain C As Necessary Lubricate
L-41 Pivot Cylinder Mount B As Necessary Lubricate
L-42 Fork Slides F As Necessary Lubricate
L-43 Traverse Gears F As Necessary Lubricate
L-44 Traverse Pinion (4 Lube Fittings) B As Necessary Lubricate
L-45 Traverse Racks F As Necessary Lubricate
L-46 Hydraulic Motor Chain C As Necessary Lubricate

Chart 10

Inspection And Adjustment

60 Days 6 Months
Index Component
250 Hours 1000 Hours
I-48 Chain Anchors & Retainers Check
I-49 Column Rollers & Channels Check
I-50 Forks Check
I-51 Hydraulic Lines, Hoses & Fittings Check
I-52 Lift Chain Check
I-53 Lift Cylinder Check
I-54 Lift Limit Switch Check
I-55 Pivot Cylinder Check
I-56 Hydraulic Motor Check
I-57 Traverse Limit Switches Check

Crown 2012 PF25709-13 TSP 7000 SERIES M1.0-1970-013

51
LUBRICATION & ADJUSTMENT
METRIC TORQUE VALUES

Metric Torque Values

It is important to tighten fasteners to the correct torque
value. This section shows the standard torque values
for the screws and bolts used in Crown trucks. Special
torque values in the maintenance and parts sections of
this manual override the standard torque values in this
section.

Grade

Grade Identification Bolt and Screw

Specification
(on Head) Size (mm)

5.8 Class 5.8 M5 through M36

8.8 Class 8.8 M5 through M36

10.9 Class 10.9 M5 through M36

12.9 Class 12.9 M5 through M36

NOTE: .Even though a bolt head is unmarked, Crown uses nothing less than class 8.8
in all of its bolted assemblies. Instances do occur when class 8.8 bolts are manufac-
tured unmarked. When a fastener is replaced that is unmarked, replace the fastener
with a class 8.8.

Figure 15048-01

M1.9-06.6-001 TSP 7000 SERIES Crown 1989 PF8514-1 Rev. 7/12

04 Rev. 7/12
52
 LUBRICATION & ADJUSTMENT
METRIC TORQUE VALUES

Torque Chart - Metric Hex Head Cap Screws and Nuts

Thread Diameter Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5-8 7-8 8 - 10
M6 x 1.00 8 - 10 12 - 14 15 - 16
M8 x 1.25 20 - 25 28 - 31 34 - 37
M10 x 1.50 39 - 43 56 - 61 68 - 75
M12 x 1.75 71 - 76 100 - 107 119 - 127
M14 x 2.00 113 - 122 159 - 171 190 - 205
M16 x 2.00 175 - 190 247 - 267 296 - 320
M20 x 2.50 340 357 479 - 518 574 - 621
M24 x 3.00 587 - 635 824 - 892 990 - 1071
M30 x 3.50 1175 - 1274 1654 - 1792 1985 - 2150
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.

Torque Chart - Metric Hex Socket Countersink Head Screws

Thread Diameter Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 4-7 5-8 7 - 10
M6 x 1.00 7 - 10 9 - 12 11 - 14
M8 x 1.25 16 - 19 23 - 26 27 - 30
M10 x 1.50 31 - 34 45 - 49 54 - 58
M12 x 1.75 56 - 60 79 - 84 94 - 102
M14 x 2.00
M16 x 2.00 124 - 146 190 - 206 228 - 247
M20 x 2.50 259 - 281 363 - 395 437 - 473
M24 x 3.00 416 - 451 586 - 635 702 - 762
M30 x 3.50
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.

Crown 1989 PF8514-2 Rev. 7/12 TSP 7000 SERIES M1.9-06.6-002

04 Rev. 7/12
53
LUBRICATION & ADJUSTMENT
METRIC TORQUE VALUES

Torque Chart - Metric Socket Head Cap Screws

Thread Diameter Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5-8 7-9 8 - 11
M6 x 1.00 9 - 12 12 - 15 15 - 18
M8 x 1.25 22 - 24 30 - 33 35 - 38
M10 x 1.50 42 - 45 58 - 64 71 - 76
M12 x 1.75 72 - 77 102 - 110 122 - 132
M14 x 2.00 115 - 125 161 - 175 194 - 210
M16 x 2.00 179 - 194 251 - 273 301 - 327
M20 x 2.50 348 - 377 489 - 530 588 - 637
M24 x 3.00 601 - 651 846 - 915 1014 - 1098
M30 x 3.50 1196 - 1296 1681 - 1822 2017 - 2187
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.

Torque Chart - Metric Flanged Hex Head Cap Screws and Nuts

Thread Diameter Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5-8 8 - 11 9 - 12
M6 x 1.00 9 - 12 14 - 16 16 - 19
M8 x 1.25 22 - 24 31 - 34 38 - 41
M10 x 1.50 44 - 48 62 - 68 75 - 81
M12 x 1.75 77 - 83 108 - 117 130 - 141
M14 x 2.00 123 - 134 174 - 187 209 - 225
M16 x 2.00 193 - 210 273 - 294 327 - 354
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.

M1.9-06.6-003 TSP 7000 SERIES Crown 1989 PF8514-3 Rev. 7/12

04 Rev. 7/12
54
 LUBRICATION & ADJUSTMENT
SAE TORQUE VALUES

SAE Torque Values Grade

It is important to tighten fasteners to the correct torque
value. This section shows the standard torque values
for the screws and bolts used in Crown trucks. Special
torque values in the maintenance and parts sections of
this manual override the standard torque values in this
section.

Grade Identifica- Bolt and Screw

Specification
tion(on Head) Size (Inches)

SAE - Grade 2 1/4 thru 1-1/2

SAE - Grade 5 1/4 thru 1-1/2

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 Grad 5 bolts are manufactured unmarked. When a fastener is re-
placed that is unmarked, replace the fastener with a Grade 5.

Fig. 7 (14916-01)

Crown 1979 PF5067-1 Rev. 6/12 TSP 7000 SERIES M1.9-14.0-001

05 Rev. 6/12
55
LUBRICATION & ADJUSTMENT
SAE TORQUE VALUES

Torque Chart

Bolt Grade 5 Grade 8

Diameter Dry Torque Specification Dry Torque Specification
in ft Ib kgm Nm ft lb 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
Torque specifications for bolts related to
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: Special torque values in the maintenance and parts sections of this manual override the
standard torque values in this section.

M1.9-14.0-001 TSP 7000 SERIES Crown 1979 PF5067-2 Rev. 6/12

05 Rev. 6/12
56
COMPONENTRY
57
Notes:

58
 COMPONENTRY
COMPONENTRY

Componentry
Introduction
The components in this section help the technician with
data for each component:
• The component designator (for example, ALM1)
that is on the electrical diagram and parts pages.
• The description of the component.
• The location of the component on the truck.
• The function of the component.
• The data of the component.
• The applicable adjustments.
• The electrical diagrams that the component is on. 2
numbers immediately follow the page number. The
first number (in parentheses) is the grid coordinate
and the second number (in parentheses) is the
manual page number (for example, DIA-1970-009
(C-2) (177)).
• The parts page that the component is on. 2 num-
bers immediately follow the page number. The first
number (in parentheses) is the component index
number and the second number (in parentheses) is
the manual page number (for example, 04.0-1970-
001 (1) (361)).

Crown 2012 PF25617-1 TSP 7000 SERIES M1.91-1970-001

59
COMPONENTRY
AUDIBLE INDICATORS

Audible Indicators
ALM1
Status Alarm
Location: ACCESS 1
Function: tells operator of changes in the truck status
Data: controlled through ACCESS 1
Adjustment: N/A
Diagrams: DIA-1970-003 (B-3)
DIA-1970-008 (C-1)
Parts Breakdown: 04.8-1960-252 (2)

ALM2
Travel Alarm (Optional)
Location: Contactor Panel
Function: audible indication when you move in for-
ward or in reverse
Data: 12 to 80 VDC (87 DB)
Adjustment: N/A
Diagrams: DIA-1970-002 (B-1)
DIA-1970-015 (C-4)
Parts Breakdown: 04.1-1970-003 (51)

HN
Horn
Location: power unit
Function: lets the operator give an audible indication
of the trucks location
Data: 72 to 80 VDC (105 to 118 DB)
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-015 (C-4)
Parts Breakdown: 04.0-1970-001 (7)

M1.91-1970-002 TSP 7000 SERIES Crown 2012 PF25617-2

60
 COMPONENTRY
BATTERY

Battery
BATT
Battery
Location: power unit
Function: supply power to the truck, components, and
sensors
Data: 72/80 VDC
Adjustment: N/A
Diagrams: DIA-1970-002 (B-4)
Parts Breakdown: N/A

Crown 2012 PF25617-3 TSP 7000 SERIES M1.91-1970-002

61
COMPONENTRY
CONTACTORS

Contactors
ED1
Emergency Disconnect
Location: contactor panel
Function: supply ability to turn OFF the power circuit
Data: 36 or 48 VDC, 54 ohms coil resistance, continu-
ous duty cycle
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-015 (C-3)
DIA-1970-025 (A-3)
Parts Breakdown: 04.1-1970-001 (5)

M1.91-1970-002 TSP 7000 SERIES Crown 2012 PF25617-4

62
 COMPONENTRY
CONTACTORS

Figure 26631

Crown 2012 PF25617-5 TSP 7000 SERIES M1.91-1970-003

63
COMPONENTRY
CONTACTORS

K2
Logic Power
Location: contactor panel
Function: supplies power to the control modules
Data: 48 VDC, 325 ohms coil resistance, continuous
duty cycle
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-015 (C-3)
DIA-1970-025 (B-3)
Parts Breakdown: 04.1-1970-001 (12)

K3
Logic Power
Location: contactor panel
Function: supplies power to the control modules
Data: 48 VDC, 325 ohms coil resistance, continuous
duty cycle
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-015 (C-4)
DIA-1970-025 (B-3)
Parts Breakdown: 04.1-1970-001 (12)

M1.91-1970-004 TSP 7000 SERIES Crown 2012 PF25617-6

64
 COMPONENTRY
ENCODERS

Encoders
ECR1
Steer Command Encoder
Location: left armrest
Function: supply steer command input to the steer
module
Data: 32 pulses for each revolution
Adjustment: N/A
Diagrams: DIA-1970-003 (A-1)
DIA-1970-021 (B-3)
Parts Breakdown: 04.5-1960-001 (13)

ECR2
Steer Command Encoder
Location: left armrest
Function: supply steer command input to the steer
module
Data: 32 pulses for each revolution
Adjustment: N/A
Diagrams: DIA-1970-003 (A-1)
DIA-1970-021 (B-3)
Parts Breakdown: 04.5-1960-001 (13)

ECR3
Auxiliary Mast Height Encoder
Location: auxiliary mast
Function: supply measured height and speed of forks
Data: 6.5 counts for each mm (166 counts per in)
Adjustment: N/A
Diagrams: DIA-1970-003 (B-3)
DIA-1970-024 (A-3)
Parts Breakdown: 07.7-1960-003 (46)

ECR4
Traverse Position Encoder
Location: load handler top
Function: supply position and speed of the traverse
drive
Data: 64 pulses for each revolution
Adjustment: N/A
Diagrams: DIA-1970-003 (B-3)
DIA-1970-024 (A-4)
Parts Breakdown: 09.1-1960-102 (39)

Crown 2012 PF25617-7 TSP 7000 SERIES M1.91-1970-004

65
COMPONENTRY
ENCODERS

Figure 26632

M1.91-1970-005 TSP 7000 SERIES Crown 2012 PF25617-8

66
 COMPONENTRY
ENCODERS

ECR5 ECR8
Height Sensing Encoder Pump Motor Encoder
Location: platform Location: internal to pump motor
Function: primary height sensor Function: give position and speed of pump motor
Data: 256 pulses for each revolution Data: 64 pulses for each revolution
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-1970-003 (A-2) Diagrams: DIA-1970-002 (C-3)
DIA-1970-009 (C-3) DIA-1970-018 (C-3)
Parts Breakdown: 09.0-1970-250 (20) Parts Breakdown: 02.2-1970-050 (22)

ECR6
Steering Feedback Encoder
Location: power unit
Function: supply steer wheel movement feedback to
the steer module
Data: 256 pulses for each revolution
Adjustment: N/A
Diagrams: DIA-1970-002 (C-2)
DIA-1970-016 (C-4)
Parts Breakdown: 06.0-1970-500 (3)

ECR7
Traction Speed Encoder
Location: internal to traction motor
Function: supply ground speed and direction to the
control system
Data: 64 pulses for each revolution
Adjustment: N/A
Diagrams: DIA-1970-002 (C-1)
DIA-1970-016 (C-3)
DIA-1970-023 (B-4)
Parts Breakdown: 03.1-1970-050 (9)

Crown 2012 PF25617-9 TSP 7000 SERIES M1.91-1970-006

67
COMPONENTRY
FUSES

Fuses
FU1
Control Fuse
Location: power unit distribution panel
Function: supply protection for the control circuit from
too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-003 (A-4)
DIA-1970-006 (B-2)
Parts Breakdown: 04.3-1970-001 (2)
04.3-1970-050 (3)

FU2
Battery Sense Fuse
Location: power unit distribution panel
Function: supply protection for battery sense and re-
lated wires from too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-006 (B-2)
Parts Breakdown: 04.3-1970-001 (2)
04.3-1970-050 (3)

M1.91-1970-006 TSP 7000 SERIES Crown 2012 PF25617-10

68
 COMPONENTRY
FUSES

Figure 26633

Crown 2012 PF25617-11 TSP 7000 SERIES M1.91-1970-007

69
COMPONENTRY
FUSES

FU3 Diagrams: DIA-1970-002 (A-4)

DIA-1970-003 (A-4)
Un-Switched Options DIA-1970-006 (B-3)
Location: power unit distribution panel Parts Breakdown: 04.3-1970-001 (2)
Function: supply protection for options and related 04.3-1970-050 (3)
wires from too much current
Data: 15 A
FU7
Adjustment: N/A Platform Logic
Diagrams: DIA-1970-002 (A-4) Location: power unit distribution panel
DIA-1970-003 (B-4) Function: supply protection for platform logic and re-
DIA-1970-006 (B-2) lated wires from too much current
Parts Breakdown: 04.3-1970-001 (2) Data: 15 A
04.3-1970-050 (3)
Adjustment: N/A
FU4 Diagrams: DIA-1970-002 (A-4)
DIA-1970-003 (A-4)
Drive and Tow Switch Fuse DIA-1970-006 (B-3)
Location: power unit distribution panel Parts Breakdown: 04.3-1970-001 (2)
Function: supply protection for the drive and tow 04.3-1970-050 (3)
switch and related wires from too much current
Data: 15 A
FU8
Adjustment: N/A Power Unit Logic and Flashing Light Fuse
Diagrams: DIA-1970-002 (A-4) Location: power unit distribution panel
DIA-1970-006 (B-2) Function: supply protection for power unit logic, flash-
Parts Breakdown: 04.3-1970-001 (2) ing light, and related wires from too much current
04.3-1970-050 (3) Data: 15 A
Adjustment: N/A
FU5
Diagrams: DIA-1970-002 (A-4)
Switched Options Fuse DIA-1970-006 (B-3)
Location: power unit distribution panel Parts Breakdown: 04.3-1970-001 (2)
Function: supply protection for options and related 04.3-1970-050 (3)
wires from too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-003 (A-4)
DIA-1970-006 (B-2)
Parts Breakdown: 04.3-1970-001 (2)
04.3-1970-050 (3)

FU6
Light and Fan Fuse
Location: power unit distribution panel
Function: supply protection for the light and fan, PS1
and related wires from too much current
Data: 15 A
Adjustment: N/A

M1.91-1970-008 TSP 7000 SERIES Crown 2012 PF25617-12

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 COMPONENTRY
FUSES

Figure 26634

Crown 2012 PF25617-13 TSP 7000 SERIES M1.91-1970-009

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COMPONENTRY
FUSES

FU9 FU13
Inner Coil Fuse ACCESS 5 (SCM) Power Fuse
Location: power unit distribution panel Location: contactor panel
Function: supply protection for the brake inner coil and Function: supply protection for ACCESS 5 and related
related wires from too much current wires from too much current
Data: 15 A Data: 50 A
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-1970-002 (B-2) Diagrams: DIA-1970-002 (A-2)
DIA-1970-006 (B-3) DIA-1970-025 (B-3)
Parts Breakdown: 04.3-1970-001 (2) Parts Breakdown: 04.1-1970-003 (48)
04.3-1970-050 (3)
FU14
FU10 12 V Accessory Fuse
Outer Coil Fuse Location: platform distribution panel
Location: power unit distribution panel Function: supply protection for 12 V accessories and
Function: supply protection for the outer coil and re- related wires from too much current
lated wires from too much current Data: 4 A
Data: 15 A Adjustment: N/A
Adjustment: N/A Diagrams: DIA-1970-003 (B-4)
Diagrams: DIA-1970-002 (B-2) DIA-1970-004 (B-2)
DIA-1970-006 (B-3) DIA-1970-005 (C-1)
Parts Breakdown: 04.3-1970-001 (2) Parts Breakdown: 04.3-1970-100 (5)
04.3-1970-050 (3) 04.3-1970-150 (5)

FU11
ACCESS 3 (TCM) Power Fuse
Location: contactor panel
Function: supply protection for ACCESS 3 and related
wires from too much current
Data: 400 A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-1)
DIA-1970-025 (B-2)
Parts Breakdown: 04.1-1970-003 (47)

FU12
ACCESS 2(HCM) Power Fuse
Location: contactor panel
Function: supply protection for ACCESS 2 and related
wires from too much current
Data: 500 A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-025 (B-2)
Parts Breakdown: 04.1-1970-003 (49)

M1.91-1970-010 TSP 7000 SERIES Crown 2012 PF25617-14

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 COMPONENTRY
FUSES

Figure 26635

Crown 2012 PF25617-15 TSP 7000 SERIES M1.91-1970-011

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COMPONENTRY
FUSES

FU15 FU17
Battery Negative Switched, Un-switched Options Battery Negative ACCESS 7 (ACM) Fuse
Fuse Location: platform distribution panel
Location: platform distribution panel Function: protect battery negative ACCESS 7 and re-
Function: supply protection for battery negative lated wires from too much current
switched, un-switched options and related wires from Data: 15 A
too much current
Adjustment: N/A
Data: 15 A
Diagrams: DIA-1970-003 (C-4)
Adjustment: N/A DIA-1970-004 (B-3)
Diagrams: DIA-1970-003 (C-4) DIA-1970-005 (A-2)
DIA-1970-004 (B-3) Parts Breakdown: 04.3-1970-100 (6)
DIA-1970-005 (A-2) 04.3-1970-150 (6)
Parts Breakdown: 04.3-1970-100 (6)
04.3-1970-150 (6) FU18
FU16 Battery Negative ACCESS 1 (DCM) ACCESS 8
(OCM) Fuse
Battery Negative Work Light 12 V Power Supply, Location: platform distribution panel
Fan Fuse
Function: protect battery negative ACCESS 1,
Location: platform distribution panel ACCESS 8, and related wires from too much current
Function: protect battery negative work dome power Data: 15 A
supply, fan, and related wires from too much current
Adjustment: N/A
Data: 15 A
Diagrams: DIA-1970-003 (C-4)
Adjustment: N/A DIA-1970-004 (B-3)
Diagrams: DIA-1970-003 (C-4) DIA-1970-005 (A-2)
DIA-1970-004 (B-3) Parts Breakdown: 04.3-1970-100 (6)
DIA-1970-005 (A-2) 04.3-1970-150 (6)
Parts Breakdown: 04.3-1970-100 (6)
04.3-1970-150 (6) FU19
Battery Negative ACCESS 4 (VCM) Fuse
Location: platform distribution panel
Function: protect battery negative ACCESS 4 and re-
lated wires from too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-1970-003 (C-4)
DIA-1970-004 (B-3)
DIA-1970-005 (A-2)
Parts Breakdown: 04.3-1970-100 (6)
04.3-1970-150 (6)

M1.91-1970-012 TSP 7000 SERIES Crown 2012 PF25617-16

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 COMPONENTRY
FUSES

Figure 26636

Crown 2012 PF25617-17 TSP 7000 SERIES M1.91-1970-013

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COMPONENTRY
FUSES

FU20 FU23
Work and Dome Lights Fuse Power Supply Fuse
Location: platform 12 V supply in Location: power supply PS4
Function: supply protection for the work and dome Function: supply protection for 48 V circuits and re-
lights and related wires from too much current lated wires from too much current
Data: 15 A Data: 15 A
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-1970-003 (B-4) Diagrams: DIA-1970-002 (A-4)
DIA-1970-008 (C-2) DIA-1970-019 (C-3)
Parts Breakdown: 04.5-1960-102 (18) DIA-1970-025 (B-4)
Parts Breakdown: 04.0-1970-005 (92)
FU21
Work and Dome Lights Fuse
Location: platform 12 V supply out
Function: supply protection for the work and dome
lights and related wires from too much current
Data: 15 A (7.5 A Optional EE)
Adjustment: N/A
Diagrams: DIA-1970-003 (B-4)
DIA-1970-008 (C-3)
Parts Breakdown: 04.5-1960-102 (18)

FU22
Power Supply Fuse
Location: power supply PS3
Function: supply protection for 48 V circuits and re-
lated wires from too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-1970-002 (A-4)
DIA-1970-019 (C-2)
DIA-1970-025 (A-4)
Parts Breakdown: 04.0-1970-005 (92)

M1.91-1970-014 TSP 7000 SERIES Crown 2012 PF25617-18

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 COMPONENTRY
LIGHTS

Lights
LGT1
Strobe or Flashing Light (Optional)
Location: power unit
Function: visual warning of the lift trucks location
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-2)
DIA-1970-015 (C-1)
Parts Breakdown: 04.9-1970-001 (1)

LGT2
Dome Light
Location: overhead guard
Function: supply light for the operator compartment
Data: 12 V
Adjustment: N/A
Diagrams: DIA-1970-007 (C-3)
Parts Breakdown: 04.0-1970-202 (45)

Crown 2012 PF25617-19 TSP 7000 SERIES M1.91-1970-014

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COMPONENTRY
LIGHTS

Power Supply

Figure 26637

M1.91-1970-015 TSP 7000 SERIES Crown 2012 PF25617-20

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 COMPONENTRY
LIGHTS

LGT3 LGT6
Dome Light Worklight (Optional)
Location: overhead guard Location: overhead guard
Function: supply light for the operator compartment Function: supply work area light outside the operator
Data: 12 V compartment
Adjustment: N/A Data: 48 V
Diagrams: DIA-1970-007 (C-3) Adjustment: limited direction of beam direction
Parts Breakdown: 04.0-1970-202 (45) Diagrams: DIA-1970-007 (C-4)
Parts Breakdown: 04.0-1970-202 (38)
LGT4
LGT7
Left and Right Worklights
Worklight (Optional)
Location: overhead guard
Location: overhead guard
Function: supply work area light outside the operator
compartment Function: supply work area light outside the operator
compartment
Data: 48 V
Data: 48 V
Adjustment: limited adjustment of beam direction
Adjustment: limited direction of beam direction
Diagrams: DIA-1970-007 (C-3)
Diagrams: DIA-1970-007 (C-1)
Parts Breakdown: 04.0-1970-202 (60)
Parts Breakdown: 04.0-1970-202 (38)
LGT5
LGT8
Left and Right Worklights
Strobe or Flashing Light (Optional)
Location: overhead guard
Location: under platform
Function: supply work area light outside the operator
compartment Function: visual warning of the lift trucks location
Data: 48 V Data: N/A
Adjustment: limited direction of beam direction Adjustment: N/A
Diagrams: DIA-1970-007 (C-1) Diagrams: DIA-1970-012 (B-4)
Parts Breakdown: 04.0-1970-202 (60) Parts Breakdown: 04.0-1970-200 (4)

Crown 2012 PF25617-21 TSP 7000 SERIES M1.91-1970-016

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COMPONENTRY
LIGHTS

Figure 26638

M1.91-1970-017 TSP 7000 SERIES Crown 2012 PF25617-22

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 COMPONENTRY
LIGHTS

LGT9
Strobe or Flashing Light (Optional)
Location: under platform
Function: visual warning of the lift trucks location
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-012 (B-4)
Parts Breakdown: 04.0-1970-200 (4)

Crown 2012 PF25617-23 TSP 7000 SERIES M1.91-1970-018

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COMPONENTRY
MISCELLANEOUS

Miscellaneous FAN3
Cooling Fan for ACCESS 2 (HCM)
BRK
Location: power unit
Brake Function: cooling for ACCESS 2 module
Location: Traction Motor Data: N/A
Function: supply braking force to traction motor to Adjustment: N/A
stop the truck and prevent movement of a parked truck
Diagrams: DIA-1970-002 (B-3)
Data: N/A DIA-1970-017 (B-2)
Adjustment: N/A Parts Breakdown: 04.0-1970-005 (74)
Diagrams: DIA-1970-002 (B-2)
DIA-1970-016 (B-1)
Parts Breakdown: 04.0-1970-001
05.3-1960-001

EAC Distribution Panel

Location: mainframe bumper
Function: supply central connection point for end aisle
control sensors
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-022 (A-2)
Parts Breakdown: 10.4-1970-300 (15)
10.4-1970-450 (15)

FAN1
Operator Fan Right Side (Optional)
Location: overhead guard
Function: operator comfort
Data: 48 V
Adjustment: limited adjustment of the air flow direction
Diagrams: DIA-1970-007 (C-1)
Parts Breakdown: 04.0-1970-202 (42)
04.9-1960-050 (10)

FAN2
Operator Fan Left Side (Optional)
Location: overhead guard
Function: operator comfort
Data: 48 V
Adjustment: limited adjustment of the air flow direction
Diagrams: DIA-1970-007 (C-4)
Parts Breakdown: 04.0-1970-202 (42)

M1.91-1970-018 TSP 7000 SERIES Crown 2012 PF25617-24

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 COMPONENTRY
MISCELLANEOUS

EAC
Distribution Panel

Figure 26639

Crown 2012 PF25617-25 TSP 7000 SERIES M1.91-1970-019

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COMPONENTRY
MISCELLANEOUS

FSB1 P1
Feedback Splitter Hydraulic Pump
Location: traction motor Location: mainframe
Function: traction motor feedback splitter Function: supply hydraulic fluid flow for the hydraulic
Data: N/A functions
Adjustment: N/A Data: 28 cc displacement
Diagrams: DIA-1970-002 (B-1) Adjustment: N/A
DIA-1970-016 (B-2) Diagrams: HYD-1970-001
DIA-1970-023 (B-2) Parts Breakdown: 02.1-1970-001 (1)
Parts Breakdown: 04.0-1970-001 (17)
PS1
FSB2
Power Supply
Feedback Splitter (Optional) Location: console
Location: rear PDS sensor bracket Function: supply 12 V for fan and lights package
Function: traction motor feedback splitter Data: 36 V or 48 V in, 12.0 V out
Data: N/A Adjustment: N/A
Adjustment: N/A Diagrams: DIA-1970-003 (B-4)
Diagrams: DIA-1970-023 (B-2) DIA-1970-008 (C-3)
Parts Breakdown: Not available Parts Breakdown: 04.5-1960-102 (18)
04.5-1970-150 (18)
JC
PS2
12 V Receptacle
Location: console Power Supply (Optional)
Function: 12 V receptacle Location: platform
Data: N/A Function: supply power for the platform strobe light
Adjustment: N/A Data: N/A
Diagrams: DIA-1970-008 (B-3) Adjustment: N/A
Parts Breakdown: 04.5-1960-102 (13) Diagrams: DIA-1970-012 (B-3)
04.5-1970-150 (13) Parts Breakdown: 04.0-1970-200 (6)

M1.91-1970-020 TSP 7000 SERIES Crown 2012 PF25617-26

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 COMPONENTRY
MISCELLANEOUS

Figure 26640

Crown 2012 PF25617-27 TSP 7000 SERIES M1.91-1970-021

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COMPONENTRY
MISCELLANEOUS

Hydraulic Reservoir
Location: mainframe
Function: hydraulic oil storage
Data: 48.5 liters (12.8 gallons)
Adjustment: N/A
Diagrams: HYD-1970-001
Parts Breakdown: 02.0-1970-001 (8)

M1.91-1970-021 TSP 7000 SERIES Crown 2012 PF25617-28

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 COMPONENTRY
MODULES

Modules ACCESS 3
Traction Control Module
ACCESS 1
Location: power unit left rear
Display Module Function: control traction operation
Location: left post of platform Data: 72 V or 80 V input
Function: display for operator information (including Adjustment: N/A
direction, speed, and position), service mode mes-
Diagrams: DIA-1970-002 (B-1)
sages and indicators
DIA-1970-013 (B-1)
Data: 22 V to 55 V input DIA-1970-025 (B-4)
Adjustment: N/A Parts Breakdown: 04.0-1970-003 (36)
Diagrams: DIA-1970-003 (B-3)
DIA-1970-008 (B-1) ACCESS 4
Parts Breakdown: 04.8-1960-252 (2) Vehicle Control Module
ACCESS 2 Location: platform
Function: control truck operation
Hydraulic Control Module
Data: 22 V to 55 V input
Location: power unit right rear
Adjustment: N/A
Function: controls hydraulic motor, hydraulic sole-
Diagrams: DIA-1970-003 (B-2)
noids, and reads CTS and HCS
DIA-1970-010 (B-1)
Data: 72 V or 80 V input
Parts Breakdown: 04.8-1960-252 (8)
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3) ACCESS 5
DIA-1970-017 (B-1)
DIA-1970-025 (B-2) Steering Control Module

Parts Breakdown: 04.0-1970-005 (70) Location: power unit left rear

Function: control steering operation
Data: 22 V to 55 V Logic Board
33 V to 92 V Power Bridge
Adjustment: N/A
Diagrams: DIA-1970-002 (B-2)
DIA-1970-014 (B-1)
DIA-1970-025 (C-4)
Parts Breakdown: 04.0-1970-003 (47)

Crown 2012 PF25617-29 TSP 7000 SERIES M1.91-1970-022

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COMPONENTRY
MODULES

Hydraulic
Reservoir

Figure 26641

M1.91-1970-023 TSP 7000 SERIES Crown 2012 PF25617-30

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 COMPONENTRY
MODULES

ACCESS 6
Guidance Control Module (Optional)
Location: power unit right rear
Function: controls automatic guidance system and
EAC (wire guidance)
Data: 22 V to 55 V input
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-022 (B-1)
Parts Breakdown: 04.0-1970-001 (10)

ACCESS 7
Accessory Control Module
Location: load handler
Function: controls load handler hydraulic valves and
reads POT5, EAC3, EAC4, FHSL, FHSR, HGTRS2,
TVRS switches and LS
Data: 22 V to 55 V input
Adjustment: N/A
Diagrams: DIA-1970-003 (B-3)
DIA-1970-024 (B-1)
Parts Breakdown: 09.1-1960-154 (16)

ACCESS 8
Operator Control Module
Location: right armrest
Function: supply data from the operator controlled in-
puts
Data: 22 V to 55 V input
Adjustment: N/A
Diagrams: DIA-1970-003 (B-1)
DIA-1970-020 (B-1)
Parts Breakdown: 04.6-1970-003 (46)

Crown 2012 PF25617-31 TSP 7000 SERIES M1.91-1970-024

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COMPONENTRY
MOTORS

Motors
M1
AC Traction Motor
Location: drive unit
Function: supply driving force for traction
Data: 7.3 KW output
Adjustment: N/A
Diagrams: DIA-1970-002 (B-1)
DIA-1970-016 (C-3)
DIA-1970-025 (C-3)
Parts Breakdown: 03.1-1970-050

M2
AC Hydraulic Pump Motor
Location: mainframe
Function: supply driving force for hydraulic pump sup-
plying hydraulic oil flow for lift, traverse, and pivot
Data: 21.2 KW output
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-018 (B-3)
DIA-1970-025 (B-1)
Parts Breakdown: 02.2-1970-050

M3
Steering Motor
Location: drive unit
Function: supply driving force for steering
Data: 72 V or 80 V
Adjustment: N/A
Diagrams: DIA-1970-002 (B-2)
DIA-1970-025 (C-2)
Parts Breakdown: 06.2-1970-050 (1)

M1.91-1970-024 TSP 7000 SERIES Crown 2012 PF25617-32

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 COMPONENTRY
MOTORS

Figure 26642

Crown 2012 PF25617-33 TSP 7000 SERIES M1.91-1970-025

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COMPONENTRY
POTENTIOMETERS

Potentiometers POT5
Pivot Position
POT1
Location: load handler
Traction Command Function: supply pivot position input to ACCESS 7
Location: right armrest Data: N/A
Function: supply traction input to ACCESS 3 Adjustment: N/A
Data: N/A Diagrams: DIA-1970-003 (B-3)
Adjustment: N/A DIA-1970-024 (A-4)
Diagrams: DIA-1970-003 (B-1) Parts Breakdown: 09.1-1960-154 (2)
DIA-1970-020 (B-2)
Parts Breakdown: 04.6-1960-001 (14)

POT2
Main Hoist Raise and Lower
Location: right armrest
Function: supply raise and lower input to ACCESS 8
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-003 (B-1)
DIA-1970-020 (B-2)
Parts Breakdown: 04.6-1960-001 (15)

POT3
Auxiliary Hoist Raise and Lower
Location: left armrest
Function: supply raise and lower input to ACCESS 8
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-003 (A-1)
DIA-1970-021 (C-2)
Parts Breakdown: 04.5-1960-001 (6)

POT4
Traverse Command
Location: right armrest
Function: supply traverse input to ACCESS 8
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-DIA-1970-003 (B-1)
DIA-1970-020 (B-2)
Parts Breakdown: 04.6-1970-001 (2)

M1.91-1970-026 TSP 7000 SERIES Crown 2012 PF25617-34

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 COMPONENTRY
RELAYS

Relays
K1
Power Up Relay
Location: platform distribution panel
Function: supply control circuit power
Data: 48 V
Adjustment: N/A
Diagrams: DIA-1970-003 (B-4)
DIA-1970-005 (C-2)
Parts Breakdown: 04.3-1970-100 (7)
04.3-1970-150 (7)

Crown 2012 PF25617-35 TSP 7000 SERIES M1.91-1970-027

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COMPONENTRY
RELAYS

Figure 26643

M1.91-1970-027 TSP 7000 SERIES Crown 2012 PF25617-36

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 COMPONENTRY
RESISTORS

Resistors RES5
Travel Alarm Resistor
RES1
Location: contactor panel
Drive Tow Resistor Function: override switch
Location: contactor panel Data: 8 Ω
Function: dropping resistor for drive tow
Adjustment: N/A
Data: 10 Ω Diagrams: DIA-1970-002 (C-3)
Adjustment: N/A DIA-1970-006 (A-1)
Diagrams: DIA-1970-002 (B-2) Parts Breakdown: 04.1-1970-001 (10)
DIA-1970-006 (A-1)
Parts Breakdown: 04.1-1970-001 (9) RES6
CTS Heater (Optional)
RES2
Location: mast
Drive Tow Resistor Function: CTS heater (freezer option)
Location: contactor panel Data: 500 Ω, 25 W
Function: dropping resistor for drive tow
Adjustment: N/A
Data: 10 Ω Diagrams: DIA-1970-002 (B-3)
Adjustment: N/A DIA-1970-018 (B-3)
Diagrams: DIA-1970-002 (B-2) Parts Breakdown: 07.5-1970-204 (51)
DIA-1970-006 (A-1)
Parts Breakdown: 04.1-1970-001 (9)

RES3
CAN Balancing Resistor
Location: load handler (inside wire harness)
Function: CAN balancing resistor
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-003 (B-3)
DIA-1970-024 (B-3)
Parts Breakdown: N/A

RES4
Travel Alarm Resistor
Location: contactor panel
Function: travel alarm
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-1)
DIA-1970-015 (C-4)
Parts Breakdown: 04.1-1970-003 (53)

Crown 2012 PF25617-37 TSP 7000 SERIES M1.91-1970-028

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COMPONENTRY
RESISTORS

(Inside wire har-

ness)

Figure 26644

M1.91-1970-029 TSP 7000 SERIES Crown 2012 PF25617-38

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 COMPONENTRY
RESISTORS

RES7 RES10
EDS Heater (Optional) Drive Tow Resistor
Location: right armrest Location: contactor panel
Function: EDS heater (freezer condition) Function: dropping resistor for drive tow
Data: 24 V, 2 W Data: 10 Ω
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-1970-003 (C-1) Diagrams: DIA-1970-002 (B-2)
DIA-1970-020 (B-2) DIA-1970-006 (A-1)
Parts Breakdown: 04.6-1970-001 (30) Parts Breakdown: 04.1-1970-001 (9)

RES8
SPS Heater (Optional)
Location: platform
Function: SPS heater (freezer condition)
Data: 500 Ω, 25 W
Adjustment: N/A
Diagrams: DIA-1970-003 (A-2)
DIA-1970-011 (C-2)
Parts Breakdown: 09.0-1970-156 (130)

RES9
Drive Tow Resistor
Location: contactor panel
Function: dropping resistor for drive tow
Data: 10 Ω
Adjustment: N/A
Diagrams: DIA-1970-002 (B-2)
DIA-1970-006 (A-1)
Parts Breakdown: 04.1-1970-001 (9)

Crown 2012 PF25617-39 TSP 7000 SERIES M1.91-1970-030

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COMPONENTRY
SENSORS

Sensors
CS1
Current Monitor
Location: contactor panel
Function: monitor current through BDI to determine
battery status
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-2)
DIA-1970-015 (C-1)
Parts Breakdown: 04.1-1970-003 (29)

EACA1
End Aisle Control A1
Location: mainframe bumper
Function: to signal the operator of the end or intersec-
tion of the aisle
Data: 12 V
Adjustment: N/A
Diagrams: DIA-1970-002 (C-4)
DIA-1970-022 (A-1)
Parts Breakdown: 10.4-1970-300 (21)
10.4-1970-450 (21)

M1.91-1970-030 TSP 7000 SERIES Crown 2012 PF25617-40

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 COMPONENTRY
SENSORS

Figure 26645

Crown 2012 PF25617-41 TSP 7000 SERIES M1.91-1970-031

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COMPONENTRY
SENSORS

EACA2 Parts Breakdown: 06.7-1960-001 (8)

End Aisle Control A2 GS2

Location: mainframe bumper
Load Wheel Sensor Bar
Function: to signal the operator of the end or intersec-
Location: mainframe
tion of the aisle
Function: sense signal strength from guide wire em-
Data: 12 V
bedded in floor
Adjustment: N/A
Data: N/A
Diagrams: DIA-1970-002 (C-4)
Adjustment: sensor bar 82 to 86 mm (3.25 to 3.38 in)
DIA-1970-022 (A-3)
from floor
Parts Breakdown: 10.4-1970-300 (21)
Diagrams: DIA-1970-002 (B-3)
10.4-1970-450 (21)
DIA-1970-022 (A-4)
EACB1 Parts Breakdown: 06.7-1960-001 (1)

End Aisle Control B1 LS

Location: mainframe bumper
Load Sense
Function: to signal the operator of the end or intersec-
Location: load handler
tion of the aisle
Function: supply approximate weight measurement
Data: 12 V
on forks for data capacity monitor
Adjustment: N/A
Data: N/A
Diagrams: DIA-1970-002 (C-3)
Adjustment: N/A
DIA-1970-022 (A-1)
Diagrams: DIA-1970-003 (B-3)
Parts Breakdown: 10.4-1970-300 (21)
DIA-1970-024 (A-2)
10.4-1970-450 (21)
Parts Breakdown: 02.0-1960-200 (35)
EACB2
End Aisle Control B2
Location: mainframe bumper
Function: to signal the operator of the end or intersec-
tion of the aisle
Data: 12 V
Adjustment: N/A
Diagrams: DIA-1970-002 (C-4)
DIA-1970-022 (A-3)
Parts Breakdown: 10.4-1970-300 (21)
10.4-1970-450 (21)

GS1
Steer Wheel Sensor Bar
Location: power unit
Function: sense signal strength from guide wire em-
bedded in floor
Data: N/A
Adjustment: sensor bar 82 to 86 mm from floor
Diagrams: DIA-1970-002 (B-4)
DIA-1970-022 (A-3)

M1.91-1970-032 TSP 7000 SERIES Crown 2012 PF25617-42

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SENSORS

Figure 26646

Crown 2012 PF25617-43 TSP 7000 SERIES M1.91-1970-033

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SENSORS

TS1 TS5
Temperature Sensor Temperature Sensor (Optional)
Location: traction motor M1 Location: hydraulic reservoir
Function: monitor motor temperature Function: monitor hydraulic oil temperature (freezer
Data: N/A condition)
Adjustment: N/A Data: N/A
Diagrams: DIA-1970-002 (C-1) Adjustment: N/A
DIA-1970-016 (C-3) Diagrams: DIA-1970-002 (B-3)
DIA-1970-023 (B-4) DIA-1970-019 (C-3)
Parts Breakdown: 03.1-1970-050 Parts Breakdown: 02.0-1970-001 (17)

TS2
Temperature Sensor
Location: hydraulic motor M2
Function: monitor motor temperature
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-018 (B-3)
Parts Breakdown: 02.2-1970-050

TS3
Temperature Sensor (Optional)
Location: platform (near ACCESS 4)
Function: monitor ambient temperature at platform
(freezer condition)
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-003 (A-2)
DIA-1970-010 (B-4)
Parts Breakdown: N/A

TS4
Temperature Sensor (Optional)
Location: power unit (near CA416)
Function: monitor ambient temperature at power unit
(freezer condition)
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-018 (B-3)
Parts Breakdown: N/A

M1.91-1970-034 TSP 7000 SERIES Crown 2012 PF25617-44

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 COMPONENTRY
SENSORS

Hydraulic Reservoir

Figure 26647

Crown 2012 PF25617-45 TSP 7000 SERIES M1.91-1970-035

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COMPONENTRY
SOLENOID VALVES

Solenoid Valves PVAL

Proportional Auxiliary Lower Valve
EML
Location: load handler manifold
Seat Locking Solenoid Function: supply proportional flow control of auxiliary
Location: bottom of the operator seat lower functions
Function: locks the operator seat in position Data: N/A
Data: N/A Adjustment: N/A
Adjustment: N/A Diagrams: HYD-1970-001
Diagrams: DIA-1970-003 (A-2) DIA-1970-003 (A-3)
DIA-1970-011 (C-2) DIA-1970-024 (B-1)
Parts Breakdown: 09.0-1970-156 (111) Parts Breakdown: 02.4-1960-054 (6)

MVL PVAR
Manual Valve Lowering Proportional Auxiliary Raise Valve
Location: power unit in mainframe manifold Location: load handler manifold
Function: supply means to lower the platform with no Function: supply proportional flow control of auxiliary
power to the truck raise functions
Data: N/A Data: N/A
Adjustment: 1 to 2 mm (0.04 to 0.08 in) gap between Adjustment: N/A
M6 nut and release beam Diagrams: HYD-1970-001
Diagrams: HYD-1970-001 DIA-1970-003 (A-3)
DIA-1970-024 (A-1)
Parts Breakdown: 02.4-1970-001 (14)
Parts Breakdown: 02.4-1960-054 (6)
PVML
PVF1
Main Lower Proportional Valve
Proportional Fork Extend Valve
Location: mainframe lift pump
Location: load handler manifold
Function: start/stop; load holding to prevent platform
drift Function: supply proportional flow control of fork ex-
tend
Data: N/A
Data: N/A
Adjustment: N/A
Adjustment: N/A
Diagrams: HYD-1970-001
DIA-1970-002 (B-3) Diagrams: HYD-1970-001
DIA-1970-018 (C-2) DIA-1970-003 (B-3)
DIA-1970-024 (A-1)
Parts Breakdown: 02.1-1970-001 (5)
Parts Breakdown: 02.4-1960-056 (30)

M1.91-1970-036 TSP 7000 SERIES Crown 2012 PF25617-46

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SOLENOID VALVES

Figure 26648

Crown 2012 PF25617-47 TSP 7000 SERIES M1.91-1970-037

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COMPONENTRY
SOLENOID VALVES

PVF2 Diagrams: HYD-1970-001

DIA-1970-003 (A-3)
Proportional Fork Retract Valve DIA-1970-024 (B-1)
Location: load handler manifold Parts Breakdown: 02.4-1960-056 (28)
Function: supply proportional flow control of fork re-
tract PVT1
Data: N/A Proportional Traverse Valve
Adjustment: N/A Location: load handler manifold
Diagrams: HYD-1970-001 Function: supply proportional flow to the traverse hy-
DIA-1970-003 (B-3) draulic motor for each operator request
DIA-1970-024 (A-2)
Data: N/A
Parts Breakdown: 02.4-1960-056 (30)
Adjustment: N/A
PVLH Diagrams: HYD-1970-001
DIA-1970-003 (A-3)
Proportional Relief Valve DIA-1970-024 (B-1)
Location: load handler manifold Parts Breakdown: 02.4-1960-056 (29)
Function: supply proportional control of auxiliary relief
pressure setting PVT2
Data: N/A Proportional Traverse Valve
Adjustment: N/A Location: load handler manifold
Diagrams: HYD-1970-001 Function: supply proportional flow to the traverse hy-
DIA-1970-003 (B-3) draulic motor for each operator request
DIA-1970-024 (B-1)
Data: N/A
Parts Breakdown: 02.4-1960-054 (7)
Adjustment: N/A
PVP1 Diagrams: HYD-1970-001
DIA-1970-003 (A-3)
Proportional Pivot Valve DIA-1970-024 (B-1)
Location: load handler manifold Parts Breakdown: 02.4-1960-056 (29)
Function: supply proportional flow to the pivot cylinder
per operator request, CW or CCW
Data: N/A
Adjustment: N/A
Diagrams: HYD-1970-001
DIA-1970-003 (A-3)
DIA-1970-024 (B-1)
Parts Breakdown: 02.4-1960-056 (28)

PVP2
Proportional Pivot Valve
Location: load handler manifold
Function: supply proportional flow to the pivot cylinder
for each operator request, CW or CCW
Data: N/A
Adjustment: N/A

M1.91-1970-038 TSP 7000 SERIES Crown 2012 PF25617-48

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 COMPONENTRY
SOLENOID VALVES

Figure 26649

Crown 2012 PF25617-49 TSP 7000 SERIES M1.91-1970-039

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SOLENOID VALVES

SVA Diagrams: HYD-1970-001

DIA-1970-002 (B-3)
Auxiliary Solenoid Valve DIA-1970-018 (B-2)
Location: mainframe manifold Parts Breakdown: 02.4-1970-001 (18)
Function: transmits hydraulic oil for all auxiliary load
handler functions
Data: N/A
Adjustment: N/A
Diagrams: HYD-1970-001
DIA-1970-002 (B-3)
DIA-1970-018 (B-2)
Parts Breakdown: 02.4-1970-003 (33)

SVAL
Velocity Fuse
Location: auxiliary cylinder base
Function: to stop the lift cylinder from lowering if speed
exceeds 36.5 m/min
Data: N/A
Adjustment: N/A
Diagrams: HYD-1970-001
DIA-1970-003 (B-3)
DIA-1970-024 (A-2)
Parts Breakdown: 02.0-1960-200 (33)

SVML
Main Lower Solenoid Valve
Location: mainframe manifold
Function: directs the flow to lower the main lift cylin-
ders
Data: N/A
Adjustment: N/A
Diagrams: HYD-1970-001
DIA-1970-002 (B-3)
DIA-1970-018 (B-2)
Parts Breakdown: 02.4-1970-003 (32)

SVMR
Main Raise Solenoid Valve
Location: mainframe manifold
Function: directs the flow to raise the main lift cylin-
ders
Data: N/A
Adjustment: N/A

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SUPPRESSOR BLOCKS

Suppressor Blocks
SB11
Key Switch Suppressor Block
Location: platform distribution panel
Function: key switch suppression
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-003 (B-4)
DIA-1970-004 (B-2)
Parts Breakdown: 04.3-1970-100 (13)
04.3-1970-150 (15)

SB31
Operator Fan Suppressor
Location: platform
Function: suppress electrical noise
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-007 (C-2)
Parts Breakdown: 04.0-1970-202 (42)

Crown 2012 PF25617-51 TSP 7000 SERIES M1.91-1970-040

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COMPONENTRY
SUPPRESSOR BLOCKS

Figure 26650

M1.91-1970-041 TSP 7000 SERIES Crown 2012 PF25617-52

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SUPPRESSOR BLOCKS

SB32
EE Operator Fan Suppressor
Location: platform
Function: suppress electrical noise
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-007 (C-2)
Parts Breakdown: 04.9-1960-050 (13)

SB41
ACCESS 2 Cooling Fan Suppressor (Optional)
Location: power unit, ACCESS 2 (HCM) fan bracket
Function: suppress electrical noise
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-002 (B-3)
DIA-1970-017 (B-2)
Parts Breakdown: 04.0-1970-005 (75)

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SWITCHES

Switches
APS
Auto Pivot Switch
Location: left armrest
Function: auto pivot switch
Data: normally open
Adjustment: N/A
Diagrams: DIA-1970-003 (B-1)
DIA-1970-021 (B-2)
Parts Breakdown: 04.5-1960-001 (7)

BRES
Battery Restraint Switch (Optional)
Location: power unit left side
Function: battery restraint switch
Data: normally closed
Adjustment: N/A
Diagrams: DIA-1970-002 (B-1)
DIA-1970-014 (C-4)
Parts Breakdown: 04.0-1970-003 (54)

BRS1
Brake Switch, Right Brake Pedal
Location: platform below floorboard
Function: lets the operator apply or release the brakes
Data: normally closed
Adjustment: N/A
Diagrams: DIA-1970-003 (B-2)
DIA-1970-012 (B-2)
Parts Breakdown: 09.2-1960-001 (5)

BRS2
Brake Switch, Right Brake Pedal
Location: platform below floorboard
Function: lets the operator apply or release the brakes
Data: normally closed
Adjustment: N/A
Diagrams: DIA-1970-003 (B-2)
DIA-1970-012 (B-2)
Parts Breakdown: 09.2-1960-001 (5)

M1.91-1970-042 TSP 7000 SERIES Crown 2012 PF25617-54

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 COMPONENTRY
SWITCHES

Located on the left side of

the power unit

Figure 26736

Crown 2012 PF25617-55 TSP 7000 SERIES M1.91-1970-043

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SWITCHES

BRS3 CHS2
Brake Switch, Left Brake Pedal Chain Slack Switch
Location: platform below floorboard Location: base of platform
Function: lets the operator apply or release the brakes Function: prohibits lowering if the mast chains be-
Data: normally closed come slack
Adjustment: N/A Data: normally closed
Diagrams: DIA-1970-003 (B-2) Adjustment: 1.5 to 4 mm air gap between the sensor
DIA-1970-012 (B-3) and spring collar
Parts Breakdown: 09.2-1960-001 (5) Diagrams: DIA-1970-003 (B-2)
DIA-1970-009 (C-2)
BRS4 Parts Breakdown: 07.6-1970-001 (11)
07.6-1970-100 (16)
Brake Switch, Left Brake Pedal
Location: platform below floorboard CHS3
Function: lets the operator apply or release the brakes
Chain Break Switch
Data: normally closed
Location: base of platform
Adjustment: N/A
Function: prohibits raising of lowering if the mast
Diagrams: DIA-1970-003 (B-2) chains become slack
DIA-1970-012 (B-3)
Data: normally closed
Parts Breakdown: 09.2-1960-001 (5)
Adjustment: 1.5 to 4 mm air gap between the sensor
and spring collar
CHS1
Diagrams: DIA-1970-003 (B-2)
Chain Slack Switch DIA-1970-009 (B-2)
Location: base of platform Parts Breakdown: 07.6-1970-001 (14)
Function: prohibits lowering if the mast chains be- 07.6-1970-100 (16)
come slack
Data: normally closed
CHS4
Adjustment: 1.5 to 4 mm air gap between the sensor Chain Break Switch
and spring collar Location: base of platform
Diagrams: DIA-1970-003 (B-2) Function: prohibits raising or lowering if the mast
DIA-1970-009 (B-2) chains become slack
Parts Breakdown: 07.6-1970-001 (10) Data: normally closed
07.6-1970-100 (16)
Adjustment: 1.5 to 4 mm air gap between the sensor
and spring collar
Diagrams: DIA-1970-003 (B-2)
DIA-1970-009 (C-2)
Parts Breakdown: 07.6-1970-001 (15)
07.6-1970-100 (16)

M1.91-1970-044 TSP 7000 SERIES Crown 2012 PF25617-56

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SWITCHES

Figure 26737

Crown 2012 PF25617-57 TSP 7000 SERIES M1.91-1970-045

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SWITCHES

CHS5 Diagrams: DIA-1970-002 (B-3)

DIA-1970-018 (C-4)
Chain Slack Switch Parts Breakdown: 07.6-1970-150 (6)
Location: top of mainframe
Function: prohibits lowering if the mast chains be- CTS (TF Mast Only)
come slack
Cable Tension Switch
Data: normally closed
Location: top of mainframe
Adjustment: 1.5 to 4 mm air gap between the sensor
Function: monitors the hose take up cable
and spring collar
Data: normally closed
Diagrams: DIA-1970-002 (B-3)
DIA-1970-018 (C-4) Adjustment: N/A
Parts Breakdown: 07.6-1970-150 (6) Diagrams: DIA-1970-002 (B-3)
DIA-1970-018 (B-3)
CHS6 Parts Breakdown: 07.5-1970-204 (45)

Chain Slack Switch DTS

Location: top of mainframe
Drive Tow Switch
Function: prohibits lowering if the mast chains be-
come slack Location: power unit distribution panel
Data: normally closed Function: release the brake for towing
Adjustment: 1.5 to 4 mm air gap between the sensor Data: normally open
and spring collar Adjustment: N/A
Diagrams: DIA-1970-002 (B-3) Diagrams: DIA-1970-002 (B-2)
DIA-1970-018 (C-4) DIA-1970-006 (A-2)
Parts Breakdown: 07.6-1970-150 (6) Parts Breakdown: 04.3-1970-001 (1)
04.3-1970-050 (2)
CHS7
Chain Break Switch
Location: top of mainframe
Function: prohibits raising or lowering if the mast
chains should break
Data: normally closed
Adjustment: 1.5 to 4 mm air gap between the sensor
and spring collar
Diagrams: DIA-1970-002 (B-3)
DIA-1970-018 (C-4)
Parts Breakdown: 07.6-1970-150 (6)

CHS8
Chain Break Switch
Location: top of mainframe
Function: prohibits raising or lowering if the mast
chains should break
Data: normally closed
Adjustment: 1.5 to 4 mm air gap between the sensor
and spring collar

M1.91-1970-046 TSP 7000 SERIES Crown 2012 PF25617-58

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SWITCHES

Distribution Panel

Figure 26738

Crown 2012 PF25617-59 TSP 7000 SERIES M1.91-1970-047

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SWITCHES

EDS FHSR
Emergency Disconnect Switch Fork Home Switch
Location: right armrest Location: fork assembly
Function: resets the emergency disconnect the con- Function: locks out the pivot function when the forks
tactor, removing the power from the power and control are out of the home position
circuitry Data: normally closed
Data: normally closed Adjustment: N/A
Adjustment: N/A Diagrams: DIA-1970-003 (B-3)
Diagrams: DIA-1970-003 (B-4) DIA-1970-024 (A-2)
DIA-1970-020 (B-2) Parts Breakdown: 07.9-1960-003 (10)
Parts Breakdown: 04.6-1970-001 (27)
FNS
EMS1
Operator Fan Switch
Emergency Switch (Traverse) Location: platform console
Location: platform Function: lets the operator turn the fan ON or OFF
Function: during an electrical malfunction allows the Data: N/A
operation of traverse functions
Adjustment: N/A
Data: N/A
Diagrams: DIA-1970-008 (B-2)
Adjustment: N/A
Parts Breakdown: 04.5-1960-102 (14)
Diagrams: DIA-1970-003 (B-3) 04.5-1960-150 (14)
DIA-1970-004 (C-1)
Parts Breakdown: 04.0-1970-200 (1)

EMS2
Traverse Override
Location: power unit right side
Function: during an electrical malfunction allows the
operation of traverse functions
Data: normally open
Adjustment: N/A
Diagrams: DIA-1970-003 (C-3)
DIA-1970-017 (C-4)
Parts Breakdown: 04.0-1970-001 (5)

FHSL
Fork Home Switch
Location: fork assembly
Function: locks out the pivot function when the forks
are out of the home position
Data: normally closed
Adjustment: N/A
Diagrams: DIA-1970-003 (B-3)
DIA-1970-024 (A-2)
Parts Breakdown: 07.9-1960-003 (10)

M1.91-1970-048 TSP 7000 SERIES Crown 2012 PF25617-60

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SWITCHES

Figure 26739

Crown 2012 PF25617-61 TSP 7000 SERIES M1.91-1970-049

119
COMPONENTRY
SWITCHES

FPS1 Diagrams: DIA-1970-003 (B-2)

DIA-1970-012 (C-2)
Foot Presence Switch Parts Breakdown: 09.2-1960-050 (3)
Location: platform floorboard
Function: senses the operators presence to enable FPS5
traction and hydraulic functions and to apply the brake
Foot Presence Switch
when a foot is removed in stand up mode
Location: platform floorboard
Data: normally open
Function: senses the operators presence to enable
Adjustment: N/A
traction and hydraulic functions and to apply the brake
Diagrams: DIA-1970-003 (B-2) when a foot is removed in stand up mode
DIA-1970-012 (C-2)
Data: normally open
Parts Breakdown: 09.2-1960-050 (3)
Adjustment: N/A
FPS2 Diagrams: DIA-1970-003 (B-2)
DIA-1970-012 (B-1)
Foot Presence Switch Parts Breakdown: 09.2-1960-050 (3)
Location: platform floorboard
Function: senses the operators presence to enable FPS6
traction and hydraulic functions and to apply the brake
Foot Presence Switch
when a foot is removed in stand up mode
Location: platform floorboard
Data: normally open
Function: senses the operators presence to enable
Adjustment: N/A
traction and hydraulic functions and to apply the brake
Diagrams: DIA-1970-003 (B-2) when a foot is removed in stand up mode
DIA-1970-012 (C-2)
Data: normally open
Parts Breakdown: 09.2-1960-050 (3)
Adjustment: N/A
FPS3 Diagrams: DIA-1970-003 (B-2)
DIA-1970-012 (C-2)
Foot Presence Switch Parts Breakdown: 09.2-1960-050 (3)
Location: platform floorboard
Function: senses the operators presence to enable
traction and hydraulic functions and to apply the brake
when a foot is removed in stand up mode
Data: normally open
Adjustment: N/A
Diagrams: DIA-1970-003 (C-2)
DIA-1970-012 (B-2)
Parts Breakdown: 09.2-1960-050 (3)

FPS4
Foot Presence Switch
Location: platform floorboard
Function: senses the operators presence to enable
traction and hydraulic functions and to apply the brake
when a foot is removed in stand up mode
Data: normally open
Adjustment: N/A

M1.91-1970-050 TSP 7000 SERIES

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SWITCHES

Figure 26740

TSP 7000 SERIES M1.91-1970-051

121
COMPONENTRY
SWITCHES

FPS7 GTSL
Foot Presence Switch Gate Switch (Not available on narrow rail)
Location: platform floorboard Location: left gate
Function: senses the operators presence to enable Function: prevents lift, lower, and traction if the gates
traction and hydraulic functions and to apply the brake are open
when a foot is removed in stand up mode Data: normally closed
Data: normally open Adjustment: N/A
Adjustment: N/A Diagrams: DIA-1970-003 (B-2)
Diagrams: DIA-1970-003 (B-2) DIA-1970-011 (C-1)
DIA-1970-012 (C-1) Parts Breakdown: 09.1-1960-001 (29)
Parts Breakdown: 09.2-1960-050 (3)
GTSR
FPS8
Gate Switch (Not available on narrow rail)
Foot Presence Switch Location: right gate
Location: platform floorboard Function: prevents lift, lower, and traction if the gates
Function: senses the operators presence to enable are open
traction and hydraulic functions and to apply the brake Data: normally closed
when a foot is removed in stand up mode
Adjustment: N/A
Data: normally open
Diagrams: DIA-1970-003 (B-2)
Adjustment: N/A DIA-1970-009 (C-1)
Diagrams: DIA-1970-003 (B-1) Parts Breakdown: 09.1-1960-001 (29)
DIA-1970-012 (B-2)
Parts Breakdown: 09.2-1960-050 (3)

FPS9
Foot Presence Switch
Location: platform floorboard
Function: senses the operators presence to enable
traction and hydraulic functions and to apply the brake
when a foot is removed in stand up mode
Data: normally open
Adjustment: N/A
Diagrams: DIA-1970-003 (B-1)
DIA-1970-012 (C-2)
Parts Breakdown: 09.2-1960-050 (3)

FS
Forward Switch
Location: right armrest
Function: informs the control system that forward
travel is being requested
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-003 (C-1)
Parts Breakdown: 04.6-1970-001 (17)

M1.91-1970-052 TSP 7000 SERIES

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SWITCHES

Figure 26741

TSP 7000 SERIES M1.91-1970-053

123
COMPONENTRY
SWITCHES

GUS HPSL
Guidance Select Switch (Optional) Left Hand Presence Switch
Location: right armrest Location: left armrest
Function: lets the operator select manual or automatic Function: senses the operators presence
steering Data: N/A
Data: N/A Adjustment: N/A
Adjustment: N/A Diagrams: DIA-1970-003 (A-1)
Diagrams: DIA-1970-002 (C-1) DIA-1970-021 (B-1)
DIA-1970-020 (B-2) Parts Breakdown: 04.5-1960-001 (8)
Parts Breakdown: 04.6-1970-003 (40)
HPSR
HGTRS1
Right Hand Presence Switch
Main Height Reset Switch Location: right armrest
Location: platform Function: senses the operators presence
Function: resets the counter in the electronic system Data: N/A
when the platform is fully lowered
Adjustment: N/A
Data: N/A
Diagrams: DIA-1970-003 (B-1)
Adjustment: 1.5 to 4.0 mm air gap between sensor DIA-1970-020 (B-1)
and mast trip bar
Parts Breakdown: 04.6-1970-001 (5)
Diagrams: DIA-1970-003 (B-2)
DIA-1970-009 (C-1)
Parts Breakdown: 09.0-1970-252 (50)

HGTRS2
Auxiliary Height Reset Switch
Location: load handler
Function: resets the counter in the electronic system
when the forks are lowered
Data: N/A
Adjustment: 3.2 to 8.1 mm air gap between sensor
and mast trip bar
Diagrams: DIA-1970-003 (B-3)
DIA-1970-024 (A-2)
Parts Breakdown: 09.1-1960-350 (22)
09.1-1960-400 (21)

HNS
Horn Switch
Location: right armrest
Function: lets the operator sound the horn
Data: normally open
Adjustment: N/A
Diagrams: DIA-1970-003 (C-1)
DIA-1970-020 (B-1)
Parts Breakdown: 04.6-1970-001 (1)

M1.91-1970-054 TSP 7000 SERIES

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SWITCHES

Figure 26742

TSP 7000 SERIES M1.91-1970-055

125
COMPONENTRY
SWITCHES

KYS ORS1
Key Switch Override Switch
Location: console Location: left armrest
Function: lets the operator start or stop the truck Function: when raise lower cutout programmed for
Data: N/A override is encountered, actuating switch permits con-
tinuation of function, supplies optional EAC override
Adjustment: N/A
Data: N/A
Diagrams: DIA-1970-003 (B-4)
DIA-1970-008 (C-1, C-4) Adjustment: N/A
Parts Breakdown: 04.5-1960-102 (4) Diagrams: DIA-1970-003 (A-1)
04.5-1970-150 (4) DIA-1970-021 (B-2)
Parts Breakdown: 04.5-1960-001 (7)
LGS1
PLS
Dome Light Switch
Location: console Pivot Left Switch
Function: lets the operator turn the dome light ON or Location: left armrest
OFF Function: controls the mechanical limit of pivot func-
Data: N/A tion to the left
Adjustment: N/A Data: N/A
Diagrams: DIA-1970-008 (B-2) Adjustment: N/A
Parts Breakdown: 04.5-1960-102 (12) Diagrams: DIA-1970-003 (A-1)
04.5-1970-150 (12) DIA-1970-021 (B-2)
Parts Breakdown: 04.5-1960-001 (7)
LGS2
Worklight Switch
Location: console
Function: lets the operator turn the worklights ON or
OFF
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-008 (B-2)
Parts Breakdown: 04.5-1960-102 (15)
04.5-1970-150 (15)

LGS3
Worklight Switch (Optional)
Location: console
Function: allows the operator to turn the spot light ON
or OFF
Data: N/A
Adjustment: N/A
Diagrams: DIA-1970-008 (B-2)
Parts Breakdown: 04.5-1960-102 (11)
04.5-1970-150 (11)

M1.91-1970-056 TSP 7000 SERIES

126
 COMPONENTRY
SWITCHES

Figure 26743

TSP 7000 SERIES M1.91-1970-057

127
COMPONENTRY
SWITCHES

PRS Diagrams: DIA-1970-003 (C-2)

Parts Breakdown: 04.6-1970-001 (17)
Pivot Right Switch
Location: left armrest RSS
Function: controls the mechanical limit of pivot func-
Release Seat Switch
tion to the right
Location: right armrest
Data: N/A
Function: release the seat lock
Adjustment: N/A
Data: normally open
Diagrams: DIA-1970-003 (A-1)
DIA-1970-021 (B-2) Adjustment: N/A
Parts Breakdown: 04.5-1960-001 (7) Diagrams: DIA-1970-003 (C-1)
DIA-1970-020 (B-1)
RGSL Parts Breakdown: 04.6-1970-001 (1)

Rail Guide Switch (Optional) SES

Location: aisle guide wheel bracket mounted under
the power unit Seat Sense Switch
Function: provide stability to turn ON automatic steer- Location: seat
ing Function: senses the operators presence on the seat
Data: N/A Data: normally open
Adjustment: set switch so that the guide wheel slides Adjustment: refer to PLATFORM > Platform > Seat
in 1 mm (0.04 in) before the switch activates Up/Down Switch Adjustment
Diagrams: DIA-1970-002 (C-2) Diagrams: DIA-1970-003 (A-2)
DIA-1970-014 (C-4) DIA-1970-011 (C-4)
Parts Breakdown: 10.4-1970-001 (13) Parts Breakdown: 09.0-1970-150 (6)
10.4-1970-075 (14)

RGSR
Rail Guide Switch (Optional)
Location: aisle guide wheel bracket mounted under
the power unit
Function: provide stability to turn ON automatic steer-
ing
Data: N/A
Adjustment: set switch so that the guide wheel slides
in 1 mm (0.04 in) before the switch activates
Diagrams: DIA-1970-002 (B-2)
DIA-1970-014 (C-4)
Parts Breakdown: 10.4-1970-001 (13)
10.4-1970-075 (14)

RS
Reverse Switch
Location: right armrest
Function: informs the traction controller that reverse
travel direction is being requested
Data: N/A
Adjustment: N/A

M1.91-1970-058 TSP 7000 SERIES

128
 COMPONENTRY
SWITCHES

(located on opposite side)

Figure 26744

TSP 7000 SERIES M1.91-1970-059

129
COMPONENTRY
SWITCHES

SLS TDS
Seat Sense Switch Tilt Down Switch
Location: seat Location: right armrest
Function: sense when the seat is locked in place Function: lets the operator select the tilt down function
Data: normally closed Data: N/A
Adjustment: refer to PLATFORM > Platform > Seat Adjustment: N/A
Rotate Switch Adjustment Diagrams: DIA-1970-003 (B-1)
Diagrams: DIA-1970-003 (B-2) DIA-1970-020 (B-1)
DIA-1970-011 (C-2) Parts Breakdown: 04.6-1970-001 (1)
Parts Breakdown: 09.0-1970-156 (120)
TVRS
SPS
Traverse Reset Switch
Seat Position Switch Location: load handler
Location: seat Function: verify and reset the traverse encoder count,
Function: senses when the seat is facing forward ECR4
Data: normally closed Data: N/A
Adjustment: N/A Adjustment: 3.2 to 8.1 mm air gap between the sen-
Diagrams: DIA-1970-003 (B-2) sor and the trip block
DIA-1970-011 (B-1) Diagrams: DIA-1970-003 (C-3)
Parts Breakdown: 09.0-1970-156 (126) DIA-1970-024 (B-4)
Parts Breakdown: 09.1-1960-100 (6)
TBS
ZSS
Tilt Back Switch (Optional)
Location: right armrest Zone Select Switch (Optional)
Function: lets the operator select the tilt back function Location: console
Data: N/A Function: lets the operator select lift height cutout
Adjustment: N/A Data: N/A
Diagrams: DIA-1970-003 (B-1) Adjustment: N/A
DIA-1970-020 (B-1) Diagrams: DIA-1970-003 (A-2)
Parts Breakdown: 04.6-1970-001 (1) DIA-1970-008 (B-3)
Parts Breakdown: 04.5-1960-102 (2)
04.5-1960-150 (2)

M1.91-1970-060 TSP 7000 SERIES

130
 COMPONENTRY
SWITCHES

Figure 26745

TSP 7000 SERIES M1.91-1970-061

131
Notes:

132
HYDRAULIC SYSTEM
133
Notes:

134

Hydraulic System
General Information
WARNING
High pressure hydraulic system
There is a risk of injury from high pressure hydraulic oil.
 Before you open a section of the hydraulic system,
release the pressure.
 Before you pressurize the hydraulic system, tighten
all hydraulic connections.
 Keep your hands and body away from pin-holes
which eject high pressure hydraulic oils.
 Use a piece of paper or cardboard to do a leak
check. Do not use your hand or body.
 High pressure oil that goes into the skin is a medical
emergency although the skin can look usual at first.
 There is a delayed start of pain and severe tissue
damage can occur.
 Get medical aid from a specialist who has experi-
ence with this type of injury.
A gear type pump (P1) supplies hydraulic power to the
hydraulic system in this truck. A three-phase AC motor
(M2) controls the speed and direction of P1. The lift
pump (P1) supplies hydraulic oil for the lift and acces-
sory functions.
P1 includes an adjustable relief valve (RV1) that con-
trols the maximum pressure. Refer to HYDRAULIC
SCHEMATIC for the correct setting for RV1.
Note: Refer to the HYDRAULIC chapter for more infor-
mation on the lift pump (P1), the lift pump motor (M2),
manifolds, and valves.
Crown 2012 PF25678-1 TSP 7000 SERIES
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
MVL
WARNING
Severe injury or death can occur when you use the
manual lowering valve if you do not obey the safety
warnings.
When you use the manual lowering valve (MVL) to
lower the operator compartment, severe injury can oc-
cur if the operator does not obey the safety warnings.
 Keep all body parts in the operator compartment.
 Make sure that the forks will not hit the rack.
 Immediately close MVL if there is chain slack.
In an emergency, you can use the manual lowering
valve (MVL) to lower the operator compartment.
Operating Temperature
Refer to Figure 8.
There are three temperature zones of operation for
Crown lift trucks. Do not use trucks that are equipped
for operation in freezer zones in high temperatures.
Refer to INSPECTION & LUBRICATION > Planned
Maintenance for the correct quantities and types of lu-
bricants for your truck.
Normal Operation and Cooler Zone
This zone is for trucks that continuously operate in tem-
peratures higher than 0 °C or (32 °F).
Standard Temperature Freezer Zone
This zone is for trucks that usually operate in a cooler
environment at -18–4 °C (0–40 °F) with intermittent
freezer entry. The storage area for these trucks is
higher than 0 °C (32 °F).
Low Temperature Freezer Zone
This zone is for trucks that continuously operate in tem-
peratures 12 °C (10 °F) or below. The storage area for
these trucks is less than 0 °C (32 °F).
M2.0-1970-001
135
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM

Normal Operation and Cooler Zone

Standard Freezer Zone

Low Temperature Freezer Zone

Temperature (°F) of the Truck Operation Environment

Fig. 8 (27221)

Hydraulic Plumbing and Fittings
• Blow air through all hoses and tubes to remove
loose particles.
• Replace a tube or hose with wire-braid inner con-
struction that collapses or that has kinks. It is possi-
ble that you will not see the damage externally.
• Replace a flexible hose if it collapses in its usual
position for operation.
• Hoses and tubes must be away from surfaces or
edges that cause wear or cuts.
• Hoses and tubes must be away from surfaces or
edges on which they can become caught.
• All connections must be free from leaks.
• Put the suction hoses in the correct position to keep
them at full volume flow. This prevents the collapse
of the suction hoses.
Refer to INSPECTION & LUBRICATION > Planned
Maintenance for the correct hydraulic oil and mainte-
nance intervals.
CAUTION
Contamination could cause damage to the hydrau-
lic system.
Contamination in the hydraulic oil or hydraulic compo-
nents could cause damage to the hydraulic system.
 Put the oil through a 10-micron filter or 100-mesh
strainer before you add it to the truck.
 Make sure that all hydraulic components are clean
before installation.

Reservoir and Filters

Reservoir
The reservoir capacity at the "FULL" mark is 56 l. Use
the filler/breather dipstick to do a check of the hydraulic
oil level. Before you examine the hydraulic oil level in
the reservoir, complete the items that follow:
• Retract all cylinders.
• Bleed all air from the hydraulic system.
If you add too much hydraulic oil to the reservoir, a leak
from the filler/breather dipstick can occur.

M2.0-1970-002 TSP 7000 SERIES Crown 2012 PF25678-2

136
 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM

Tank Top Filter

Refer to Figure 9.
To replace the filter element
Note: Refer to INSPECTION & LUBRICATION >
Planned Maintenance for the correct replacement in-
terval for the filter element.
1. Turn the filter cap (2) counterclockwise to remove
it.
2. Hold the inner support tube (3) and remove the fil-
ter element (4).
3. Put the replacement filter element (4) into the inner
support tube (3).
4. Install the support tube (3) and the filter cap (2).
5. Torque the filter cap (2) to 15–16 Nm.
6. Discard the filter and used oil in compliance with
applicable laws for the removal of hazardous
waste.

Breather
Refer to Figure 9.
A hydraulic breather (5) is adjacent to the tank top filter
on the reservoir. Replace the breather at the same time
as the filter element in the tank top filter. Refer to IN-
SPECTION & LUBRICATION > Planned Maintenance
for the correct replacement interval.

Fig. 9 (27217)

Crown 2012 PF25678-3 TSP 7000 SERIES M2.0-1970-003

137
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM

Drift Tests

WARNING
Lowering forks and mast can cause injury or death.
The forks and mast can automatically lower when the
hydraulic system pressure releases and during the drift
test.
 Do not stand below a raised fork.
 Do not do work around or below a mast that is not
correctly blocked.
• Do the drift tests with a capacity load. Refer to the
data plate for the truck capacity.
• Equally put the material for the load test in the limits
of a 1.2x1.2 m pallet.
• Adjust the forks to the maximum width and attach
the pallet to the fork carriage.
• Read the lift measurement from the tip of the fork to
the floor.

Lift Drift Test

To do a drift test of the lift cylinders
1. Lift the capacity load on the auxiliary mast approx-
imately 305–610 mm.
2. Raise the operator compartment until the second
stage mast raises approximately 610–915 mm.
3. Turn the truck OFF.
4. Record the lift measurement from the tip of the fork
to the floor.
5. Wait five minutes.
6. Record the lift measurement from the tip of the fork
to the floor.
Note: Permitted drift is less than 13 mm for each min-
ute or 64 mm in a period of five minutes.
To correct platform drift or fork carriage drift
1. Make sure that MVL is fully closed and does not
have a leak.
2. Make sure that there are no leaks in the hoses or
hydraulic connections.
3. Do a check for leaks at check valves and control
valves.
 If there are leaks in the valves, raise and lower the
fork carriage two to three times to flush the contam-
ination out of the valve seats.

M2.0-1970-004 TSP 7000 SERIES Crown 2012 PF25678-4

138

Hydraulic Circuits
Lift Circuit
Lift and Lower circuit functions are controlled by con-
trolling the speed of the P1 lift pump (item 2 below) by
controlling the direction and speed of the lift motor M.
When the operator starts lift, SVMR in the lift manifold
block (item 1 below) is energized. The lift motor M is
then energized to turn the P1 pump to supply oil flow to
the lift manifold block. Hydraulic fluid goes from the
reservoir, across the CVs check valve, into the P1
pump, and across PVML. RV1, which is internal to the
lift pump P1, is the system relief valve that gives pro-
tection to the hydraulic system from too much pres-
sure. PVML stays de-energized and functions as a
secondary load holding check valve.
With SVMR energized, oil flows out of the lift pump, into
the lift manifold block, and across SVMR. SVML will
stay de-energized, and functions as the primary load
holding check valve. The hydraulic oil goes through
SVML and out the C1 port to the lift cylinder(s).
Fig. 10 (26943)
Crown 2012 PF25679-1 TSP 7000 SERIES
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS
As the operator changes the command for higher lift
speed, the lift motor M and P1 pump speed adjusts to
the operator command. A speed sensor on the lift mo-
tor monitors the lift motor/pump speed and holds the
correct speed for the load and system pressure. With
the same operator command, the same flow will be
sent out of port C1 regardless of load weight or pres-
sure. Smooth start and stop movement control is con-
trolled by the truck software and parameter
adjustments, which lets the operator set maximum
speed and ramp conditions.
When lift stops and you move the control handle to
neutral, the lift motor M and pump P1 smoothly slow to
a stop. Hydraulic oil flow and pressure are contained in
the lift cylinder by SVML to prevent a lowering move-
ment, with PVML operating as a secondary load hold-
ing valve. After the P1 pump comes to a complete stop,
SVMR is de-energized.
M2.0-1970-050
139
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS
Lower Circuit
The weight of the platform, load handler, and load
causes pressure in the circuit. SVML is a "no leak" so-
lenoid check valve that prevents leakage and keeps
the platform from moving during operation when the
platform is raised. When an operator starts the lower
function, the HCM energizes SVML. As SVML is ener-
gized, the P1 pump turns to "charge" the circuit be-
tween the P1 pump and SVMR. PVML is then
energized to let lift cylinder pressure and flow to the P1
pump.
The lift motor M is controlled to let P1 to turn in the
opposite direction to operate as a motor. P1 then drives
lift motor M as a generator to supply regenerative low-
ering. Some of the energy made by the opposite turn-
ing of P1 is saved by the lift motor M and is sent back
to the battery. The rate that P1 turns (controlled by M
Fig. 11 (26944)
M2.0-1970-051 TSP 7000 SERIES
140
as directed by the operator) controls the rate of oil flow
through P1. The check valve CVS in the pump valve
section prevents the oil from going back to the reservoir
through the suction plumbing. The oil exits the P1
pump section through check valve CVT. The exit flow
then goes back to the reservoir after it goes through the
oil filter (item 3).
When the lower function decreases/stops and the con-
trol handle is moved to neutral, the lift motor M and
pump P1 smoothly stop. SVML and PVML are then de-
energized to contain hydraulic oil flow and pressure in
the lift cylinder to prevent lowering movement. In event
of too much movement of P1, "motoring" to a stop with
PVML or SVML closed, the anti-cavitation valve CV
lets oil go back to the oil input side of P1 to prevent
cavitation in the pump.
Crown 2012 PF25679-2
 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

Lower Circuit (MVL) The weight of the platform, load handler and load
causes pressure in the circuit. Oil pressure is supplied
The platform lowers when you open the manual lower to MVL. When MVL is opened, a path for oil flow is
valve at the back of the power unit. Pull the handle to made for the oil to flow through MVL and out of port T
open the valve. The more the handle is pulled back, the to the reservoir. Note that ORF1 limits maximum oil
faster the platform lowers. flow across MVL and limits the lowering speed of the
platform. Releasing the handle lets MVL close, which
stops the manual lower movement of the platform.
CAUTION
Injury could occur.
 Before you use the Manual Lowering Valve, tell the
operator to keep all body parts in the operator's
compartment.
 Make sure the forks are away from the racks.
 Close the valve immediately if the chains become
loose.
 Do not let personnel below the platform when you
lower it.

Fig. 12 (27001)

Crown 2012 PF25679-3 TSP 7000 SERIES M2.0-1970-052

141
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS
Load Handler Circuit through the
Mainframe Manifold Block
(Except Auxiliary Lower)
Fig. 13 (27002)
Mainframe Manifold - Auxiliary Cir-
cuit:
Auxiliary load handler functions, other than the auxil-
iary lower function, are controlled by proportional con-
trol of the P1 lift pump (item 16 above) by controlling
the direction and speed of the lift motor M. When the
operator commands a load handler function, SVA in the
lift manifold block (item 10 above) is energized. The lift
motor M is then energized to turn the P1 pump to sup-
ply flow to the load handler manifold block. The hydrau-
lic fluid goes from the reservoir, across the CVs check
valve, into the P1 pump, and across PVML. RV1, in lift
pump P1, is the primary system relief valve that pro-
tects the hydraulic system from too much pressure.
PVML will stay de-energized and function as a second-
ary load holding check valve.
With SVA energized and the lift motor and P1 pump
rotating, oil flows out of the lift pump, into the lift mani-
fold block, and across SVA. SVMR stays de-energized
and prevents hydraulic fluid from going in the lift circuit.
Hydraulic oil goes through SVA and out the A1 port to
the load handler manifold block.
M2.0-1970-053 TSP 7000 SERIES
142
To main lift cylinders
To load handler manifold
From load handler manifold
Lift motor and pump speed is controlled by the truck
software to provide sufficient flow for the load handler
function(s) as commanded by the operator. A speed
sensor on the lift motor monitors the lift motor/pump
speed and keeps the applicable speed regardless of
load and system pressure. With the same operator
command, the same flow will be supplied out port "A"
regardless of the load weight or pressure. Smooth start
and stop movement control is controlled by the truck
software and parameter positions, and lets the opera-
tor set the maximum speed and ramp conditions.
When the auxiliary function command is stopped and
the control handle is moved to neutral, the lift motor M
and pump P1 smoothly slow to a stop. SVA is then de-
energized, and hydraulic flow and pressure are con-
tained in the auxiliary plumbing at port A.
Note that main lift or main lower cannot be operated at
the same time with a load handler function (except
main lower and auxiliary lower).
Hydraulic oil flow from the load handler manifold block
is sent back to the filter (item 11 above) in the reservoir
through the plumbing directly to the filter.
Crown 2012 PF25679-4

Auxiliary Lift Circuit
PVAR is the auxiliary raise proportional control valve
that controls the load handler raise function. ACCESS
7 controls PVAR position by changing the applied volt-
age to the coil. The more voltage applied to the PVAR
coil, the more PVAR spool moves letting more oil flow
to the load handler lift cylinder.
When an operator commands auxiliary raise, ACCESS
7 energizes PVAR coil opening the valve in proportion
to the operator's command. ACCESS 7 also energizes
PVLH coil adjusting the auxiliary relief pressure to 24.1
MPa (3500 psi) (PVLH is an electronic proportional pi-
lot operated relief valve providing proportional control
of the auxiliary relief pressure setting. It adjusts to sup-
ply sufficient pressure based on feedback from the load
sense pressure transducer, LS.). Oil flows out of the
manifold into port AP of the auxiliary manifold block, to
PVLH and through PCAR. PVAR is opened in propor-
tion to the operator command and lets the oil flow
through CV3, out port AH, and into the load handler lift
cylinder. Oil also flows to the load sensor pressure
transducer, LS, which senses the pressure applied to
the system from a load.
Part of Load Handler Manifold
SUCTION
PRESSURE
RETURN
PILOT PRESSURE
from Main Frame Manifold
to Reservoir
Fig. 14 (12878-01)
Crown 2012 PF25679-5 TSP 7000 SERIES
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS
Pilot pressure is delivered to the two sides of PCAR
and is sensed from the two sides of PVAR. If PVAR is
not fully opened then a pressure differential will exist
across PVAR. If pilot pressure sensed after PVAR is
more than the PCAR spring pressure and the pilot
pressure sensed before PVAR, then PCAR spool will
move left and limit flow to PVAR and increasing pres-
sure to PVLH which releases the pressure by sending
the oil flow to the reservoir. This lets full pressure com-
pensation of the auxiliary lift circuit. With the same op-
erator command to PVAR, the same flow will be sent
out port AH regardless of load weight or pressure. It
also gives a smooth stop and start by preventing a sud-
den raise or drop in pressure if the operator suddenly
stops and starts raising the forks.
When lift is stopped and PVAR is de-energized, ORF7
lets pilot pressure sensed after PCAR to be bled off to
reservoir through port AT. Also, when lift is stopped and
PVLH is de-energized, PVLH's pressure decreases to
the spring pressure (set at 1.38 MPa [200 psi]) and lets
the oil pressure before PVAR to be bled down to 1.38
MPa (200 psi).
M2.0-1970-054
143
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS
Auxiliary Lower Circuit
When an operator commands auxiliary lower, AC-
CESS 7 energizes SVAL to let oil flow go back to the
reservoir. The weight of the forks and load makes the
pressure in the circuit. Pilot pressure goes through
ORF6 to PCAL. ORF6's function is to slow PCAL's re-
sponse causing smooth lowering. ACCESS 7 then en-
ergizes PVAL, with PVAL opening in proportion to the
operator command to control lower speed.
During auxiliary lower, oil flows from the lift cylinder to
port AH of the auxiliary hydraulic manifold, through
PVAL, PCAL, out port AT of the auxiliary hydraulic
manifold and goes back to the reservoir.
When PVAL is opened, the spring in PCAL and the pilot
pressure that is sent to the right side of PCAL, keeps
PCAL open and lets it lower. If the pressure difference
before PVAL is more than PCAL's spring pressure and
the pilot pressure after PVAL, the pilot pressure sent to
the left side of PCAL will cause PCAL to gradually
Part of Load Handler Manifold
SUCTION
PRESSURE
RETURN
PILOT PRESSURE
from Main Frame Manifold
to Reservoir
Fig. 15 (12879)
M2.0-1970-055 TSP 7000 SERIES
144
close. Because of this, the flow across PVAL and PCAL
will be constant for a given command regardless of
load weight or pressure at port AH of the manifold as-
sembly providing pressure compensated lower control.
For example, a capacity load will cause more system
pressure then a load 10% of capacity but can be low-
ered at the same speed if the lower command (move-
ment of the multi-task handle) is the same. The cause
for this is pilot pressure supplied to the left side of
PCAL will be greater for the capacity load and more
fully close PCAL. Maximum auxiliary lower speed is
controlled by the maximum opening of PVAL. PVAL's
position is electronically controlled by ACCESS 7 giv-
ing ACCESS 7 electronic control of lower speed. Lower
speed, as controlled by ACCESS 7, can be changed in
the PERFORMANCE menu.
SVAL acts as a velocity fuse. If the lowering speed is
more than 36.5 m/min (120 ft/min), SVAL will be de-
energized stopping the lift cylinder from lowering.
Crown 2012 PF25679-6

Traverse Left Circuit
PVT provides control of the traverse function. When
moving right, the S1 coil is energized, moving the PVT
spool to the right (S1 is the top coil). When moving left,
the S2 coil is energized moving the PVT spool to the
left (S2 is the bottom coil). ACCESS 7 controls PVT by
changing the applied voltage to the coils. The more
voltage applied to the PVT coils, the more PVT spool
moves which lets more oil flow to the traverse motor.
Two valves in the load handler manifold control the
pressure for the traverse circuit, PVLH and PR1. When
Part of Load Handler
Manifold
SUCTION
PRESSURE
RETURN
PILOT PRESSURE
from Main Frame Manifold
to Reservoir
Fig. 16 (12880)
When an operator commands traverse left, ACCESS 7
energizes the PVT S2 coil and moves the valve spool
in proportion to the operator's command. ACCESS 7
also energizes PVLH coil and changes the pressure to
as much as 9.7 MPa (1400 psi). Oil flows from the
mainframe manifold into port AP of the load handler
manifold to PVLH. PVLH pilot line senses the pressure
and if the pressure is more than 9.7 MPa (1400 psi),
PVLH's spool will move and send some oil flow to the
reservoir. As oil flows through PR1, pilot pressure is
sent to the left side of PR1. If the pressure is more than
16.6 MPa (2400 psi), pilot pressure will overcome the
spring pressure and move the PR1 spool to the right
Crown 2012 PF25679-7 TSP 7000 SERIES
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS
the operator commands only traverse, the valve pres-
sures are the same so the valves do the same function.
When there is more than one load handler function,
pressures may be different. For example, if the opera-
tor commands auxiliary lift and traverse, PVLH will be
electronically adjusted by ACCESS 7 to 24.1 MPa
(3500 psi) to make sure there is sufficient pressure for
lift while PR1 is factory set to limit the pressure to 16.5
MPa (2400 psi) to make sure there is sufficient pres-
sure for traverse.
decreasing the oil flow to PCT (limiting the pressure to
16.6 M [2400 psi]). Oil flows through PCT, PVT to
CBV1. Oil pressure is sent to CBV2 through a pilot line.
Oil flows through CBV1, out port T2 and into the trav-
erse motor. Oil flows from the traverse motor through
CBV2's top pilot line moving CBV2's spool and let the
oil go back to the reservoir. Oil flows through CBV2,
PVT, CV4, out port AT of the load handler manifold and
to the reservoir. After a load handler function is no
longer necessary, CV4 will work with CV1 (in the main-
frame manifold) to keep approximately 1.38 MPa (200
psi) the circuit to get a fast response.
M2.0-1970-056
145
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

Pilot pressure is supplied to the two sides of PCT and
is sensed from pressure across PVT. If PVT is not fully
opened, there will be a pressure difference across PVT.
If pilot pressure sensed before PVT is more than PCT's
spring pressure and the pilot pressure sensed at the
load sense port of PVT, then PCT spool will move to the
right and decrease flow into PVT. This gives full pres-
sure compensation of the traverse circuit. With the
same operator command to PVT, the same flow will be
sent out of port T2 regardless of load weight or pres-
sure. It also makes for a smooth stop and start by pre-
venting a sudden raise or drop in pressure if the
operator suddenly stops and starts moving.
Traverse Right Circuit
PVT controls of the traverse function. When moving
right, the S1 coil is energized, moving the PVT spool to
the right (S1 is the top coil). When moving left, the S2
coil is energized moving the PVT spool to the left (S2 is
the bottom coil). ACCESS 7 controls PVT by changing
the applied voltage to the coils. The more voltage ap-
plied to the PVT coils, the more PVT spool moves,
which lets more oil flow to the traverse motor.
Two valves in the load handler manifold control the
pressure for the traverse circuit, PVLH and PR1. When
traverse only is requested, the valve pressures are the
same so the valves do the same function. When more
than one load handler function is requested, pressures
may be different. For example, if auxiliary lift and trav-
erse are selected, PVLH will be electronically adjusted
by ACCESS 7 to 24.1 MPa (3500 psi) to make sure
there is sufficient pressure for lift while PR1 is factory
set to limit the pressure to 16.6 MPa (2400 psi) to make
sure there is sufficient pressure for traverse.

Part of
Load Handler
Manifold

SUCTION
PRESSURE
RETURN
PILOT PRESSURE

from Main Frame Manifold

to Reservoir

Fig. 17 (12881)

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146
 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

When an operator commands traverse right, ACCESS

7 energizes the PVT S1 coil and moves the valve spool
in proportion to the operator's command. ACCESS 7
also energizes the PVLH coil and changes the pres-
sure to as much as 9.7 MPa (1400 psi). Oil flows from
the mainframe manifold into port AP of the load handler
manifold to PVLH. PVLH pilot line senses the pressure
and if the pressure is more than 9.7 MPa (1400 psi),
PVLH's spool will move and divert some of the flow to
the reservoir. As oil flows through PR1, pilot pressure
is sent to the left side of PR1. If the pressure is more
than 16.6 MPa (2400 psi), the pilot pressure will over-
come the spring pressure and move PR1's spool to the
right decreasing the flow to PCT (limiting the pressure
to 16.6 MPa [2400 psi]). Oil flows through PCT, PVT to
CBV2. Pressure is diverted to CBV1 through a pilot
line. Oil flows through CBV2, out port T1 and into the
traverse motor. Oil flows from the traverse motor
through CBV1's top pilot line moving CBV1's spool and
making a path for the return oil. Oil flows through
CBV1, PVT, CV4, out port AT of the load handler man-
ifold and to the reservoir. After a load handler function
is no longer necessary, CV4 will work with CV1 (in the
mainframe manifold) to keep approximately 1.38 M200
psi) in the circuit to get a fast response.
Pilot pressure is supplied to the two sides of PCT and
is sensed from pressure across PVT. If PVT is not fully
opened, there will be a pressure difference across PVT.
If pilot pressure sensed before PVT becomes more
than the PCT spring pressure and the pilot pressure
sensed at the load sense port of PVT, then the PCT
spool will move to the right and decreases the flow into
PVT. This lets full pressure compensation of the trav-
erse circuit. With the same operator command to PVT,
the same flow will be supplied out port T1 regardless of
load weight or pressure. It also provides for a smooth
stop and start by preventing a sudden raise or drop in
pressure if the operator suddenly stops and starts tra-
versing.

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147
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

Fork Extend Circuit
PVF is the proportional control valve that controls the
fork extend function. When extending the forks, S1 coil
is energized moving PVF spool to the left and when
retracting the forks, S2 coil is energized moving PVF
spool to the right (S1 is the top coil and S2 is the bottom
coil). ACCESS 7 controls PVF by changing the applied
voltage to the coils. The more voltage applied to the
PVF coils, the more PVF spool moves which lets more
oil flow to the forks.
Two valves in the load handler manifold control the
pressure for the fork extend circuit, PVLH and PR2.
When fork retract only is requested, the valve pres-
sures are the same so the valves do the same function.
When more than one load handler function is re-
quested, pressures may be different. For example, if
auxiliary lift and fork retract are selected, PVLH will be
electronically adjusted by ACCESS 7 to 24.1 MPa
(3500 psi) to make sure there is sufficient pressure for
lift, while PR2 is factory set to limit maximum pressure
to 9.7 MPa (1400 psi) to make sure there is sufficient
pressure for fork retract.

SUCTION
PRESSURE
RETURN
PILOT PRESSURE

Part of Load Han- FORK EXTEND

dler Manifold MANIFOLD
from Main Frame Mani-
fold

to Reservoir

Fig. 18 (12882)

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148
 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

When an operator commands fork extend, ACCESS 7

energizes the PVF S1 coil and moves the valve spool
in proportion to the operator's command. ACCESS 7
also energizes the PVLH coil adjusting the pressure to
9.7 MPa. Oil flows from the mainframe manifold into
port AP of the load handler manifold and to PVLH. The
PVLH pilot line senses a pressure and if the pressure
is more than 9.7 MPa it will move the PVLH spool and
send some of the flow to reservoir. Oil flows through
PR2. Pilot pressure is supplied to the top of PR2. If the
pressure is more than 9.7 MPa, pilot pressure will be
more than the spring pressure and it will gradually
move the PR1 spool down decreasing the flow to PVF
(limiting pressure to 9.7 MPa [1400 psi]). Oil flows
through PVF, out the F2 port and into the fork extend
manifold. Oil flows through a pilot line to SPC1 and un-
seats the pilot check valve making a path for return flow
from the forks. Oil flows through SPC2, through the
flow divider control valve (restricted) FDC, out manifold
ports C3 and C4 and into the front of the forks. Pilot
pressure is supplied to the two flow divider restrictions
and is sensed from pressure on opposite sides of the
restrictions. If there is a pressure difference across the
restrictions, pilot pressure will adjust the restrictions to
equalize the pressure to each fork make sure of equal
movement of the rams. Oil flows from the back of the
forks, through ports C1 and C2 of the fork extend man-
ifold, through SPC1, out the fork extend manifold and
into the load handler manifold through port F1. Oil flows
through PVF, CV4, out port AT of the load handler man-
ifold and to the reservoir. After a load handler function
is no longer necessary, CV4 will work with CV1 (in the
mainframe manifold) to keep approximately 1.38 MPa
in the circuit to get a fast response.

Crown 2012 PF25679-11 TSP 7000 SERIES M2.0-1970-060

149
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

Fork Retract Circuit function is not necessary, CV4 will work in conjunction
with CV1 (in the mainframe manifold) to keep approxi-
PVF is the proportional control valve that controls the mately 1.38 MPa in the circuit to get a fast response.
fork extend function. When extending the forks, the S1
coil is energized moving the PVF spool to the left (S1 is
the top coil). When retracting the forks, the S2 coil is
energized moving the PVF spool to the right (S2 is the
bottom coil). ACCESS 7 controls PVF by changing the
applied voltage to the coils. The more the voltage is
applied to the PVF coils, the more the PVF spool
moves, which lets more oil flow to the forks.
Two valves in the load handler manifold control the
pressure for the fork extend circuit, PVLH and PR2.
When the operator only commands the fork extend
function, the valve pressures are the same so the
valves do the same function. When the operator com-
mands more than one load handler function, pressures
may be different. For example, if auxiliary lift and fork
extend are selected, PVLH will be electronically ad-
justed by ACCESS 7 to 24.1 MPa to make sure there
is sufficient lift pressure. PR2 is factory set to limit max-
imum pressure to 9.7 MPa to make sure there is suffi-
cient fork extend pressure.
When an operator commands fork retract, ACCESS 7
energizes the PVF S2 coil and moves the valve spool
in proportion to the operator's command. ACCESS 7
also energizes PVLH coil and changes the pressure to
as much as 9.7 MPa. Oil flows from the mainframe
manifold block into port AP of the load handler manifold
block and to PVLH. PVLH pilot line senses the pres-
sure and if the pressure is more than 9.7 MPa will move
PVLH's spool and divert some of the flow to reservoir.
Oil flows through PR2. Pilot pressure is sent to the top
of PR2. If pressure is more than 9.7 MPa, pilot pres-
sure will overcome the spring pressure and gradually
move PR1's spool down, decreasing the flow to PVF
(limiting pressure to 9.7 MPa). Oil flows through PVF,
out port F1 and into the fork extend manifold block. Oil
flows through a pilot line to SPC2 unseating the pilot
check valve giving a path for return flow from the forks.
Oil flows through SPC1, through the flow divider control
valve (restricted) FDC, out manifold block ports C1 and
C2 and into the back of the forks. Pilot pressure is sent
to the two flow divider restrictions and is sensed from
pressure on opposite sides of the restrictions. If there
is a pressure difference across the restrictions, pilot
pressure will adjust the restrictions to equalize the
pressure to each fork for equal movement of the rams.
Oil flows from the front of the forks, through ports C3
and C4 of the fork extend manifold block, through
SPC2, out the fork extend manifold block and into the
load handler manifold block through port F2. Oil flows
through PVF, CV4, out port AT of the load handler man-
ifold block and to the reservoir. When the load handler

M2.0-1970-061 TSP 7000 SERIES Crown 2012 PF25679-12

150
 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

SUCTION
PRESSURE
RETURN
PILOT PRESSURE

Part of Load Han-

dler Manifold Fork Extend
Manifold

from Main Frame

Manifold

to Reservoir

Fig. 19 (12883)

Crown 2012 PF25679-13 TSP 7000 SERIES M2.0-1970-062

151
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

Pivot Right Circuit Pilot pressure is sent to the two sides of PCP and is
sensed from pressure across PVP. If PVP is not fully
PVP is the proportional control valve that controls the opened there will be a pressure difference across PVP.
pivot function. When moving right, the S1 coil is ener- If the pilot pressure sensed before PVP is more than
gized moving the PVP spool to the left (S1 is the top the PCP spring pressure and the pilot pressure sensed
coil). When moving counterclockwise, the S2 coil is en- at the load sense port of PVP, then the PCP spool will
ergized moving the PVP spool to the right (S2 is the move to the right and slow the flow and equalize the
bottom coil). The hydraulic control module (ACCESS 7) pressure across PCP. This lets full pressure compen-
controls PVP by changing the applied voltage to the sation of the pivot circuit flow. With the same operator
coils. The more voltage applied to the PVP coils, the command to PVP, the same flow will be supplied out
more PVP spool moves, which lets more oil flow to the the R2 port regardless of load weight or pressure. It
pivot cylinders. also provides for a smooth stop and start by preventing
Two valves in the load handler manifold block control a sudden raise or drop in pressure if the operator sud-
the pressure for the pivot circuit, PVLH and PR2. When denly stops and starts pivoting.
pivot only is necessary, the valve pressures are the
same so the valves do the same function. When more
than one load handler function is necessary, pressures
may be different. For example, if the auxiliary lift and
pivot are selected, PVLH will be electronically adjusted
by ACCESS 7 to 24.1 MPa to make sure there is suffi-
cient lift pressure. PR2 is factory set to limit maximum
pressure to 9.7 MPa to make sure there is sufficient
pivot pressure for pivot.
When an operator commands right pivot, ACCESS 7
energizes the PVP S1 coil and moves the valve spool
in proportion to the operator's command. ACCESS 7
also energizes the PVLH coil and changes the pres-
sure to as much as 9.7 MPa. Oil flows from the main-
frame manifold block into port AP of the load handler
manifold to PVLH. PVLH pilot line senses the pressure
and if the pressure is more than 9.7 MPa it will move
the PVLH spool and send some of the flow to the res-
ervoir. Oil flows through PR2. Pilot pressure is sent to
the top of PR2. If the pressure is more than 9.7 MPa,
pilot pressure will be more than the spring pressure
and it will gradually move the PR2 spool down and lim-
its flow to PVP. Oil flows through PCP and PVP to
CBV3. Pressure is diverted to CBV4 through a pilot
line. Oil flows through CBV3, out port R2 of the load
handler manifold, and into the front right pivot cylinder
causing the right pivot cylinder piston rod to retract.
This sends pressurized oil from the rear right cylinder
into the rear left pivot cylinder and causes the left piston
rod to extend. Oil flows from the left cylinder, into port
R1 of the load handler manifold block through CBV4's
top pivot line and moves the CBV4 spool making a path
for the return oil. Oil flows through CBV4, PVP, CV4,
out port AT of the load handler manifold block and to
the reservoir. After a load handler function is no longer
requested, CV4 will work in conjunction with CV1 (in
the mainframe manifold) to keep approximately 1.38
MPa in the circuit to get a fast response.

M2.0-1970-063 TSP 7000 SERIES Crown 2012 PF25679-14

152
 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

SUCTION
PRESSURE
RETURN
PILOT PRESSURE

Part of Load Han-

dler Manifold

from Main Frame

Manifold

to Reservoir

Fig. 20 (12884-01)

Crown 2012 PF25679-15 TSP 7000 SERIES M2.0-1970-064

153
HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

Pivot Left Circuit If pilot pressure sensed before PVP is more than PCP's
spring pressure and the pilot pressure sensed at the
PVP is the valve that controls the pivot function. When load sense port of PVP, then PCP spool will move to
moving left, the S1 coil is energized moving the PVP the right and slow the flow and equalize the pressure
spool to the left (S1 is the top coil). When moving coun- across PCP. This lets full pressure compensation of the
terclockwise, the S2 coil is energized moving the PVP pivot circuit flow. With the same operator command to
spool to the right (S2 is the bottom coil). The hydraulic PVP, the same flow will be supplied out port R1 regard-
control module (ACCESS 7) controls PVP by changing less of load weight or pressure. It also provides for a
the applied voltage to the coils. The more voltage ap- smooth stop and start by preventing a sudden raise or
plied to the PVP coils, the more the PVP spool moves, drop in pressure if the operator suddenly stops and
which lets more oil flow to the pivot cylinders. starts pivoting.
Two valves in the load handler manifold control the
pressure for the pivot circuit, PVLH and PR2. When
pivot only is requested, the valve pressures are the
same so the valves do the same function. When more
than one load handler function is requested, pressure
may be different. For example, if auxiliary lift and pivot
are selected, PVLH will be electronically adjusted by
ACCESS 7 to 24.1 MPa (3500 psi) to make sure there
is sufficient pressure for lift, while PR2 is factory set to
limit maximum pressure to 9.7 MPa (1400 psi) to make
sure there is sufficient pressure for pivot.
When an operator commands left pivot, ACCESS 7 en-
ergizes the PVP S2 coil and moves the valve spool in
proportion to the operator's command. ACCESS 7 also
energizes the PVLH coil and changes the pressure to
as much as 9.7 MPa. Oil flows from the mainframe
manifold into port AP of the load handler manifold to
PVLH. PVLH pilot line senses the pressure and if the
pressure is more than 9.7 MPa, it will move the PVLH
spool and divert some of the flow to the reservoir. Oil
flows through PR2. Pilot pressure is sent to the top of
PR2. If pressure is more than 9.7 MPa, pilot pressure
will overcome the spring pressure and gradually move
PR2's spool down to decrease flow to PVP (limiting
pressure to 9.7 MPa). Oil flows through PCP and PVP
to CBV4. Pressure is sent to CBV3 through a pilot line.
Oil flows through CBV4, out port R1 of the load handler
manifold and into the front left pivot cylinder causing
the pivot cylinder piston rod to retract. Pressurized oil
is forced from the rear left cylinder into the rear right
pivot cylinder causing the right piston rod to extend. Oil
flows from the right cylinder, into port R2 of the load
handler manifold through CBV3's top pivot line, moving
the CBV3 spool and making a path for the return oil. Oil
flows through CBV3, PVP, CV4, out port AT of the load
handler manifold and to the reservoir. After a load han-
dler function is no longer necessary, CV4 will work with
CV1 (in the mainframe manifold) to keep approxi-
mately 1.38 MPa in the circuit to get a fast response.
Pilot pressure is sent to the two sides of PCP and is
sensed from pressure across PVP. If PVP is not fully
opened there will be a pressure difference across PVP.

M2.0-1970-065 TSP 7000 SERIES Crown 2012 PF25679-16

154
 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS

SUCTION
PRESSURE
RETURN
PILOT PRESSURE

Part of Load Handler

Manifold

from Main Frame

Manifold

to Reservoir

Fig. 21 (12885-01)

Crown 2012 PF25679-17 TSP 7000 SERIES M2.0-1970-066

155
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC SYMBOLS

Hydraulic Schematic Symbols

VENTED RESERVOIR
with the lines above the fluid ELECTRIC MOTOR
M
level operates in one direction and speed

ELECTRIC MOTOR
VENTED RESERVOIR M operates in one direction in a speed
with the lines below the fluid that changes
level

ELECTRIC MOTOR
M operates in two opposite directions in
FILTER or STRAINER a speed that changes

HYDRAULIC PLUMBING HYDRAULIC PUMP

with full flow (this includes tubes, fixed displacement, operates in one
hoses, and the flow paths in the direction
manifolds)
HYDRAULIC PUMP-MOTOR
fixed displacement, operates in two
PILOT or DRAIN LINE opposite directions in a speed that
limited flow changes

LINES CROSSING
HYDRAULIC MOTOR
operates in two opposite directions

LINES CONNECTED
GAUGE
pressure

QUICK DISCONNECT
(disconnected)

GAUGE
temperature
PLUGGED PORT
(test port)

ACCUMULATOR
gas charged, diaphragm type
FLOW METER

Fig. 22 (3559-05)

M2.1-00.0-001 TSP 7000 SERIES Crown 1979 PF5066-1 Rev. 6/12

07 Rev. 6/12
156
 HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC SYMBOLS

PRESSURE SWITCH ACTUATOR MANUAL

CYLINDER
double-acting cylinder, SPRING
unequal area (spring-bias in the
de-energized position)

CYLINDER
double acting cylinder, equal area
(steer) (two end) SOLENOID
one coil or winding

CYLINDER
single-acting cylinder with spring return
(the rod end has a vent)

HYDRAULIC PILOT
OPERATED

CYLINDER
single-acting cylinder, ram type

SOLENOID
pilot operated

CYLINDER
single-acting cylinder, with cushion

SOLENOID DUAL

COMPONENT ENCLOSURE
manifold block

SOLENOID PROPORTIONAL

ACTUATOR MANUAL LEVER

VALVE PILOT CHECK
(pilot to open)

Fig. 23 (3560-05)

Crown 1979 PF5066-2 Rev. 6/12 TSP 7000 SERIES M2.1-00.0-002

07 Rev. 6/12
157
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC SYMBOLS

ORIFICE THROTTLE
VALVE SHUTTLE
fixed

ORIFICE THROTTLE
adjustable

VALVE
SINGLE COUNTERBALANCE
FLOW CONTROL in manifold
PRESSURE COMPENSATED
fixed

FLOW CONTROL
PRESSURE COMPENSATED
fixed with reverse flow bypass FLOW DIVIDER/COMBINER

FUSE VELOCITY
BYPASS FLOW CONTROL
controlled flow, pressure
adjusted

VALVE RELIEF
VALVE MANUAL SHUTOFF
fixed

P TORQUE GENERATOR
VALVE RELIEF T
adjustable

STEER UNIT
T L hydrostatic
VALVE CHECK P R

Fig. 24 (3561-05)

M2.1-00.0-003 TSP 7000 SERIES Crown 1979 PF5066-3 Rev. 6/12

07 Rev. 6/12
158
 HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC SYMBOLS

VALVE
VALVE
two-way valve with two positions
three-way valve with two positions
spring-bias, solenoid control

VALVE
three-way valve with two positions

VALVE
four-way valve with three positions
two spring centered, manual lever
VALVE control
four-way valve with two positions

VALVE
four-way valve with three positions

Note: The type of valve is the number

of spools found in the component (the
three spool valve is above)
VALVE
two-way valve with all positions

VALVE
four-way valve with all positions

Fig. 25 (3562-04)

Crown 1979 PF5066-4 Rev. 6/12 TSP 7000 SERIES M2.1-00.0-004

07 Rev. 6/12
159
HYDRAULIC SYSTEM
HYDRAULIC PUMP

Hydraulic Pump

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 pressure.
 Keep hands and body away from pinholes which
eject fluids under high-pressure.
 Use a piece of cardboard or paper to search for
leaks. Do not use your hand.
Consider any fluid injected into the skin under high-
pressure as a serious medical emergency despite an
initial normal appearance of the skin. There is a de-
layed onset of pain, and serious tissue damage may
occur. Seek medical attention immediately by a spe-
cialist who has experience with this type of injury.

Before replacing the hydraulic pump, relieve the hy-

draulic system pressure by following the procedure
listed under Hydraulic in the Control of Hazardous En-
ergy section of this manual.
Note: Whenever the hydraulic pump is replaced, the
new pump must be primed prior to use.

Pump Replacement
Refer to Figure 26.
1. Remove oil from the reservoir until the oil level is
approximately 588 mm from the top of the reser-
voir.
2. Disconnect the hose assembly (2) from the pump
(1).
3. Seal the hose assembly (2) to prevent contamina-
tion.
4. Seal the breather on the reservoir to reduce oil loss
when the suction hose (5) is removed.
5. Loosen the clamps (3, 4) and remove the suction
and return hoses (5, 6) from the pump ports. Fig. 26 (25712)
6. Seal the hoses (5, 6) to prevent contamination. 8. Remove the two screws (10) that secure the pump
(1) to the motor.
7. Remove the adapter (7) from the pump (1).
9. Remove the pump (1) exactly in line to avoid dam-
age to the shafts or coupler (9).
10. Remove the spline coupler (9) between the pump
and motor shafts.

M2.1-1970-001 TSP 7000 SERIES Crown 2011 PF25372-1

160

11. Inspect the splines on the coupler and motor
shafts. Replace the coupler if the splines are worn.
12. Remove the old grease from the coupler and motor
splines.
13. Lubricate the coupler and motor and pump splines
with spline grease (063002-039).
14. Install the pump (1) and secure it to the motor with
the screws (10) previously removed in Step 8.
Torque screws 130 Nm.
15. Check components and hoses for contaminates.
Clean or replace as necessary.
16. Check the o-rings (8, 9) on the adapter (7) to make
sure they are not worn. Replace the o-rings if nec-
essary.
17. Install the adapter (7) on the pump (1). Torque
adapter 88–95 Nm.
18. Install the suction and return hoses (5 & 6), that
were previously removed in Step 5, on the pump
(1).
19. Secure the suction and return hoses to the pump
with the clamps (3 & 4) that were previously re-
moved in Step 5.
20. Install the hose assembly (2) that was previously
removed in Step 2. Torque hose fitting 88–95 Nm.
21. Remove the breather plug on top of the reservoir
and replace the breather. Also inspect the breather
cap and replace the filler-breather assembly if it's
severely contaminated.
22. Add clean fresh oil to the reservoir midway be-
tween the "add" and "fill" marks.
23. Perform the procedure outlined under Lift Pump
Priming Procedure.
Crown 2011 PF25372-2 TSP 7000 SERIES
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Lift Pump Priming Procedure
This procedure covers the steps to be taken when first
starting a lift pump on a vehicle that has had any of the
following operations performed:
CAUTION
It is critical that the regen lift pump is completely
primed prior to operating at high speed or elevated
pressure. Failure to do so may result in pump dam-
age.
• 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 operation that may have caused the lift pump
to lose its prime.
WARNING
Before proceeding, review the Control of Hazard-
ous Energy Lockout - Tagout section and Hydrau-
lic chapter of this manual.
1. Move the truck to a secure non-traffic maintenance
area with a level floor.
2. Lockout or tagout the truck as described under
Lockout - Tagout in the Control of Hazardous En-
ergy section in this manual.
3. Check to make sure the hydraulic reservoir oil level
is at the full mark. Add oil if necessary.
M2.1-1970-002
161
HYDRAULIC SYSTEM
HYDRAULIC PUMP

4. Refer to Figure 27. Remove the bleed plug from

the M1 port on the hydraulic pump (1). Wait ap-
proximately 10 minutes before proceeding to the
next step. Note that slow oil seepage may be ob-
served at M1.

Fig. 27 (25875)
5. Connect a short hose and adapter to M1 port (to
empty into a catch pan) to vent pump outlet at low
pressure.
6. Run the pump at very low speed (i.e., less that 500
rpm) until a solid stream of oil is observed. Then
stop the pump as it is now primed.
7. Remove the vent hose and adapter from the M1
port.
8. Inspect the o-ring on the bleed plug that was previ-
ously removed in Step 4. Replace o-ring if neces-
sary.
9. Install the bleed plug and torque to 18–20 Nm.
10. With the pump primed, slowly operate the hoist
and platform functions to assure proper operation.

M2.1-1970-003 TSP 7000 SERIES Crown 2011 PF25372-3

162

Manifolds
Relief Valve (RV1)
RV1 supplies protection from high oil pressure for the
lift circuit. RV1 (2) is on the main lift pump (1). Refer to
Figure 28.
1 top of the load handler assembly. Refer to
2 5
3
4 •
Fig. 28 (27216)
If the oil pressure in the circuit is more than the relief
valve was set at, the valve will open and send oil to the
reservoir, keeping a maximum pressure limit for the cir-
cuit.
Note: Make sure the truck battery is fully charged and
that all truck calibrations and feature configurations are
complete before you do measurements or adjustments
on the truck.
To adjust RV1:
Refer to Figure 28.
• Connect a 0 to 35 MPa pressure gauge to the test
port (5) on the mainframe manifold (3).
• Put a thermometer in the hydraulic oil.
• Install a spacer above the auxiliary lift cylinder to
limit cylinder extension.
• Raise the auxiliary forks and hold the control in the
full up position while you read the pressure gauge.
Note: Read the pressure while the oil goes full flow
over the relief valve with the pump operating. The pres-
sure range is 24.8 MPa at standard operating temper-
ature.
Crown 2012 PF25503-1 TSP 7000 SERIES
HYDRAULIC SYSTEM
MANIFOLDS
• If the relief valve setting is not in the necessary
range, loosen the jam nut on RV1 (2) and adjust the
valve.
• Tighten the jam nut when the adjustment is correct.
• Read the pressure setting again and adjust if nec-
essary.
Manifold Block O-Ring Replacement
• The mainframe manifold (4) is on the left side of
mainframe and the load handler manifold is in the
Figure 28.
• Open the manual lowering valve (MVL) (4) on the
mainframe manifold (3) to release the system pres-
sure.
WARNING
AVOID HIGH PRESSURE FLUIDS
High pressure fluid can go through the skin and
cause serious injury.
• Release the pressure before you disconnect the hy-
draulic lines.
• Tighten all connections before you apply the pres-
sure.
• Keep your hands and body away from pin holes
which eject high pressure fluids.
• Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
• High pressure fluid that goes into the skin can be-
come a severe medical emergency even when the
skin looks normal.
• There is a delayed start of pain, and severe tissue
damage may occur.
• You must get medical aid from a specialist who has
had experience with this type of injury.
• Remove all the valves from manifold blocks and put
them on a clean piece of cardboard.
Note: It is important to keep work surfaces and parts as
clean as possible to prevent contamination during the
disassembly procedure (e.g., replacement of o-rings,
putting valves into manifolds, correct torque of valves).
• Seal the manifold block ports when you remove
valves to prevent contamination in the block.
• Catch oil that is left in the block.
• Do not remove orifices or SAE plugs from the man-
ifold blocks.
M2.4-1970-001
163
HYDRAULIC SYSTEM
MANIFOLDS

• Make a visual inspection of valves and valve holes
for signs of contamination.
Note: Make sure that the valve mechanisms move
freely. Look for signs of contamination. Discard the
valve and replace it with a new valve if there is contam-
ination in the valve.
• Remove the top o-ring (cap) from each valve.
– Put tape on the valve threads to prevent damage
to the replacement o-ring.
– Replace the top o-ring.
Note: The top o-ring (cap) will be the one that is near-
est to the outer surface of the manifold block after the
valve is installed in manifold block.
• Visually examine all the other o-rings and backup
rings. Replace as necessary.
• Install each valve into the manifold block and hand
tighten.
• Refer to section 02.4 for valve location and Chart 1
for torque values of valves.
– Torque each valve to the value given.
Note: If you use a crow foot wrench or other extension,
position it at 90° to the torque wrench handle to keep
the same torque value as the torque wrench setting.
Seal kits are available to replace all o-rings on each
cartridge type valve. Refer to section 02.4 for seal kit
part numbers.
Chart 1 shows the torque values for all cartridge type
valves installed in the mainframe and load handler
manifolds. Refer to the chart when you install a re-
placement cartridge valve.

CHART 1

Mainframe Manifold
Cartridge Coil Nut Cartridge Coil Nut
Valve Part Torque Torque Valve Part Torque Torque
Item Item
Number Number
Nm ft lb Nm ft lb Nm ft lb Nm ft lb
MVL 135722 38 28 - - SVMH 149406-001 71 52 8 6
SVA 149405-001 54 40 8 6
Load Handler Manifold
Cartridge Coil Nut Cartridge Coil Nut
Valve Part Torque Torque Valve Part Torque Torque
Item Item
Number Number
Nm ft lb Nm ft lb Nm ft lb Nm ft lb
PVLH 135727 52 38 11 8 CBV1 135725 52 38 - -
PCAR 135732 52 38 - - CBV2 135725 52 38 - -
PVAR 135724-002 61 45 8 6 CBV3 135718 47 35 - -
PCAL 135731 52 38 - - CBV4 135718 47 35 - -
PVAL 135724-002 61 45 8 6 CV3 117380-002 57 42 - -
PCT 135732 52 38 - - CV4 114816-003 38 28 - -
PVT 135729-002 38 28 8 6 PR1 135726-001 38 28 - -
PVF 135730 38 28 8 6 PR2 135726-002 38 28 - -
PCP 135732 52 38 - - RV2 138361 52 38 - -
PVP 135728 38 28 8 6 RV3 138361 52 38 - -

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 HYDRAULIC SYSTEM
TRAVERSE MOTOR

Traverse Motor • Masking tape

Prepare the Traction Motor for Dis-
assembly
Special Tools and Equipment
• 363119-001 Brake and Parts Cleaner
• Crocus cloth or emery paper
• Hydraulic press
• SAE 10W40 SE or SF oil
• Special bearing mandrel (refer to Figure 29)
• 0.13 mm feeler gauge
• Calipers
• Blind hole bearing puller for 26.9 mm and 41.1 mm
diameter bearing or seal puller
• Corrosion resistant grease, part number 107334.
Note: The seal kits include the grease.

3 11.94 mm (.470 in)

11.68 mm (.460 in)

0.74 mm
5 (0.029 in)
0.53 mm
(0.021 in)

6 4.06 mm
(0.160 in)
3.86 mm
(0152 in)

7 15.11 mm
(0.595 in)
14.86 mm
8 (0.585 in)

Fig. 29 (27349)
1 63.5 mm Diameter Minimum
2 50.42 mm to 50.37 mm Diameter
3 41.20 mm to 41.15 mm Diameter
4 Knurl
5 12.70 mm Minimum
6 15° Typical (2x)
7 26.92 mm to 26.87 mm Diameter
8 32.94 mm to 32.89 mm Diameter
9 0.76 mm x 45° Typical (4x)

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HYDRAULIC SYSTEM
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CAUTION
If you incorrectly clean components you can cause
damage to the motor components.
If you use a steam cleaner or power washer you can
cause damage to the motor components.
 Do not use a steam cleaner or power washer to
clean the traverse motor components.
 Use the cleaner specified in the Special Tools and
Equipment to clean the components.

1. Clean the contamination off the fittings and hose

connections before you disconnect and remove
the traverse motor.
2. Remove the contamination from the motor shaft.
3. Remove the motor shaft connections and hose fit-
tings.
4. Put plugs in the motor ports and hydraulic hose fit-
tings.
5. Remove the traverse motor from truck.
6. Drain the oil from the motor and move the motor to
a clean work surface.
7. Clean and dry the motor.
Note: As you disassemble the motor, clean the compo-
nents with 363119-001 Brake and Parts Cleaner. Keep
the components apart to prevent damage.

Traverse Motor Disassembly

Refer to Figure 30.

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 HYDRAULIC SYSTEM
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20
19 18

17
16
15
14
13
12
10

11
4

7a
7b
7c

4
7 21

6
4
5
3

5
1
4

Fig. 30 (27357)

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HYDRAULIC SYSTEM
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Remove and examine the end cover

WARNING
A motor that falls can cause injury.
If the vise does not hold the motor, the motor can fall
and cause injury.
 After you put the motor in the vise, make sure the
vise is tight.

8. Put the traverse motor in a soft-jawed vise, with the

motor shaft (11) down. Tighten the vise on the
sides of the housing (18) mounting flange or ports.
9. Make a mark down and across the traverse motor
components from the end cover (2) to the housing
(18) to help with reassembly. Refer to Figure 31.
Fig. 33 (12926)
12. Remove the end cover (2) and seal (4). Discard the
seal (4). Refer to Figure 34.

Fig. 31 (12924) Fig. 34 (12927)

10. Remove the six bolts. Refer to Figure 32.
13. Examine the end cover for cracks and the bolt
head recesses for good sealing surfaces. If neces-
sary, replace the end cover.
Note: If the part of the cover that touches the commu-
tator looks polished (not scratches), ignore it. This is
usual. If the cover is discolored, examine the system
for the cause. Discoloration is a sign of high oil temper-
ature or too much speed.

Fig. 32 (12925)
11. Examine the bolts for damaged threads, or dam-
aged sealing rings below the bolt head. Refer to
Figure 33.

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 HYDRAULIC SYSTEM
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Remove and examine the commutator

14. Remove the commutator ring (5). Refer to CAUTION
Figure 35.
Compressed air can cause injury.
Compressed air can cause unwanted material or parti-
cles to cause injury. Compressed air can also go into
the body through areas without skin and cause pain or
severe injury.
 Use eye and face protection when you use com-
pressed air to clean components.
 Do not use more than 205 kPa (30 psi) compressed
air to clean components.
 Do not use compressed air on your skin or clothes.
 Use applicable protective devices for personnel in
the area.

Fig. 35 (12928)
17. Use low pressure air to lift the seal (3) from the seal
15. Examine the commutator ring (5) for cracks or groove (3). Refer to Figure 37.
burrs.
16. Remove the commutator (5) and the seal (3). Refer
to Figure 36.

Fig. 37 (12930)
18. Remove the seal (3) from the commutator (5). Dis-
card the seal (3).
Fig. 36 (12929) 19. Examine the commutator for damage. If neces-
sary, replace the commutator and commutator
ring.
Note: The commutator and commutator ring are a
matched set (21). You must replace them at the same
time.

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HYDRAULIC SYSTEM
TRAVERSE MOTOR

Remove and examine the manifold

Note: When you remove the manifold, compare the
sides of the manifold. Make sure that you assemble the
manifold with the same side against the rotor set.
20. Remove the manifold (6). Refer to 12931.

Fig. 38 (12931)
21. Remove and discard the seals (4).
22. Examine the manifold for damage and if neces-
sary, replace it.
Remove and examine the rotor set
Note: For maximum component life, you must assem-
ble the rotor set (7) and mating components in the
same position.
23. Make a mark on the surface of the components
with ink or a grease pencil.
Note: When you remove the rotor set and wear plate,
the drive link (9) may come away from the motor shaft
(11). If necessary, move the rotor set on the wear plate
to remove the drive link out of the rotor set and wear
plate. Refer to Figure 40.
24. Remove the rotor set (7) and the wear plate (8) to-
gether to keep the rotor set in the same position
when it is assembled. Refer to Figure 39.
Fig. 40 (12933)
25. Examine the rotor set, wear plate and seal be-
tween the rotor set and wear plate for damage. If
necessary, replace the components.
Note: The rotor components are a matched set. You
must replace the components at the same time.
Note: A wear plate that looks polished is usual.
26. Put the rotor set (7) and the wear plate (8) on a flat
surface.
27. Turn the rotor (7a) until two rotor lobes (180 de-
grees apart) and a roller vane (7c) centerline are
on the same stator (7b) centerline.
28. Measure the rotor lobe to roller vane clearance
with a feeler gauge at the centerline. If there is
more than 0.13 mm of clearance, replace the rotor
set. Refer to Figure 41.

Fig. 41 (12934)

Fig. 39 (12932)

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 HYDRAULIC SYSTEM
TRAVERSE MOTOR

Remove and examine the drive link, shaft and bear-

ing
29. Remove the drive link (9) from the motor shaft (11).
Refer to Figure 42.

Fig. 44 (12937)
35. Examine the motor shaft bearing and seal surfaces
for damage. Refer to Figure 45 for important areas
(1) to examine. If necessary replace the motor
Fig. 42 (12935)
shaft.
30. Examine the drive link for cracks, wear or damage.
Examine the drive link and mating spline parts for
backlash. If there is backlash, replace the compo-
nents. 1
31. Remove and discard the seal (4) from the housing
(18).
32. Remove the key (10) from the motor shaft (11).
33. Examine the part of the motor shaft (11) that ex-
tends from the housing. If the shaft has corrosion
on it, remove the corrosion with crocus cloth or em-
ery paper. Refer to Figure 43.

Fig. 45 (27353)
Note: Some shaft wear in the seal area is permitted. If
the shaft is worn more than 0.51 mm around the diam-
eter, replace the motor shaft. A light polish is permitted
in the shaft bearing areas.
36. Remove the thrust bearing (13) and thrust washer
(14) from the housing.

Fig. 43 (12936)
34. Push on the output end of the motor shaft (11) and
remove the shaft. Refer to Figure 44.

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HYDRAULIC SYSTEM
TRAVERSE MOTOR

37. Examine the bearing. If it is worn or has corrosion

on it, replace the bearing. Make sure that the bear-
ing has all the rollers and that they are in good con-
dition. Refer to Figure 46.

Fig. 48 (12941)
41. Examine the housing (18) for cracks, burrs and
other damage. Examine the tapped holes for
Fig. 46 (12939) thread damage. If the housing is damaged, discard
it. Refer to Figure 49.
38. Remove the seal (15), the backup ring (17) and
backup washer (16) from the housing (18). Discard
the seal and backup ring. Refer to Figure 47.

Fig. 49 (12942)
Note: Measure the depth of the inner (12) and outer
bearing (19) before you remove them. Refer to
Fig. 47 (12940)
Figure 50.
39. Remove the housing (18) from the vise and turn
the housing 180 degrees.
40. Use a blind hole bearing or seal puller and remove
the seal (20). Discard the seal. Refer to Figure 48.

Fig. 50 (12945)
42. Examine the inner (12) and outer bearing (19). The
bearings must be tight in the housing. If they are

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 HYDRAULIC SYSTEM
TRAVERSE MOTOR

corroded or damaged, replace them. Refer to

Figure 51. CAUTION
43. If the thrust bearing (13) and thrust washer (14) are
held in the housing by the inner bushing (12), ex- Do not mix greases
amine the thrust bearing and washer. If necessary, If you mix greases, you can decrease the life of a bear-
replace them. ing.
 Only use the grease specified in the Special Tools
and Equipment list.

Note: Apply oil or grease to a component only when

the assembly steps include it.
Install the inner and outer bearings

Fig. 51 (12943)
44. The clearance of the bearing (12, 19) and the shaft
must not be more than 0.025 mm (0.010 in). If
more, replace the bushings. Make sure that you
use the correct bearing puller. Refer to Figure 52.
CAUTION
Used bearings can cause the motor to stop.
A press is used to install the inner and outer bearings
(12, 19). If you remove them do not install them in the
motor.
 If you remove the inner and outer bearing, always
replace them with new bearings.
1. Apply oil or grease to all the seals.
2. Apply 107334 grease to the bearings.

Fig. 52 (12944)

Traverse Motor Assembly

Refer to Figure 30.

CAUTION
Used seals can cause leaks.
You can not always see damage to a seal or if it is
worn. Seals that are worn or damaged can cause
leaks.
 Always use new seals when assembling the trav-
erse motor.

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HYDRAULIC SYSTEM
TRAVERSE MOTOR

3. Use a bearing mandrel and press and push the

outer bearing (19) into the mounting flange end of
the housing (18). Push the bearing to a depth of
3.84–4.09 mm measured from the end of the bear-
ing counterbore. Refer to Figure 53.

Fig. 55 (12952)
Install the thrust bearing and shaft
6. Put the traverse motor in a soft-jawed vise, with the
motor shaft (11) bore down. Tighten the vise on the
Fig. 53 (12948) sides of the housing (18) mounting flange or ports.
Refer to Figure 56.
Note: Refer to step 2 below. When you push the bear-
ing in the housing, the bearing mandrel must be
against the end of the bearing with letters. Make sure
that the housing bore is square with the press. Make
sure that you push the bearing straight into the hous-
ing.
4. Use the bearing mandrel and press and push the
inner bearing (12) in the housing. The bearing (12)
must be flush to 6 mm below the contact face of the
housing wear plate. Refer to Figure 54.

Fig. 56 (12953)
7. Install the backup ring (17), backup washer (16)
and seal (15) with the seal lip facing toward the mo-
tor. Refer to Figures 57 and 58.

Fig. 54 (12950)
5. Press the seal (20) into the housing (18). The seal
flange must be flush with the housing. Refer to
Figure 55.

Fig. 57 (12954)

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 HYDRAULIC SYSTEM
TRAVERSE MOTOR

1 2 3

Fig. 60 (12956)
Note: The outer bearing (19) is not lubricated by the
4 5 6 7 hydraulic fluid. Make sure that you put a larger quantity
of 107334 grease in the bearing.
Fig. 58 (27358) 10. Install the motor shaft (11) into the housing (18).
1 Thrust washers Push the shaft against the thrust bearing (14). Re-
fer to Figure 61.
2 Seal
3 Housing
4 Shaft
5 Thrust bearing
6 Backup washer
7 Backup ring

8. Assemble the thrust washer (14) and thrust bear-

ing (13). Refer to Figure 59.

Fig. 61 (12957)

Fig. 59 (12955)
Note: Use one thrust washer (14) and one thrust bear-
ing (13).
9. Apply masking tape around the splines or key slot
on the shaft (11) to prevent damage to seal. Refer
to Figure 60.

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HYDRAULIC SYSTEM
TRAVERSE MOTOR

11. Examine the shaft (11). The shaft (11) must be

flush or a small distance below the housing sur-
face. The shaft (11) must turn smoothly on the
thrust bearing (13). Refer to Figure 62.

Fig. 64 (12960)
14. Assemble the wear plate (8). Refer to Figure 65.

Fig. 62 (12958)
Install the drive link and rotor set
12. Install the seal (4) in the housing (18) groove. Refer
to Figure 63.

Fig. 65 (12961)
15. Install the seal (4) on the wear plate side of the ro-
tor set stator (7b). Refer to Figure 66.

Fig. 63 (12959)
Note: One or two studs assembled in the housing (18)
bolt holes, approximately 180° apart, will help with the
assembly. You can make the studs. Use two bolts with
a 3/8-24 UNF 2A or 5/16-24 UNF threads. The bolts
must be 13 mm longer than the bolts (1) in the traverse
motor. Remove the bolt heads. Refer to Figure 64.
13. Install the drive link (9) in the motor shaft (11). Use
the marks you put on the motor shaft and drive link
before disassembly to align the drive link in the Fig. 66 (12962)
shaft. Refer to Figure 64.
16. Remove one of the studs.

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 HYDRAULIC SYSTEM
TRAVERSE MOTOR

17. Install the rotor set (7) on the wear plate (8) with the
counterbore and seal (4) down. Engage the splines
with the drive link splines. Refer to Figure 67.
Note: The counterbore side of the rotor must be down
for drive link clearance. This also keeps the drive link
spline in the correct position.

Fig. 69 (12965)
20. Install the stud removed in step 16.
21. Install the seal (4) in the manifold groove (6). Refer
to Figure 70.

Fig. 67 (12963)
Install the manifold, commutator and end head
18. Install the seal (4) in the groove of the rotor set side
of the manifold (6). Refer to Figure 68.

Fig. 70 (12966)
22. Install the commutator ring (5). Refer to Figure 71.

Fig. 68 (12964)
19. Assemble the manifold (6) over the alignment
studs and drive link (9) and onto the rotor set. Make
sure the correct manifold surface is against the ro-
tor set (7). Refer to Figure 69.

Fig. 71 (12967)

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HYDRAULIC SYSTEM
TRAVERSE MOTOR

23. Install a seal (3) with the flat side up, into commu-
tator (5). Refer to Figure 72.

Fig. 72 (12968) Fig. 75 (12971)

24. Assemble the commutator (5) with the seal up. Re- 27. Use the mark you made on the cover to align the
fer to Figure 73. end cover. Refer to Figure 76.

Fig. 73 (12969)
25. Install a seal (4) into the end cover (2). Refer to
Figure 74.

Fig. 76 (12972)

Fig. 74 (12970)
26. Install the end cover (2). Refer to Figure 75.

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 HYDRAULIC SYSTEM
TRAVERSE MOTOR

28. Assemble the six bolts (1) and tighten by hand. Re-
fer to Figure 77.
32. Apply 690 kPa of dry air or nitrogen to the motor
and submerge the motor in petroleum-based sol-
vent. Examine the motor for leaks.
33. Use a torque wrench to turn the motor shaft. The
torque necessary to turn the motor shaft must not
be more than 68 Nm.
Note: Refer to the motor housing ports. If you connect
the input pressure hose to the A port, the motor shaft
will turn clockwise. If you connect the input pressure
hose to the B port, the motor shaft will turn counter-
clockwise.
34. If a test stand is available, examine the operation
of the traverse motor.

Fig. 77 (12973)
29. Torque the six bolts to approximately 15 Nm in the
sequence shown in Figure 78.
30. Torque the six bolts to approximately 22 Nm in the
sequence shown in Figure 78.
31. Torque the six bolts to 30-35 Nm in the sequence
shown in Figure 78.

Fig. 78 (12975)
Examine the operation

WARNING
An explosion or fire can cause injury or death.
Be careful when you use a solvent. Even a small explo-
sion or fire can cause injury or death.
 Have fire protection equipment present
 Do not use open flame around a solvent
 Make sure that the area where you use the solvent
has good airflow.

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HYDRAULIC SYSTEM
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Troubleshooting
Refer to Figure 30. CAUTION
Overheated oil can cause motor leaks.
If the hydraulic oil temperature becomes hotter than
93 °C (200 °F), the motor seals can become smaller,
hard and crack. This can cause leaks.
 If the oil becomes hotter than 93 °C (200 °F), exam-
ine the motor for leaks.

Troubleshooting Chart

The motor leaks The hose fittings are loose, worn or dam- Tighten the fittings. Replace the o-rings or
aged hoses
The oil seals (4) are damaged from over- Replace the seals (4)
heated oil.
A bolt (1) is loose or the bolt sealing ring
Tighten the bolt (1) or replace it.
is damaged
The internal shaft seal (15) is worn or
Replace the seal (15)
damaged
The shaft (11) and seal (15) is worn or Replace the shaft (11) and seal (15)
damaged
The motor shaft Low oil flow Examine the oil. Add oil if necessary. If the
speed decreases truck has the incorrect oil for the tempera-
ture of the truck operation, replace the oil
Examine the relief valve and pressure re-
ducing valve. If necessary, replace the
valves
Examine and repair or replace a worn pump
Internal leaks in the motor Replace the rotor set (7)
The splines are worn or damaged Replace the rotor set (7), drive link (9) and
shaft (11)
The motor is hot Correct the cause for the hot motor. Exam-
ine for blocked oil flow.
High oil pressure is Oil flow is blocked. Repair
necessary to oper-
The motor is damaged Repair the motor
ate the motor
Low pump pressure Repair the motor
The load handler is not operating cor- Troubleshoot the load handler operation
rectly

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180
DRIVE UNIT
181
Notes:

182
 DRIVE UNIT
DRIVE UNIT

Drive Unit Tire Replacement

To remove the tire from the hub
Drive Tire Replacement 1. Remove the tire from the hub.
Necessary Special Tools and Equipment Note: Examine the hub for damage. Replace a dam-
aged hub. If the hub has paint on the seats of the lug
• Hydraulic press
nuts and the truck axle, remove it.
• Torque wrench
To push new tires on the hubs
Drive Tire Removal
Refer to Figure 79.
To prepare the truck WARNING
1. Move the truck to a maintenance area with a level Truck accidents and injury can be caused by incor-
floor. rect tire compound or tire dimension.
2. Fully lower the forks. An incorrect tire type can have an unwanted effect on
how the truck can stop or steer. It can also have an
3. Turn the drive tire until the lug nuts are in a position
unwanted effect on the truck capacity.
that lets you loosen them.
 Use only a tire with the correct compound and di-
4. Turn the truck OFF.
mension.
5. Put chocks against the wheels to prevent move-
ment of the truck. Refer to SAFETY > Control of
Hazardous Energy > Lockout/Tagout. 2. Put a new tire on a flat and stable plate (1). Refer
to Figure 80.
6. Disconnect the battery.
7. Lockout/tagout the truck.
8. Lift the power unit until the drive tire is off the floor.
Put hardwood blocks below the power unit. Refer
to SAFETY > Control of Hazardous Energy > Jack-
ing and Blocking.
To remove the drive tire from the truck
1. Remove the rear, center door of the power unit. 2
2. Remove the center skirt (1) from the power unit.

3
1

2
1

Fig. 80 (27220)
Note: The plate must not bend when you push the hub
into the tire. If the plate bends, the hub will be tilted in
the tire.
3. Align the hub (2) on the tire (3).
Fig. 79 (27218)
4. Apply a thin layer of oil to the outer surface of the
3. If the truck has wire guidance, remove the sensor hub.
bar (2).
4. Remove the lug nuts and drive tire.

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DRIVE UNIT
DRIVE UNIT

5. Push the hub slowly into the tire until the hub (1) is
flush with the tire (2). Refer to Figure 81.

1 1
12 5
8 9

4 3

10 7

6 11
2

Fig. 82 (27222)
Fig. 81 (27219)
2. In the 1st step, torque the lug nuts to 40–55 Nm.
Drive Tire Installation
3. In the 2nd step, torque the lug nuts to 120–
To install the drive tire 135 Nm.
1. Install the drive tire on the truck and tighten the lug 4. Last, torque the lug nuts to 205–216 Nm.
nuts by hand. 5. If the truck has wire guidance, install the sensor
bar. Refer to ELECTRICAL > Wire Guidance >
Sensors for sensor height adjustment.
CAUTION 6. Install the center skirt on the power unit.
Too high torque could cause cracks in the wheel 7. Install the door on the power unit.
studs. 8. Remove the blocks.
If the torque value applied to the lug nuts is too high, 9. If the truck has wire guidance, calibrate wire guid-
the wheel studs could get cracks. ance. Refer to ELECTRICAL > Access 1 2 3® >
 Make sure that you torque the lug nuts to the spec- CALIBRATION > C5 WIRE GUIDANCE.
ifications that follow. 10. Examine the truck operation.

Note: Obey the torque procedure that follows. Always
torque the lug nuts in the sequence shown in
Figure 82.
Changing the Oil
Specifications
• Change the oil the 1st time at 250 hours of opera-
tion. Then, each 2500 hours of operation.
• The oil capacity of the drive unit is 7.1 l.
• Fill the drive unit with 363514-001 gear oil (Mobi-
lube 1 SHC 75W-90 synthetic oil).

Necessary Special Tools and Equipment

• Catch pan

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 DRIVE UNIT
DRIVE UNIT

• 7.1 l of 363514-001 gear oil

To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the drive unit until you get access to the check
and fill plugs.
1
4. Turn the truck OFF.
5. Put the chocks against the wheels to prevent
movement of the truck.
6. Disconnect the battery.
7. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
8. Remove the rear, center door of the power unit.
To change the oil
Fig. 84 (27235)
1. Put a catch pan below the drive unit.
2. Remove the drain plug (1).Refer to Figure 83. Drive Unit Removal
To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent move-
ment of the truck.
5. Disconnect the battery.
6. Lockout/tagout the truck. Refer to SAFETY > Con-
1 trol of Hazardous Energy > Lockout/Tagout.
7. Lift the power unit until the drive tire is off the floor.
Put hardwood blocks below the power unit. Refer
to SAFETY > Control of Hazardous Energy > Jack-
ing and Blocking.
Fig. 83 (27223) 8. Remove the rear, center door of the power unit.
3. Remove the fill plug (1). Refer to Figure 84. To remove the drive unit
4. Examine the seal on the drain and fill plugs. If the 1. Remove the traction motor. Refer to Traction Motor
seals are damaged, replace them. Removal.
5. After you remove the oil, install the drain plug. 2. Remove the center skirt (1) from the power unit.
6. Fill the drive unit with gear oil until oil starts to flow Refer to Figure 79.
out of the fill plug hole. 3. If the truck has wire guidance, remove the sensor
7. Install the fill plug. bar (2).
8. Examine the truck operation and the drive unit for 4. Use hardwood blocks to hold the power unit in po-
leaks. sition.
5. Attach a strap to the drive unit. Attach the strap to
a lift device.
6. Remove the six screws that hold the drive unit to
the mounting plate.

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DRIVE UNIT
DRIVE UNIT

7. Use the lift device to remove the drive unit from the
truck.
Note: Examine the bumpers (1). If the bumpers are
worn or damaged, replace them. Refer to Figure 85.
1 5. Remove the four screws that hold the motor to the
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent move-
ment of the truck.
5. Disconnect the battery.
6. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
7. Remove the rear, center door of the power unit.
To remove the traction motor
1. Remove the cover on top of the traction motor.
2. Disconnect the electrical cables from the traction
motor.
3. Disconnect the brake connector, CA407.
4. Attach a strap to the motor. Use a lift device to hold
the motor.
mounting plate.
6. Use the lift device to remove the motor and brake
assembly from the truck.

Traction Motor Installation

Necessary Special Tools and Equipment
Fig. 85 (27224)
• 127801S Spline Grease
Drive Unit Installation • Torque wrench
To install the drive unit To install the traction motor
Note: To install the drive unit, do the opposite of the 1. Apply 127801S spline grease to the motor shaft
removal steps. Torque the six screws that hold the and drive unit spline.
drive unit to the mounting plate to 43 Nm. After you in- 2. Attach a strap to the motor.
stall the drive unit:
3. Use a lift device and install the motor.
1. Examine the level of the drive unit oil. If necessary,
4. Install the four screws that hold the motor. Torque
add oil.
the screws to 43 Nm.
2. Torque the traction motor screws to 43 Nm.
5. Connect the electrical cables to the motor.
Note: For the part number of the oil, refer to Changing
6. Connect CA407.
the Oil.
7. Examine the truck operation.
3. If the truck has wire guidance, refer to ELECTRI-
CAL > Wire Guidance > Sensors for sensor height
adjustment.
4. If the truck has wire guidance, calibrate wire guid-
ance. Refer to ELECTRICAL > Access 1 2 3 >
CALIBRATION > C5 WIRE GUIDANCE.
5. Examine the truck operation.

Traction Motor Removal

To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.

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186
ELECTRICAL SYSTEM
187
Notes:

188
 ELECTRICAL SYSTEM
ENCODERS

Encoders
Operation
Encoders have many different functions. Encoders
change a mechanical movement into a digital signal.
The encoder sends a digital signal of channel A and
Common
channel B. The signals change from 0 V to the supply
voltage at different times. The electronic controller Index
compares the digital signals to calculate which channel Channel A
comes first and how quickly they change. Then, the 5V
controller calculates the direction and speed of the Channel B
component. Most encoders have four wires, some
have five.

Wire Designations
• Supply wire: The supply wire supplies the positive
voltage input to the encoder. The voltage can be
5 V, 11.3 V or 12 V.
• Common wire: The common wire supplies the neg-
ative input to the encoder.
• Channel A wire: The channel A wire supplies one of
the output signals from the encoder to the control-
ler.
• Channel B wire: The channel B wire supplies one of
the output signals from encoder to the controller.
• Index wire: Not all encoders have an index wire.
The index wire supplies a "center" reference point
in such functions as steering feedback.
Fig. 86 (25535)
• Channel A Feedback Test: The encoder sends a
digital pulse of supply voltage from each channel
wire. Digital volt-meters (DVOM) are too slow to
show the pulse signal. The DVOM shows the aver-
age voltage as the encoder turns. This is approxi-
mately ½ of the signal voltage. For example, a 5 V
encoder sends pulses of 5 V on each channel. The
DVOM shows approximately 2.5 V. A voltage that
changes from an average 2.5 V indicates a defec-
tive encoder. Refer to Figure 87.

Troubleshooting
• Supply Test: Do a voltage test from the common
wire to the supply wire. For example, a 5 V encoder
has 5 V between the common wire and supply wire.
Refer to Figure 86.
Common
Index
Channel A
5V
Channel B

Fig. 87 (25536)

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ELECTRICAL SYSTEM
ENCODERS

• Channel A Feedback Test: The encoder sends a

digital pulse of supply voltage from each channel
wire. Digital volt-meters (DVOM) are too slow to
show the pulse signal. The DVOM shows the aver-
age voltage as the encoder turns. This is approxi-
mately ½ of the signal voltage. For example, a 5 V
encoder sends pulses of 5 V on each channel. The
Common
DVOM shows approximately 2.5 V. A voltage that
changes from an average 2.5 V indicates a defec- Index
tive encoder. Refer to Figure 88. Channel A
5V
Channel B

Common
Index
Channel A Fig. 89 (25538)
5V
Channel B

Fig. 88 (25537)
• Index Test: The index wire supplies a signal to show
the center or index position. When the encoder is at
the index position, the supply voltage is on the in-
dex wire. For example, a 5 V encoder sends a 5 V
signal on the index wire when the encoder at the
index position. Refer to Figure 89.

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Access 1 2 3®
ACCESS 1 (the display) is the interface between the
operator, the service technician, and the truck elec-
tronic system. This section includes the components of
ACCESS 1 used to monitor and control the truck.
CAUTION
If you connect the control connectors when the
truck is ON, the truck could be damaged.
The truck electrical system could be damaged.
 Do not turn the truck ON with the control connectors
disconnected.
 Do not remove or connect the control connectors
while the truck is ON.
CAUTION
When you replace an access module and do an up-
date to the module software, make sure that the ad-
justments are correct.
The truck will not operate correctly.
 Calibrate the truck. Refer to the CALIBRATION
menu in this section.
Note: To make sure that your Access 1 2 3® software
is the newest version, refer to the UTILITIES menu
(U1). In this menu, you can look at the applicable mod-
ule and the software part numbers.
Note: To use the ACCESS 1 menus:
• Push the up and down arrows to go through the
menus.
• Push ENTER to accept a selection, or go into or out
of a menu.
Static Return to Off (SRO)
A static return to off is a message that tells you when
you do an incorrect operator sequence. The message
(1) is at the bottom of the display screen on
ACCESS 1. The status alarm sounds until the operator
corrects the sequence or turns the truck OFF. Refer to
Figure 27243.
Crown 2011 PF25326-1 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
1
Fig. 90 (27243)
Access 1 2 3® Menus
Your menu system has three user levels:
LEVEL 1: OPERATOR MODE
LEVEL 2: FIELD SERVICE MODE (Full Truck Opera-
tion)
LEVEL 3: ANALYZER/TEST MODE (No Truck Opera-
tion)
LEVEL 1 Menu
The LEVEL 1 menu contains operator controlled
ACCESS 1 selections. To go into the LEVEL 1 menu:
1. Turn the truck ON.
2. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
3. At the display screen, push the up and down ar-
rows or ENTER to go into the LEVEL 1 menu.
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ELECTRICAL SYSTEM
ACCESS 1 2 3®

4. Push the up and down arrows to go through these – LAST-12 = ___

available selections (provided a higher priority – LAST-13 = ___
message is not active):
– LAST-14 = ___
– HOUR METERS
– LAST-15 = ___.
– EVENT CODES
PERFORMANCE Menu
– PERFORMANCE
The PERFORMANCE menu is available if the F22
– DATE & TIME SETUP.
USER PERFORM menu is set to F22.2 YES. The
HOUR METERS Menu PERFORMANCE menu lets you accept one of three
The HOUR menu shows one of four hour meters. To go truck performance levels. To go into the PERFOR-
into the HOUR METERS menu: MANCE menu:
1. Push the up and down arrows to go to the HOUR 1. Push the up and down arrows to go to the PER-
METERS menu. FORMANCE menu.
2. Push ENTER to go into the HOUR METERS 2. Push ENTER to go into the PERFORMANCE
menu. menu.
3. Push the up and down arrows to go through these 3. Push the up and down arrows to go through these
hour meters: performance levels:
– H1 TRUCK RUNTIME - Shows the total time that – P1 LEVEL ACTIVE - The highest performance.
the truck is ON and a minimum of one foot pres- Use the P1 LEVEL ACTIVE menu for maximum
ence switch pedals are in operation. performance and energy use.
– H2 TRACTION MOTOR - Shows the total time – P2 LEVEL ACTIVE - The middle performance.
that the traction motor is in operation. Use the P2 LEVEL ACTIVE menu for decreased
performance and energy use.
– H3 HYDRAULIC MOTOR - Shows the total time
that the hydraulic motor is in operation. – P3 LEVEL ACTIVE- The lowest performance.
Use the P3 LEVEL ACTIVE menu when the low-
– H4 STEER MOTOR - Shows the total time that
est truck performance conditions are necessary
the steer motor is in operation.
(for example, slick floors, novice operators, and
EVENT CODES Menu traffic areas).
The EVENT CODES menu shows the last 16 event DATE & TIME SETUP Menu
codes. The first event code is the newest. To go into the
The DATE & TIME SETUP menu lets you change the
EVENT CODES menu:
specified display data. To go into the DATE & TIME
1. Push the up and down arrows to go to the EVENT SETUP menu:
CODES menu.
1. Push the up and down arrows to go to the DATE &
2. Push ENTER to go into the EVENT CODES menu. TIME SETUP menu.
3. Push the up and down arrows to go through the 2. Push ENTER to go into the DATE & TIME SETUP
last 16 event codes: menu.
– LAST = ___ 3. Push the up and down arrows to go through the
– LAST-01 = ___ display data:
– LAST-02 = ___ – DATE SETUP - Lets you change the month, the
– LAST-03 = ___ day, and the year (MM/DD/YY). For example, 03/
14/12 for March 14, 2012.
– LAST-04 = ___
– CLOCK TYPE SETUP - Lets you set a 24-hour
– LAST-05 = ___
clock or an AM/PM clock.
– LAST-06 = ___
– TIME SETUP - Sets the clock to the correct time
– LAST-07 = ___ of day.
– LAST-08 = ___ – SAVE DATE AND TIME - Push the up and down
– LAST-09 = ___ arrows to cancel the changes, or push ENTER to
– LAST-10 = ___ accept the changes.
– LAST-11 = ___

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

BACK TO INFO SCREEN

Push ENTER to go to the display screen.

LEVEL 2 and LEVEL 3 Menus

You must use a user code to go into these menus. Re-
fer to your local Crown dealer to get this user code. To
go into the LEVEL 2 or LEVEL 3 menus:
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2. To access LEVEL 3, hold the up
and down arrows and turn the truck ON.
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

TSP 7000 72/80 V

ACCESS 1 (DCM)

ACCESS 7 (ACM)

• Accessory Hydraulic Valves

• Position Sensors
– Pivot
ACCESS 8 (OCM) – Traverse
– Aux Lift Height

• Left Hand Sensors ACCESS 4 (VCM)

• Right Hand Sensors
• Platform Sensors
– Foot Pedals
– Gates
– Chain
– Main Lift Height
CAN BUS

– Seat Position
• Seat Release Solenoid

Platform
Power Unit • 72/80 V Hydraulic Pump Motor
• Motor Sensor
ACCESS 3 (TCM) ACCESS 2 (HCM)• Sensors/Switches
– Chain Slack/Broke (TT Only)
– Cable Tension Sw (TF Only)
• Battery Restraint
– Emergency Override
• Travel Alarm
– Height Cable Switch (TF & TN)
• 72/80 V Traction Motor
– Motor Temp Sensor
• Motor Sensor
– Oil Temp Sensor (Freezer Only)
E.D. Contactor • Fan
• Horn
• Main Hoist & Aux Valves
– SVML (Main Lower Valve)
ACCESS 5 (SCM) – PVML (Main Lower Proportional Valve)
– SVMR (Main Raise Valve)
+ 48 V to Logic – SVA (Accessory Valve)
• Steer Motor board only
• Traction Brake
• Sensors
– Current Sensor
– Rail Guide Switches
ACCESS 6 (GCM)
– Steer Wheel Position • Wire Guide Sensor Bars
• EAC Sensors

+ 48 V

72/80 V Battery
72/80 V to 48 V DC/DC Converter

Fig. 91 (26299-01)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

DCM - ACCESS 1 Display Control Module

HCM - ACCESS 2 Hydraulic Control Module
TCM - ACCESS 3 Traction Control Module
VCM - ACCESS 4 Vehicle Control Module
SCM - ACCESS 5 Steering Control Module
GCM - ACCESS 6 Guidance Control Module
ACM - ACCESS 7 Accessory Control Module
OCM - ACCESS 8 Operator Control Module

ACCESS 1
Display Module (DCM)

Power ON
Indicator
Display Service Required
Screen Indicator

Battery Discharge
Capacity Data Indicator
Monitor

Enter

Up and Down Arrows

Fig. 92 (27244)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Operator Menu
Truck
ON

Service Access Level Push the up and down arrows and ENTER to
put in the password.

Enter Password

Typical display screen.

FK HT LOAD BATT Push the up and down arrows or ENTER to go into the opera-
(in) (lbs) (%) tor menus.

MM/DD/YY __:__ AM/PM

Hour Meters H1 Truck Runtime

(hours)
enter next escape next prev

H2 Traction Motor
(hours)
escape next prev

H3 Hydraulic Motor
(hours)
escape next prev

H4 Steer Motor
(hours)
escape next prev

Event Codes Event Codes

Last = ___
enter next prev escape next

Event Codes
Last-15 = ___
escape prev
continued on page -008

Fig. 93 (27245)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Operator Menu
continued from page -007

Performance Performance Level

P1 Level Active
enter next prev escape change

Performance Level
P2 Level Active
escape change

Performance Level
P3 Level Active
escape change

Date & Time Setup Date Setup

MM/DD/YY
enter next prev enter change

Clock Type Setup

24 hr or am/pm
enter change

Time Setup
__:__
enter change

Save Date and Time

MM/DD/YY __:__
set abort

Back to Info Screen

goes to the display screen

escape prev

Fig. 94 (27246)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Main Menu

Truck
ON

Service Access Level Enter password using the up and down

arrow keys and enter key to select
each number or letter.

Enter Password

FIELD SERVICE MODE

Analyzer
enter next prev

FIELD SERVICE MODE:

Menus:

ANALYZER refer to page -010

CALIBRATION refer to page -046
FEATURES refer to page -072
HOUR METERS refer to page -095
EVENT CODES refer to page -096
PERFORMANCE refer to page -097
UTILITIES refer to page -115

Fig. 95 (27247)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Menus

Analyzer
A1 Status
select next prev

Analyzer
A2 Inputs refer to page -013

select next prev

Analyzer
A3 Outputs refer to page -020

select next prev

Analyzer
A4 Test Outputs
refer to page -023
(2 button mode)
select next prev

Analyzer
A99 Escape goes to FIELD SERVICE MODE

select next prev

A1.1 Steering
Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

continued on page -011

Fig. 96 (26300-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Menus

A1.2 Limp Travel

Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.3 Full Travel

Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.4 Main Raise

Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.5 Main Lower

Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.6 Aux Raise

Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.7 Aux Lower

Enabled/Disabled goes to ANALYZER A1 STATUS
escape next prev

A1.8 Traverse
Enabled/Disabled goes to ANALYZER A1 STATUS
escape next prev

continued on page -012

Fig. 97 (26301-01)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Menus

A1.9 Pivot
Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.10 Fork Extend

Enabled/Disabled goes to ANALYZER A1 STATUS
escape next prev

A1.11 ED Closed
Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.12 Full Hoist

Enabled/Disabled goes to ANALYZER A1 STATUS

escape next prev

A1.13 Brake - ED
Enabled/Disabled goes to ANALYZER A1 STATUS
escape next prev

A1.14 1234567890123
NNNNNNNNNN goes to ANALYZER A1 STATUS
escape next prev

Fig. 98 (26302-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Input Menus

A2 Inputs
1 Load Handler
select next prev

A2 Inputs
2 Platform refer to page -017

select next prev

A2 Inputs
3 Seat Controls refer to page -020

select next prev

A2 Inputs
4 Power Unit refer to page -023

select next prev

A2 Inputs
99 Escape goes to ANALYZER A2 INPUTS
select next prev

continued on page -014

Fig. 99 (26303-01)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A2.1.1.1 Position
A2.1.1 ECR3 (cm/in)
enter next prev next prev

A2.1.1.2 Speed
(cm/sec or in/sec)
next prev

A2.1.1.3 Count
(counts)
next prev

A2.1.1.99 Escape
goes to A2.1.1
ECR3
enter next prev

A2.1.2.1 Position
A2.1.2 ECR4 (cm/in)
enter next prev next prev

A2.1.2.2 Speed
(cm/sec or in/sec)
next prev

A2.1.2.3 Count
(counts)
next prev

A2.1.2.99 Escape
goes to A2.1.2
continued on page -015 ECR4
enter next prev

Fig. 100 (26304-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A2.1.3.1 Position
A2.1.3 POT5 (deg)
enter next prev next prev

A2.1.3.2 Speed
(deg/sec)
next prev

A2.1.3.3 Voltage
(volts)
next prev

A2.1.3.99 Escape
goes to A2.1.2
ECR4
enter next prev

A2.1.4 FHSL & FHSR

Switch Opened/Switch Closed
beep next prev

A2.1.5 HGTRS2
Switch Opened/Switch Closed
beep next prev

A2.1.6 TVRS
Switch Opened/Switch Closed
beep next prev

continued on page -016

Fig. 101 (26305-01)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A2.1.7 LS A2.1.7.1 Weight

(kg/lb)
enter next prev next prev

A2.1.7.2 Current
(μa)
next prev

A2.1.7.3 Count
(counts)
next prev

A2.1.7.99 Escape
goes to A2.1.7 LS

enter next prev

A2.1.99 Escape
goes to A2 INPUTS
enter next prev

Fig. 102 (26306-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Platform Menu

A2.2.1 ECR5 A2.2.1.1 Position

(cm/in)
enter next prev next prev

A2.2.1.2 Speed
A2.2.2 BRS1 & BRS3
Switch Opened/Switch Closed
(cm/sec or in/sec)

beep next prev next prev

A2.2.1.3 Count
A2.2.3 CHS1 & CHS2 (counts)
Switch Opened/Switch Closed
next prev
beep next prev

A2.2.1.99 Escape
A2.2.4 CHS3 & CHS4 goes to A2.2.1
ECR5
Switch Opened/Switch Closed enter next prev
beep next prev

A2.2.5 FPS1, 2 & 3

Switch Opened/Switch Closed
beep next prev

A2.2.6 FPS4, 5 & 6

Switch Opened/Switch Closed
beep next prev

A2.2.7 FPS7, 8 & 9

Switch Opened/Switch Closed
beep next prev

continued on page -018

Fig. 103 (26307-01)

M4.3-1970-017 TSP 7000 SERIES Crown 2011 PF25326-17 Rev. 6/12

01 Rev. 6/12
206
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Platform Menu

A2.2.8 GTSL & GTSR

Switch Opened/Switch Closed
beep next prev

A2.2.9 HGTRS1
Switch Opened/Switch Closed
beep next prev

A2.2.10 SLS
Switch Opened/Switch Closed
beep next prev

A2.2.11 SPS
Switch Opened/Switch Closed
beep next prev

A2.2.13 ZSSA
Switch Opened/Switch Closed
beep next prev

A2.2.14 ZSSB
Switch Opened/Switch Closed
beep next prev

continued on page -019

Fig. 104 (26308-01)

Crown 2011 PF25326-18 Rev. 6/12 TSP 7000 SERIES M4.3-1970-018

01 Rev. 6/12
207
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Platform Menu

A2.2.15 ZSSC
Switch Opened/Switch Closed
beep next prev

A2.2.99 Escape
goes to A2 INPUTS 2 PLATFORM

enter next prev

Fig. 105 (26309-01)

M4.3-1970-019 TSP 7000 SERIES Crown 2011 PF25326-19 Rev. 6/12

01 Rev. 6/12
208
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Seat Controls Menu

continued on page -021

Fig. 106 (26310)

Crown 2011 PF25326-20 Rev. 6/12 TSP 7000 SERIES M4.3-1970-020

01 Rev. 6/12
209
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Seat Controls Menu

continued on page -022

Fig. 107 (26311)

M4.3-1970-021 TSP 7000 SERIES Crown 2011 PF25326-21 Rev. 6/12

01 Rev. 6/12
210
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Seat Controls Menu

A2.3.15 PRS
Switch Opened/Switch Closed
beep next prev

A2.3.16 RSS
Switch Opened/Switch Closed
beep next prev

A2.3.17 SES
Switch Opened/Switch Closed
beep next prev

A2.3.18 TBS
Switch Opened/Switch Closed
beep next prev

A2.3.19 TDS
Switch Opened/Switch Closed
beep next prev

A2.3.99 Escape
goes to A2 INPUTS 3
SEAT CONTROLS
enter next prev

Fig. 108 (26312-01)

Crown 2011 PF25326-22 Rev. 6/12 TSP 7000 SERIES M4.3-1970-022

01 Rev. 6/12
211
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A2.4.1 ECR6
(counts)
next prev

A2.4.2 ECR7 A2.4.2.1 Access 5

(rpm)
enter next prev next prev

A2.4.2.2 Access 5
(counts)
next prev

A2.4.2.3 Access 3
(rpm)
next prev

A2.4.2.99 Escape
goes to A2.4.2
ECR7
enter next prev

A2.4.3 ECR8
(rpm)
next prev

A2.4.4 CS1
(amps)
next prev

continued on page -024

Fig. 109 (26313-01)

M4.3-1970-023 TSP 7000 SERIES Crown 2011 PF25326-23 Rev. 6/12

01 Rev. 6/12
212
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

Optional
A2.4.5 GS1 Steer A2.4.5.1 GS1 Raw
__% __% __% __%
enter next prev next prev

A2.4.5.2 GS1 Scaled

__% __% __% __%
next prev

A2.4.5.99 Escape
goes to A2.4.5
GS1 STEER
enter next prev

Optional
A2.4.6 GS2 Load A2.4.6.1 GS2 Raw
__% __% __% __%
enter next prev next prev

A2.4.6.2 GS2 Scaled

__% __% __% __%
next prev

A2.4.6.99 Escape
goes to A2.4.6
GS2 LOAD
enter next prev

continued on page -025

Fig. 110 (26314-01)

Crown 2011 PF25326-24 Rev. 6/12 TSP 7000 SERIES M4.3-1970-024

01 Rev. 6/12
213
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

Optional
A2.4.7 EAC A2.4.7.1 EACA1
Switch Opened/Switch Closed
enter next prev next prev

A2.4.7.2 EACA2
Switch Opened/Switch Closed
next prev

A2.4.7.3 EACB1
Switch Opened/Switch Closed
next prev

A2.4.7.4 EACB2
Switch Opened/Switch Closed
next prev

A2.4.7.5 Signal
(percent)
next prev

A2.4.7.99 Escape
goes to A2.4.7 EAC

enter next prev

A2.4.8 BRES
Switch Opened/Switch Closed Optional

enter next prev

continued on page -026

Fig. 111 (26315-01)

M4.3-1970-025 TSP 7000 SERIES Crown 2011 PF25326-25 Rev. 6/12

01 Rev. 6/12
214
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

TF Masts Only

Optional

continued on page -027

Fig. 112 (26316)

Crown 2011 PF25326-26 Rev. 6/12 TSP 7000 SERIES M4.3-1970-026

01 Rev. 6/12
215
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A2.4.13 Voltages A2.4.13.1 Battery

(volts)
enter next prev next prev

A2.4.13.2 Steering
(volts)
next prev

A2.4.13.3 BRK Inner

(volts)
next prev

A2.4.13.4 BRK Outer

(volts)
next prev

A2.4.13.99 Escape
goes to A2.4.13
VOLTAGES
enter next prev

A2.4.14 PDS A2.4.14.1 Alarm

Switch Opened/Switch Closed
enter next prev beep next prev

A2.4.14.2 Active
A2.4.15 CHS5 & CHS6
Switch Opened/Switch Closed
Switch Opened/Switch Closed TT Masts Only
beep next prev
beep next prev

A2.4.14.99 Escape
goes to A2.4.14 PDS
continued on page -028 enter next prev

Fig. 113 (26317-01)

M4.3-1970-027 TSP 7000 SERIES Crown 2011 PF25326-27 Rev. 6/12

01 Rev. 6/12
216
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A2.4.16 CHS7 & CHS8

Switch Opened/Switch Closed TT Masts Only

beep next prev

A2.4.17 Access2 Temp

Degrees C
next prev

A2.4.18 M2 Temp
Degrees C
next prev

A2.4.19 Access3 Temp

Degrees C
next prev

A2.4.20 M1 Temp
Degrees C
next prev

A2.4.21 Hydr Oil Tmp

Degrees C Low Temperature Freezer
Condition Only
next prev

A2.4.99 Escape
goes to A2 INPUTS
4 POWER UNIT
enter next prev

Fig. 114 (26318-01)

Crown 2011 PF25326-28 Rev. 6/12 TSP 7000 SERIES M4.3-1970-028

01 Rev. 6/12
217
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Outputs Menus

A3 Outputs
1 Load Handler
select next prev

A3 Outputs
2 Platform refer to page -035

select next prev

A3 Outputs
3 Seat Controls refer to page -035

select next prev

A3 Outputs
4 Power Unit refer to page -036

select next prev

A3 Outputs
99 Escape goes to ANALYZER A3 OUTPUTS

select next prev

continued on page -030

Fig. 115 (26319-01)

M4.3-1970-029 TSP 7000 SERIES Crown 2011 PF25326-29 Rev. 6/12

01 Rev. 6/12
218
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A3.1.1 PVAL A3.1.1.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.1.2 Current
(mA)
next prev

A3.1.1.99 Escape
goes to A3.1.1 PVAL

enter next prev

A3.1.2 PVAR A3.1.2.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.2.2 Current
(mA)
next prev

A3.1.2.3 Resistance
(ohms)
next prev

A3.1.2.99 Escape
goes to A3.1.2
PVAR
enter next prev

continued on page -031

Fig. 116 (26320-01)

Crown 2011 PF25326-30 Rev. 6/12 TSP 7000 SERIES M4.3-1970-030

01 Rev. 6/12
219
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A3.1.3 PVLH A3.1.3.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.3.2 FET Voltage

(volts)
next prev

A3.1.3.99 Escape
goes to A3.1.3
PVLH
enter next prev

A3.1.4 PVT1 A3.1.4.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.4.2 Current
(mA)
next prev

A3.1.4.99 Escape
goes to A3.1.4 PVT1

enter next prev

continued on page -032

Fig. 117 (26321-01)

M4.3-1970-031 TSP 7000 SERIES Crown 2011 PF25326-31 Rev. 6/12

01 Rev. 6/12
220
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A3.1.5 PVT2 A3.1.5.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.5.2 Current
(mA)
next prev

A3.1.5.99 Escape
goes to A3.1.5 PVT2

enter next prev

A3.1.6 PVF1 A3.1.6.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.6.2 Current
(mA)
next prev

A3.1.6.99 Escape
goes to A3.1.6 PVF1

enter next prev

continued on page -033

Fig. 118 (26322-01)

Crown 2011 PF25326-32 Rev. 6/12 TSP 7000 SERIES M4.3-1970-032

01 Rev. 6/12
221
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A3.1.7 PVF2 A3.1.7.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.7.2 Current
(mA)
next prev

A3.1.7.99 Escape
goes to A3.1.7 PVF2

enter next prev

A3.1.8 PVP1 A3.1.8.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.8.2 Current
(mA)
next prev

A3.1.8.99 Escape
goes to A3.1.8 PVP1

enter next prev

continued on page -034

Fig. 119 (26323-01)

M4.3-1970-033 TSP 7000 SERIES Crown 2011 PF25326-33 Rev. 6/12

01 Rev. 6/12
222
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A3.1.9 PVP2 A3.1.9.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.9.2 Current
(mA)
next prev

A3.1.9.99 Escape
goes to A3.1.9 PVP2
enter next prev

A3.1.10 SVAL A3.1.10.1 Duty Cycle

(percent)
enter next prev next prev

A3.1.10.2 FET Voltage

(volts)
next prev

A3.1.10.99 Escape
goes to A3.1.10 SVAL

enter next prev

A3.1.99 Escape
goes to A3 OUTPUTS
1 LOAD HANDLER
enter next prev

Fig. 120 (26324-01)

Crown 2011 PF25326-34 Rev. 6/12 TSP 7000 SERIES M4.3-1970-034

01 Rev. 6/12
223
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Platform and Seat Controls Menus

A3.2.1 ALM1
OFF or ON
next prev

A3.2.2 EML
(percent)
next prev

A3.2.99 Escape
goes to A3 OUTPUTS 2
PLATFORM
enter next prev

A3.3.1 CC1 Duty Cycl

(percent)
next prev

A3.3.99 Escape
goes to A3 OUTPUTS 3
SEAT CONTROLS
enter next prev

Fig. 121 (26325-01)

M4.3-1970-035 TSP 7000 SERIES Crown 2011 PF25326-35 Rev. 6/12

01 Rev. 6/12
224
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A3.4.1 SVML Duty Cyc

(percent)
next prev

A3.4.2 SVMR Duty Cyc

(percent)
next prev

A3.4.3 SVA Duty Cycl

(percent)
next prev

A3.4.4 PVML Duty Cyc

(percent)
next prev

A3.4.5 ED A3.4.5.1 Access 5

OFF or ON
enter next prev next prev

A3.4.6 ALM2 Duty Cyc A3.4.5.2 Access 3

(percent) Optional (percent)
next prev next prev

A3.4.7 HN A3.4.5.99 Escape

OFF or ON goes to A3.4.5 ED

next prev enter next prev

continued on page -037

Fig. 122 (26326-01)

Crown 2011 PF25326-36 Rev. 6/12 TSP 7000 SERIES M4.3-1970-036

01 Rev. 6/12
225
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A3.4.8 M1 Current
(amps)
next prev

A3.4.9 M2 Current
(amps)
next prev

A3.4.10 M3 Duty Cycle

(percent)
next prev

A3.4.11 BRK Inner A3.4.11.1 PWM

(percent)
enter next prev next prev

A3.4.11.2 Current
(amps)
next prev

A3.4.11.3 Resistance
(ohms)
next prev

A3.4.11.99 Escape
goes to A3.4.11
continued on page -038 BRK INNER
enter next prev

Fig. 123 (26327-01)

M4.3-1970-037 TSP 7000 SERIES Crown 2011 PF25326-37 Rev. 6/12

01 Rev. 6/12
226
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A3.4.12 BRK Outer A3.4.12.1 PWM

(percent)
enter next prev next prev

A3.4.12.2 Current
A3.4.13 FAN3 (amps)
(percent)
next prev
next prev

A3.4.12.3 Resistance
(ohms)
next prev

A3.4.12.99 Escape
goes to A3.4.12
BRK OUTER
enter next prev

A3.4.14 PDS A3.4.14.1 Plat. Down

OFF or ON
enter next prev next prev

A3.4.14.2 Quit Key

OFF or ON
next prev

A3.4.14.3 End Aisle

OFF or ON
next prev
A3.4.99 Escape

A3.4.14.4 In Aisle
enter next prev OFF or ON
next prev

goes to A3 OUTPUTS A3.4.14.99 Escape

4 POWER UNIT
goes to A3.4.14
PDS
enter next prev

Fig. 124 (26328-01)

Crown 2011 PF25326-38 Rev. 6/12 TSP 7000 SERIES M4.3-1970-038

01 Rev. 6/12
227
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Test Outputs Menus

A4 Test Outputs
1 Load Handler
select next prev

A4 Test Outputs
2 Platform refer to page -042

select next prev

A4 Test Outputs
3 Seat Controls refer to page -042

select next prev

A4 Test Outputs
4 Power Unit refer to page -043

select next prev

A4 Test Outputs
99 Escape goes to ANALYZER A4
TEST OUTPUTS
select next prev

continued on page -040

Fig. 125 (26329-01)

M4.3-1970-039 TSP 7000 SERIES Crown 2011 PF25326-39 Rev. 6/12

01 Rev. 6/12
228
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A4.1.1 PVAL
1

test next prev

A4.1.2 PVAR
1

test next prev

A4.1.3 PVLH
1

test next prev

A4.1.4 PVT1
1

test next prev

A4.1.5 PVT2
1

test next prev

A4.1.6 PVF1
1

test next prev

1 Connect a digital volt-

A4.1.7 PVF2 ohm multimeter to the
component and push
1 TEST to do a test of the
test next prev output

continued on page -041

Fig. 126 (26330-01)

Crown 2011 PF25326-40 Rev. 6/12 TSP 7000 SERIES M4.3-1970-040

01 Rev. 6/12
229
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Load Handler Menu

A4.1.8 PVP1
1

test next prev

A4.1.9 PVP2
1

test next prev

A4.1.10 SVAL
1

test next prev

A4.1.99 Escape
goes to A4 TEST OUTPUTS
1 LOAD HANDLER
enter next prev

1 Connect a digital volt-ohm multimeter to the com-

ponent and push TEST to do a test of the output

Fig. 127 (26331-01)

M4.3-1970-041 TSP 7000 SERIES Crown 2011 PF25326-41 Rev. 6/12

01 Rev. 6/12
230
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Platform and Seat Controls Menus

A4.2.1 ALM1
1

test next prev

A4.2.2 EML
1

test next prev

A4.2.99 Escape
goes to A4 TEST OUTPUTS 2
PLATFORM
enter next prev

A4.3.1 Seat/CC
1

test next prev

A4.3.99 Escape
goes to A4 TEST OUTPUTS
3 SEAT CONTROLS
enter next prev

1 Connect a digital volt-ohm

multimeter to the component
and push TEST to do a test of
the output

Fig. 128 (26332-01)

Crown 2011 PF25326-42 Rev. 6/12 TSP 7000 SERIES M4.3-1970-042

01 Rev. 6/12
231
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A4.4.1 SVML
1 1 Connect a digital volt-ohm
multimeter to the component
test next prev and push TEST to do a test of
the output

A4.4.2 SVMR
1
test next prev

A4.4.3 SVA
1

test next prev

A4.4.4 PVML
1

test next prev

A4.4.5 ED A4.4.5.1 Access 5

1

enter next prev test next prev

A4.4.5.2 Access 3
1

test next prev

A4.4.5.3 Both
1

test next prev

A4.4.5.99 Escape
goes to A4.4.5 ED
continued on page -044
enter next prev

Fig. 129 (26333-01)

M4.3-1970-043 TSP 7000 SERIES Crown 2011 PF25326-43 Rev. 6/12

01 Rev. 6/12
232
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A4.4.6 ALM2
1 1 Connect a digital volt-ohm multime-
ter to the component and push
test next prev TEST to do a test of the output

A4.4.7 HN
1

test next prev

A4.4.8 M1
1

test next prev

A4.4.9 M2
1

test next prev

A4.4.10 M3 A4.4.10.1 Clockwise

1

enter next prev test next prev

A4.4.10.2 CCWise
1

test next prev

A4.4.10.99 Escape
goes to A4.4.10 M3

enter next prev

A4.4.11 BRK Inner
1

test next prev

continued on page -045

Fig. 130 (26334-01)

Crown 2011 PF25326-44 Rev. 6/12 TSP 7000 SERIES M4.3-1970-044

01 Rev. 6/12
233
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Analyzer Power Unit Menu

A4.4.12 BRK Outer 1 Connect a digital volt-ohm multimeter to

1 the component and push TEST to do a
test of the output
test next prev

A4.4.13 FAN3
1

test next prev

A4.4.14 PDS A4.4.14.1 Plat. Down

1

enter next prev test next prev

A4.4.14.2 Quit Key

1

test next prev

A4.4.14.3 End Aisle

1

test next prev

A4.4.14.4 In Aisle
1

test next prev

A4.4.14.99 Escape
goes to A4.4.14 PDS

enter next prev

A4.4.99 Escape
goes to A4 TEST OUTPUTS
4 POWER UNIT
enter next prev

Fig. 131 (26335-01)

M4.3-1970-045 TSP 7000 SERIES Crown 2011 PF25326-45 Rev. 6/12

01 Rev. 6/12
234
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Menus

Calibration
C1 Handles refer to page -047

select next prev

Calibration
C2 Hydraulics refer to page -050

select next prev

Calibration
C3 Height Cutouts refer to page -065

select next prev

Calibration
C4 Steer Encoder refer to page -066

select next prev

Calibration
C5 Wire Guidance refer to page -067
select next prev

Calibration
C99 Escape goes to FIELD SERVICE MODE
select next prev

Fig. 132 (26336-01)

Crown 2011 PF25326-46 Rev. 6/12 TSP 7000 SERIES M4.3-1970-046

01 Rev. 6/12
235
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Handles Menu

C1 Handles C1.1 Traction

1
1 Traction Forward = 1.08 V
select next prev enter

C1.1 Traction
1
Reverse = 3.85 V
enter

C1.1 Traction
Center = 2.32 V 1
enter

C1 Handles C1.2 Main R/L

2 Main R/L Raise = 1.06 V 1
select next prev enter

C1.2 Main R/L

1
Lower = 3.58 V
enter

C1.2 Main R/L

Center = 2.31 V 1
enter

continued on page -048

1 The values are approximate

Fig. 133 (26337-01)

M4.3-1970-047 TSP 7000 SERIES Crown 2011 PF25326-47 Rev. 6/12

01 Rev. 6/12
236
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Handles Menu

C1 Handles C1.3 Traverse

3 Traverse 1
Right = 3.93 V
select next prev enter

C1.3 Traverse
Left = 1.11 V 1
enter

C1.1 Traverse
Center = 2.41 V 1
enter

C1 Handles C1.4 Aux Raise/Lower

4 Aux Raise/Lower Raise = 1.25 V 1
select next prev enter

C1.4 Aux Raise/Lower

Lower = 3.78 V 1
enter

C1.4 Aux Raise/Lower

Center = 2.63 V 1
enter

continued on page -049

1 The values are approximate

Fig. 134 (26338-01)

Crown 2011 PF25326-48 Rev. 6/12 TSP 7000 SERIES M4.3-1970-048

01 Rev. 6/12
237
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Handles Menu

Fig. 135 (26339)

M4.3-1970-049 TSP 7000 SERIES Crown 2011 PF25326-49 Rev. 6/12

01 Rev. 6/12
238
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Menu

refer to page -052

refer to page -053

refer to page -054

refer to page -055

refer to page -056

refer to page -057

refer to page -058

continued on page -051

Fig. 136 (26340)

Crown 2011 PF25326-50 Rev. 6/12 TSP 7000 SERIES M4.3-1970-050

01 Rev. 6/12
239
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Menu

C2 Hydraulics
11 Aux R Valve refer to page -059

select next prev

C2 Hydraulics
12 Weight Sense refer to page -060

select next prev

C2 Hydraulics
13 Aux L Valve refer to page -061

select next prev

C2 Hydraulics
14 Aux Hgt Sense refer to page -062

select next prev

1 If not setup in FEATURES,
then = N/A

C2 Hydraulics
1
15 Tilt Valve refer to page -063

select next prev C2.99 Save Hydr Cal

1 No Save
select change
C2 Hydraulics 1
16 Fork Pos Valve refer to page -064
C2.99 Save Hydr Cal
select next prev
2 Yes, Save Values
select change

C2 Hydraulics
99 Save Hydr Cal C2.99 Save Hydr Cal
select prev 3 Load Defaults
select change

Fig. 137 (26341-01)

M4.3-1970-051 TSP 7000 SERIES Crown 2011 PF25326-51 Rev. 6/12

01 Rev. 6/12
240
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics PVLH Aux Relief Menu

C2 Hydraulics
1 PVLH Aux Relief continued on page -053

select next prev

C2.1 PVLH Aux Relief C2.1.5 PVLH Aux Relief

Press Enter when
at 3500 psi

C2.1.0 PVLH Aux Relief C2.1.6 PVLH Aux Relief

Stop aux function Calibration Accepted
at 3500 psi

OR the message shows

momentarily
C2.1.1 PVLH Aux Relief C2.1.7 PVLH Aux Relief
Stay Attended
Calibration Failed

C2.1.2 PVLH Aux Relief

Connect gauge,
then press Enter

C2.1.3 PVLH Aux Relief

Press Enter when
at 700 psi

C2.1.4 PVLH Aux Relief

Press Enter when
at 1700 psi

Fig. 138 (26342-01)

Crown 2011 PF25326-52 Rev. 6/12 TSP 7000 SERIES M4.3-1970-052

01 Rev. 6/12
241
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Traverse Sense Menu

C2 Hydraulics
2 Traverse Sense continued on page -054

select next prev

C2.2 Traverse Sense

C2.2.0 Traverse Sense C2.2.2 Traverse Sense

Traverse Fully Right Calibration Accepted
1
then 765 counts
OR

C2.2.1 Traverse Sense C2.2.3 Traverse Sense

Traverse Fully Left Failed, Invalid Range the message shows
1 momentarily
then -803 counts
OR

C2.2.0 Traverse Sense C2.2.4 Traverse Sense

Traverse Fully Right Failed, No Reset Sw
then 1 767 counts

1 The values are approximate

Fig. 139 (26343-01)

M4.3-1970-053 TSP 7000 SERIES Crown 2011 PF25326-53 Rev. 6/12

01 Rev. 6/12
242
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Pivot Sense Menu

C2 Hydraulics
3 Pivot Sense continued on page -055
select next prev

C2.3 Pivot Sense

C2.3.0 Pivot Sense

Pivot Fully Left 1 The values are approximate
then 1 0.98 V

C2.3.1 Pivot Sense

Pivot Fully Right
then 1 4.07

C2.3.2 Pivot Sense

Calibration Accepted

OR
the message shows
momentarily
C2.3.3 Pivot Sense
Calibration Failed

Fig. 140 (26344-01)

Crown 2011 PF25326-54 Rev. 6/12 TSP 7000 SERIES M4.3-1970-054

01 Rev. 6/12
243
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Main Hgt Sense Menu

C2 Hydraulics
4 Main Hgt Sense continued on page -056

select next prev

1 The values are approximate

C2.4 Main Hgt Sense 2 The value is negative until the platform raises
above where HGTRS1 opens (approximately
457 mm [18 in])
3 The value is positive until the platform lowers
below where HGTRS1 closes (approximately
-1188 counts)
C2.4.0 Main Hgt Sense 4 Platform height only
Restrict Cal Height TF & TT Masts Only
to 426"
Yes No

C2.4.1 Main Hgt Sense

Lower Below Reset the message shows if the
1 platform starts above where
2500 counts HGTRS1 opens

C2.4.2 Main Hgt Sense

Raise Above Reset
1 2 -975 counts

C2.4.3 Main Hgt Sense C2.4.5 Main Hgt Sense

Lower to Min, then
Calibration Accepted
1 3
press 25 counts
OR the message shows
momentarily
C2.4.4 Main Hgt Sense C2.4.6 Main Hgt Sense
Raise to Max, then
Calibration Failed
press 4 x.xx mm/in

Fig. 141 (26345-01)

M4.3-1970-055 TSP 7000 SERIES Crown 2011 PF25326-55 Rev. 6/12

01 Rev. 6/12
244
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Traverse Valve Menu

C2 Hydraulics
8 Traverse Valve continued on page -057
select next prev

C2.8 Traverse Valve

C2.8.0 Traverse Valve

Traverse Left or Rt
to Begin

C2.8.1 Traverse Valve

Maintain Command finds the valve breakout two times

_ 1_ _ mA
1 Counts up in 1 mA increments

C2.8.2 Traverse Valve

the message shows if the operator stops the command
Paused-Traverse

C2.8.3 Traverse Valve C2.8.4 Traverse Valve

Stop Command Calibration Accepted

OR the message shows

momentarily
C2.8.5 Traverse Valve
Calibration Failed

Fig. 142 (26346-01)

Crown 2011 PF25326-56 Rev. 6/12 TSP 7000 SERIES M4.3-1970-056

01 Rev. 6/12
245
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Pivot Valve Menu

C2 Hydraulics
9 Pivot Valve continued on page -058
select next prev

C2.9 Pivot Valve

C2.9.0 Pivot Valve

Pivot Left or Right
to Begin

C2.9.1 Pivot Valve

Maintain Command finds the valve breakout two times

_ 1
_ _ mA
1 Counts up in 1 mA increments

C2.9.2 Pivot Valve

Paused-Pivot to Cont the message shows if the operator stops the command

C2.9.3 Pivot Valve C2.9.4 Pivot Valve

Stop Command Calibration Accepted

OR the message shows

momentarily
C2.9.5 Pivot Valve
Calibration Failed

Fig. 143 (26347-01)

M4.3-1970-057 TSP 7000 SERIES Crown 2011 PF25326-57 Rev. 6/12

01 Rev. 6/12
246
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Extend Valve Menu

C2 Hydraulics
10 Extend Valve continued on page -059

select next prev

C2.10 Extend Valve

C2.10.0 Extend Valve

Traverse Left or Rt
to Begin

C2.10.1 Extend Valve

Paused - Traverse the message shows if the operator stops the command

C2.10.2 Extend Valve C2.10.5 Extend Valve

Extend Stop Command
maintain _ 1_ _ mA

C2.10.3 Extend Valve C2.10.6 Extend Valve

Retract Calibration Accepted
maintain _ _1 _ mA

OR
the message shows
momentarily
C2.10.7 Extend Valve
Calibration Failed

finds the valve breakout two times

1 Counts up in 1 mA increments

Fig. 144 (26348-01)

Crown 2011 PF25326-58 Rev. 6/12 TSP 7000 SERIES M4.3-1970-058

01 Rev. 6/12
247
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Aux R Valve Menu

C2 Hydraulics
11 Aux R Valve continued on page -060

select next prev

C2.11 Aux R Valve

1 The message shows when the fork carriage is at the
top, or if the operator stops the command
2 Goes automatically from menu to menu
3 Counts up in 1 mA increments
C2.11.0 Aux R Valve 4 Counts up in 5 mA increments
Lower to Min, Raise
to Begin _ _ . _ mm/in

C2.11.1 Aux R Valve

Paused - Lower, Raise 1

to Cont _ _ . _ mm/in
C2.11.7 Aux R Valve
C2.11.2 Aux R Valve Finding Speed 5
Finding Breakout Maintain _ _4 _ mA
Maintain _ 3_ _ mA 2
C2.11.8 Aux R Valve
C2.11.3 Aux R Valve Finding Speed 6
Finding Speed 1 Maintain _ _4 _ mA
Maintain _ _4 _ mA
C2.11.11 Aux R Valve
C2.11.4 Aux R Valve 2 Stop Command
Finding Speed 2
Maintain _ _4 _ mA

C2.11.5 Aux R Valve C2.11.12 Aux R Valve

Finding Speed 3 Calibration Accepted
Maintain _ _4 _ mA

OR
C2.11.6 Aux R Valve the message shows
momentarily
Finding Speed 4 C2.11.13 Aux R Valve
Maintain _ 4_ _ mA Calibration Failed

Fig. 145 (26349-01)

M4.3-1970-059 TSP 7000 SERIES Crown 2011 PF25326-59 Rev. 6/12

01 Rev. 6/12
248
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Weight Sense Menu

C2 Hydraulics
12 Weight Sense continued on page -061
select next prev

C2.12 Weight Sense

1 Goes automatically from menu to menu

C2.12.0 Weight Sense 2 The values are approximate

Empty & Lower Forks

then _ _ . _ mm/in

C2.12.1 Weight Sense

Lower Completely

C2.12.2 Weight Sense

Slowly Raise Aux
2 5170 mA
C2.12.5 Weight Sense
C2.12.3 Weight Sense Calibration Accepted
1
Stop Aux Function
2 5170 mA OR
the message shows
momentarily
C2.12.4 Weight Sense C2.12.6 Weight Sense
Wait to Stabilize Calibration Failed
2
5170 mA

Fig. 146 (26350-01)

Crown 2011 PF25326-60 Rev. 6/12 TSP 7000 SERIES M4.3-1970-060

01 Rev. 6/12
249
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Aux L Valve Menu NOTE: You must have 91 to 227 kg on the forks for this
calibration
C2 Hydraulics
13 Aux L Valve continued on page -062

select next prev

C2.13 Aux L Valve

1 The message shows when the forks are at the bottom and
must go to the top, or if the operator stops the command
2 Goes automatically from menu to menu
3 Counts up in 1 mA increments
4 Counts up in 5 mA increments
C2.13.0 Aux L Valve
Raise to Max, Lower
to Begin _ _ . _ mm/in

C2.13.1 Aux L Valve

Paused - Raise, Lower 1

to Cont _ _ . _ mm/in
C2.13.7 Aux L Valve
C2.13.2 Aux L Valve Finding Speed 5
Finding Breakout maintain
Maintain _ 4_ _ mA
Maintain _ 3_ _ mA 2
C2.13.8 Aux L Valve
C2.13.3 Aux L Valve Finding Speed 6
Finding Speed 1 Maintain _ _4 _ mA
Maintain _ 4_ _ mA
C2.13.11 Aux L Valve
C2.13.4 Aux L Valve 2 Stop Command
Finding Speed 2
Maintain _ 4_ _ mA

C2.13.5 Aux L Valve C2.13.12 Aux L Valve

Finding Speed 3 Calibration Accepted
Maintain _ 4_ _ mA
OR
C2.13.6 Aux L Valve the message shows
momentarily
Finding Speed 4 C2.13.13 Aux L Valve
Maintain _ 4_ _ mA Calibration Failed

Fig. 147 (26351-01)

M4.3-1970-061 TSP 7000 SERIES Crown 2011 PF25326-61 Rev. 6/12

01 Rev. 6/12
250
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Aux Hgt Sense Menu

C2 Hydraulics
14 Aux Hgt Sense continued on page -063

select next prev

C2.14 Aux Hgt Sense

C2.14.0 Aux Hgt Sense

Lower Below Reset the message shows if the forks start above
where HGTRS2 opens
1 2850 counts

C2.14.1 Aux Hgt Sense

Raise Above Reset 1 The values are approximate
1 1580 counts

C2.14.2 Aux Hgt Sense

Lower to Min
then 1 -1680 counts

C2.14.4 Aux Hgt Sense

Calibration Accepted

OR
the message shows
momentarily
C2.14.5 Aux Hgt Sense
Calibration Failed

Fig. 148 (26352-01)

Crown 2011 PF25326-62 Rev. 6/12 TSP 7000 SERIES M4.3-1970-062

01 Rev. 6/12
251
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Tilt Valve Menu

C2 Hydraulics
15 Tilt Valve continued on page -064
select next prev

C2.15 Tilt Valve

C2.15.0 Tilt Valve

Select Tilt
up or down to begin
1 Counts up in 1 mA increments

C2.15.1 Tilt Valve

Suspended the message shows if the operator stops the command

use tilt to cont

C2.15.2 Tilt Valve

Tilt Cal C2.15.5 Tilt Valve
Maintain _ _ _ mA Stop Tilt

C2.15.3 Tilt Valve

Tilt Up Cal C2.15.6 Tilt Valve
Maintain _ _1 _ mA Calibration Accepted

OR
C2.15.4 Tilt Valve the message shows
momentarily
Tilt Down Cal C2.15.7 Tilt Valve
Maintain _ _1 _ mA Calibration Failed

Fig. 149 (26353-01)

M4.3-1970-063 TSP 7000 SERIES Crown 2011 PF25326-63 Rev. 6/12

01 Rev. 6/12
252
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Hydraulics Fork Pos Valve Menu

C2 Hydraulics C2.99 Save Hydr Cal

16 Fork Pos Valve 1 No Save
select next prev select change

C2.16 Fork Pos Valve C2.99 Save Hydr Cal

2 Yes, Save Values
select change

C2.16.0 Fork Pos Valve C2.99 Save Hydr Cal

Select Fork Positioner 3 Load Defaults
up or down to begin select change

C2.16.1 Fork Pos Valve

Suspended the message shows if the operator stops the command

use fork pos to cont

C2.16.2 Fork Pos Valve

Fork Positioner C2.16.5 Fork Pos Valve
Maintain Stop Fork Positioner

C2.16.3 Fork Pos Valve

Fork Pos Open Cal C2.16.6 Fork Pos Valve
Maintain _ _1 _ mA Calibration Accepted

OR
C2.16.4 Fork Pos Valve the message shows
momentarily
Fork Pos Closed Cal C2.16.7 Fork Pos Valve
Maintain _ _1 _ mA Calibration Failed

1 Counts up in 1 mA increments

Fig. 150 (26354-01)

Crown 2011 PF25326-64 Rev. 6/12 TSP 7000 SERIES M4.3-1970-064

01 Rev. 6/12
253
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Height Cutouts Menu

Calibration goes to C2 HYDRAULICS

C3 Height Cutouts
continued on page -066
select next prev

C3 Height Cutouts C3 Height Cutouts

1 Cutout 1 2 Cutout 2
enter next prev select next prev

C3.1 Cutout 1 C3 Height Cutouts

1 The menu flow is the same for
R/L to Cutout 1 all CUTOUT menus 3 Cutout 3
set _ _ _ mm/in select next prev

C3.1 Cutout 1 C3 Height Cutouts

Type: NONE 4 Cutout 4
enter change NONE, select next prev
PCT - RAISE CUTOUT WITH OVERRIDE
1 PST - RAISE CUTOUT WITHOUT OVERRIDE
NCT - LOWER CUTOUT WITH OVERRIDE
C3.1 Cutout 1 C3 Height Cutouts
When? Always ALWAYS or FR (Free Range) Only 5 Cutout 5
enter change select next prev

C3.1 Cutout 1 C3 Height Cutouts

Zone? A A, B, C or ALL 6 Cutout 6
enter change select next prev
the menu shows if the F17.3
ZONES menu is set from 1 to 4

C3 Height Cutouts C3.7 Save Cutouts

7 Save Cutouts 1 No Save
enter next prev enter change
1 NO SAVE
2 YES, SAVE VALUES
3 CLEAR ALL

Fig. 151 (26355-01)

M4.3-1970-065 TSP 7000 SERIES Crown 2011 PF25326-65 Rev. 6/12

01 Rev. 6/12
254
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Steer Encoder Menu

Calibration goes to C3 HEIGHT CUTOUTS

C4 Steer Encoder
continued on page -067
select next prev

C4 Steer Encoder
Rotate ECR to Index
escape

C4.1 Steer Encoder

Encoder is at Index
escape

goes to C4 STEER ENCODER

Fig. 152 (26356-01)

Crown 2011 PF25326-66 Rev. 6/12 TSP 7000 SERIES M4.3-1970-066

01 Rev. 6/12
255
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Wire Guide Menu

Calibration goes to C4 STEER ENCODER

C5 Wire Guidance
select next prev

Calibration
C99 Escape
select next prev
C5.1 Calibrate
1 Calibrate refer to page -068

select next prev

C5.2 Wire Guide

Adjust X-Offset refer to page -071
select next prev

C5 Wire Guide C5.99 Save Guidance

99 Save Guidance 1 No Save
select next prev select next prev

C5.99 Save Guidance

2 Yes, Save Values
select next prev

C5.99 Save Guidance

3 Load Defaults
select next prev

Fig. 153 (26357-01)

M4.3-1970-067 TSP 7000 SERIES Crown 2011 PF25326-67 Rev. 6/12

01 Rev. 6/12
256
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Wire Guide Menu

from page -067

GUS = Manual
C5.1.1 Set Response
9
Default Setting
enter change Soft = 1
Quick = 9 GUS = Auto

C5.1.2 Sensor Coil C5.1.2 Sensor Coil

Go to Auto when done GUS = Manual Switch to Manual
escape escape

GUS = Auto

Operate the truck across a guide wire at an angle of

five degrees or less a minimum of two times. The two
guidance sensor bars must fully go across the wire.
C5.1.2 Sensor Coil If it is possible, do the sensor coil calibration on a
Go to Auto when done wire with a high field strength.
escape
Coil saturated

The status alarm does not operate.

Recommended checks for saturated coils:

GUS = Auto 1 Make sure that the field strength agrees with the requirements of Crown.
2 Make sure that you install the guidance sensor bars 82 to 86 mm from
the floor.
C5.1.3 Wheel Angle
A saturated coil does not cancel sensor coil calibration. If a guidance sen-
Travel on Wire
sor bar changes its position or field strength is adjusted, push ENTER to
Auto Wire Guide do the sensor coil calibration again.
escape

continued on page -069

Fig. 154 (26358-01)

Crown 2011 PF25326-68 Rev. 6/12 TSP 7000 SERIES M4.3-1970-068

01 Rev. 6/12
257
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Wire Guide Menu

from page -068

Travel = forks leading direction Travel = forks trailing direction

Direction change (your truck automatically adds

the total travel distance if your environment is
C5.1.3 Wheel Angle not 18 m long) C5.1.3 Wheel Angle
Forks Leading _ _ _ % Forks Trailing _ _ _ %
escape escape

The truck goes 18 m (60 ft) in the forks

leading or forks trailing direction

C5.1.3 Wheel Angle The display shows LEADING or TRAILING in re-

lation to which direction (forks leading or forks
Forks Leading 100%
trailing) goes 18 m first. The status alarm operates
escape one time.
Change direction

C5.1.3 Wheel Angle

The display shows LEADING or TRAILING in
Forks Leading ___% relation to which direction (forks leading or
forks trailing) does not go 18 m.
escape

The travel distance is complete

in the two direction

C5.1.3 Wheel Angle

The display shows LEADING or TRAILING in
Forks Leading 100% relation to which direction (forks leading or
forks trailing) goes 18 m last. The status alarm
escape
operates one time.
Come to Stop
Travel speed < 0.16 kph (0.1 mph)

C5.1.3 Wheel Angle

Switch to Manual continued on page -070
escape
GUS = Manual

C5.1.3 Wheel Angle C5.1.4 Truck Angle

GUS = Automatic Travel on Wire
Switch to Auto Auto Wire Guide
escape escape

Fig. 155 (26359-01)

M4.3-1970-069 TSP 7000 SERIES Crown 2011 PF25326-69 Rev. 6/12

01 Rev. 6/12
258
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Wire Guide Menu

from page -069

Travel = forks leading direction Travel = forks trailing direction

Direction change (your truck automati-

C5.1.4 Truck Angle cally adds the total travel distance if your C5.1.4 Truck Angle
environment is not 18 m long)
Forks Leading _ _ _ % Forks Trailing _ _ _ %
escape escape
The truck goes 18 m in the forks leading or
forks trailing direction

C5.1.4 Truck Angle The display shows LEADING or TRAILING in

relation to which direction (forks leading or forks
Forks Leading 100% trailing) goes 18 m first. The status alarm oper-
escape ates one time.
Change direction

C5.1.4 Truck Angle The display shows LEADING or TRAILING in

Forks Leading ___% relation to which direction (forks leading or forks
trailing) does not go 18 m.
escape

The travel distance is complete

in the two direction

C5.1.4 Truck Angle The display shows LEADING or TRAILING in

relation to which direction (forks leading or
Forks Leading 100%
forks trailing) goes 18 m last. The status alarm
escape operates one time.
Come to Stop
Travel speed < 0.16 kph (0.1 mph)

C5.1.4 Truck Angle

GUS = Manual
Switch to Manual
escape

C5.1.4 Truck Angle

GUS = Automatic
Switch to Auto
escape

goes to C5 WIRE GUIDE 1 CALIBRATE

Fig. 156 (26360-01)

Crown 2011 PF25326-70 Rev. 6/12 TSP 7000 SERIES M4.3-1970-070

01 Rev. 6/12
259
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Calibration Wire Guide Menu

GUS = Auto GUS = Manual
When you go into X-OFFSET calibration,
the X-OFFSET value is set to zero in the
two travel directions. C5.2 Adjust X-Offset C5.2 Adjust X-Offset
Travel on Wire Switch to Auto
The truck stops before escape escape
12 m (40 ft)

The truck stops before

12 m

Travel = forks leading direction Travel = forks trailing direction

The travel distance

C5.2 Adjust X-Offset goes to zero when C5.2 Adjust X-Offset
Forks Leading _ _ _ % the truck stops Forks Trailing _ _ _ %
escape escape

The truck goes 18 m in the forks leading or

forks trailing direction

C5.2 Adjust X-Offset The display shows LEADING or TRAILING in

relation to which direction (forks leading or forks
Forks Leading 100%
trailing) goes 12 m first. The status alarm oper-
escape ates one time.
Distance reached
Travel speed < 0.16 kph (0.1 mph)

The display shows RIGHT or LEFT C5.2 Adjust X-Offset

in relation to the direction you select
last.
Move Truck Right
enter change

C5.2 Adjust X-Offset English units Metric units

C5.2 Adjust X-Offset
_ _ 16ths in _ _ mm
enter change enter change

Maximum value = Maximum value = 50

32 (32 = 2 in)

C5.2 Adjust X-Offset

Travel to Continue
exit

go to 5.99 SAVE GUIDANCE to save the calibration

Fig. 157 (26361-01)

M4.3-1970-071 TSP 7000 SERIES Crown 2011 PF25326-71 Rev. 6/12

01 Rev. 6/12
260
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Menus

refer to page -077

refer to page -077

refer to page -077

refer to page -078

refer to page -078

refer to page -079

refer to page -079

continued on page -073

Fig. 158 (26362)

Crown 2011 PF25326-72 Rev. 6/12 TSP 7000 SERIES M4.3-1970-072

01 Rev. 6/12
261
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Menu

refer to page -079

refer to page -080

refer to page -080

refer to page -081

refer to page -084

refer to page -084

continued on page -074

Fig. 159 (26363)

M4.3-1970-073 TSP 7000 SERIES Crown 2011 PF25326-73 Rev. 6/12

01 Rev. 6/12
262
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Menu

refer to page -085

refer to page -085

refer to page -085

refer to page -087

refer to page -087

continued on page -075

Fig. 160 (26364)

Crown 2011 PF25326-74 Rev. 6/12 TSP 7000 SERIES M4.3-1970-074

01 Rev. 6/12
263
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Menu

refer to page -088

refer to page -088

refer to page -089

refer to page -089

refer to page -090

refer to page -091

continued on page -076

Fig. 161 (26365)

M4.3-1970-075 TSP 7000 SERIES Crown 2011 PF25326-75 Rev. 6/12

01 Rev. 6/12
264
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Menu

refer to page -092

refer to page -093

refer to page -094

refer to page -094

Fig. 162 (26366)

Crown 2011 PF25326-76 Rev. 6/12 TSP 7000 SERIES M4.3-1970-076

01 Rev. 6/12
265
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Language, Measurement, and Truck Model Menus

Features F1 Language
F1 Language F1.1 English
= English F1.2 Deutsch
select next prev F1.3 Francais
F1.4 Espanol
F1.5 Nederlands
F1.6 Italiano
F1.99 Escape
select next prev

Features F2 Measurement
F2 Measurement F2.1 Metric
= English F2.2 English
F2.99 Escape
select next prev
select next prev

Features F3 Truck Model

F3 Truck Model F3.1 TSP6500/7000-33
= TSP6500/7000-___ F3.2 TSP6500/7000-1.00
select next prev F3.3 TSP6500/7000-1.25
F3.4 TSP6500/7000-1.50
F3.99 Escape
select next prev

continued on page -078

Fig. 163 (26367-01)

M4.3-1970-077 TSP 7000 SERIES Crown 2011 PF25326-77 Rev. 6/12

01 Rev. 6/12
266
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Battery Setup and Truck Weight Menus

Features F4 Battery Setup F4.1 Battery Voltage

F4 Battery Setup F4.1 Battery Voltage F4.1.1 48 Volts
select next prev = 80 Volts F4.1.2 72 Volts
F4.1.3 80 Volts
select next prev F4.1.99 Escape
select next prev

F4 Battery Setup F4.2 Battery Box 1

F4.2 Battery Box F4.2.1 AA = 550 mm (21.6 in)
= A 634 mm (25 in) F4.2.2 A = 634 mm (25 in)
F4.2.3 B = 721 mm (28 in)
select next prev F4.2.4 C = 865 mm (34 in)
F4.2.5 D = 1010 mm (39.75 in)
F4.2.99 Escape
select next prev

1 Shows the battery compartments that are

available for the voltage you select

F4 Battery Setup F4.3 Batt Retain

F4.3 Battery Retain F4.3.1 No
= No F4.3.2 Yes
F4.3.99 Escape
select next prev
select next prev

F4 Battery Setup
F4.99 Escape goes to FEATURES F4
select next prev BATTERY SETUP

Features
F5 Truck Weight
F5 Truck Weight
(kg/lb) (kg/lb)
select next prev enter change

Minimum = 6350 kg
Maximum = 15000 kg
continued on page -079

Fig. 164 (26368-01)

Crown 2011 PF25326-78 Rev. 6/12 TSP 7000 SERIES M4.3-1970-078

01 Rev. 6/12
267
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Max Load, Mast Type, and Mast Height Menus

1 The F3 TRUCK MODEL

selection has an effect on
the maximum load
Features F6 Max Load
F6 Max Load (kg/lb)
(kg/lb)
enter change
select next prev
1
Minimum = 225 kg
Maximum = 1500 kg

Features F7 Mast Type

F7 Mast Type F7.1 TN Mast
= ___ Mast F7.2 TF Mast
select next prev F7.3 TT Mast
F7.99 Escape
select next prev

Features F8 Mast Height F8.1 Lift Height

F8 Mast Height F8.1 Lift Height (mm/in)
select next prev (mm/in)
enter change
select next prev

Minimum = 4600 mm
Maximum = 17755 mm

F8 Mast Height F8.2 Collapsed Ht

F8.2 Collapsed Ht (mm/in)
(mm/in)
enter change
select next prev

Minimum = 2845 mm
Maximum = 8890 mm

Features
F8.99 Escape goes to FEATURES F8
select next prev MAST HEIGHT

continued on page -080

Fig. 165 (26369-01)

M4.3-1970-079 TSP 7000 SERIES Crown 2011 PF25326-79 Rev. 6/12

01 Rev. 6/12
268
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Aux Mast Height and Traverse Frame Menus

Features F9 Aux Mast Height

F9 Aux Mast Height (mm/in)
(mm/in)
enter change
select next prev

Minimum = 1750 mm
Maximum = 2895 mm

Features F10 Traverse Frame F10.1 Frame Width

F10 Traverse Frame F10.1 Frame Width (mm/in)
(mm/in)
select next prev enter change
select next prev

Minimum = 1220 mm
Maximum = 2286 mm

F10 Traverse Frame F10.2 Stop Width

F10.2 Stop Width (mm/in)
(mm/in)
enter change
select next prev

Minimum = 200 mm
Maximum = 2286 mm
Features
F10.99 Escape goes to FEATURES F10
select next prev TRAVERSE FRAME

continued on page -081

Fig. 166 (26370-01)

Crown 2011 PF25326-80 Rev. 6/12 TSP 7000 SERIES M4.3-1970-080

01 Rev. 6/12
269
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Fork Type Menu

Features F11 Fork Type

F11 Fork Type F11.1 Telescopic
= _________ F11.2 Fixed Fork
select next prev F11.3 Tilting Fork
F11.4 Fork Position
F11.5 Shuttle Forks
F11.6 Roll Loader
F11.99 Escape
select next prev

F11 Fork Type F11.1 Telescopic

F11.1 Telescopic F11.1.1 Fork Offset (n/a)
select next prev enter change

F11.1 Telescopic
F11.1.2 Fork Spread = (mm/in)
enter change

Default Setting = 30
Minimum = 762 mm
Maximum = 1675 mm

F11.1 Telescopic
F11.1.99 Escape
select next prev

continued on page -084 continued on page -082

Fig. 167 (26371-01)

M4.3-1970-081 TSP 7000 SERIES Crown 2011 PF25326-81 Rev. 6/12

01 Rev. 6/12
270
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Fork Type Menu

F11 Fork Type F11.2 Fixed Fork

F11.2 Fixed Fork F11.2.1 Fork Offset = (mm/in)
select next prev enter change

Default Setting = 5
Minimum = 76 mm
Maximum = 305 mm

F11.2 Fixed Fork

F11.2.2 Fork Spread = (mm/in)
enter change

Default Setting = 30
Minimum = 762 mm
Maximum = 1675 mm

F11.2 Fixed Fork

F11.2.99 Escape
select next prev

F11 Fork Type F11.3 Tilting Fork

F11.3 Tilting Fork F11.3.1 Fork Offset = (mm/in)
select next prev enter change

Default Setting = 5
Minimum = 76 mm
Maximum = 305 mm

F11.3 Tilting Fork

F11.3.2 Fork Spread = (n/a)
enter change

continued on page -084

F11.3 Tilting Fork

F11.3.99 Escape
select next prev

continued on page -083

Fig. 168 (26372-01)

Crown 2011 PF25326-82 Rev. 6/12 TSP 7000 SERIES M4.3-1970-082

01 Rev. 6/12
271
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Fork Type Menu

F11 Fork Type F11.4 Fork Position

F11.4 Fork Position F11.4.1 Fork Offset = (n/a)
select next prev enter change

F11.2 Fork Position

F11.4.2 Fork Spread = (mm/in)
enter change

Default Setting = 30
Minimum = 762 mm
Maximum = 1675 mm

F11.2 Fork Position

F11.4.99 Escape
select next prev

F11 Fork Type F11.5 Shuttle Forks

F11.5 Shuttle Forks F11.5.1 Disable
select next prev select next prev

F11.5 Shuttle Forks

F11.5.2 Enable
select next prev

continued on page -084

F11.5 Shuttle Forks

F11.5.99 Escape
select next prev

continued on page -084

Fig. 169 (26373-01)

M4.3-1970-083 TSP 7000 SERIES Crown 2011 PF25326-83 Rev. 6/12

01 Rev. 6/12
272
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Fork Type, Fork Length, and Load Handler Length Menus

F11 Fork Type F11.6 Roll Loader

continued from page -081 F11.6 Roll Loader F11.6.1 Disable
select next prev select next prev

F11 Fork Type F11.6 Roll Loader

F11.99 Escape F11.6.2 Enable
select next prev select next prev

goes to FEATURES F11

FORK TYPE F11.6 Roll Loader
F11.6.99 Escape
select next prev

Features F12 Fork Length

Minimum = 762 mm
F12 Fork Length (mm/in) Maximum = 1524 mm
= (mm/in)
enter change
select next prev

Features F13 Load Hndlr Lngth

Minimum = 584 mm
F13 Load Hndlr Lngth (mm/in) Maximum = 2515 mm
= (mm/in)
enter change
select next prev

continued on page -085

Fig. 170 (26374-01)

Crown 2011 PF25326-84 Rev. 6/12 TSP 7000 SERIES M4.3-1970-084

01 Rev. 6/12
273
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Pallet Width, Pallet Length, and Capacity Data Menus

Features F14 Pallet Width

Minimum = 762 mm (30 in)
F14 Pallet Width (mm/in) Maximum = 2845 mm (112 in)
= (mm/in)
enter change
select next prev

Features F15 Pallet Length Minimum = 762 mm (30 in)

F15 Pallet Length (mm/in) Maximum = 2085 mm (82 in)
= (mm/in)
enter change
select next prev

Features
F17 Capacity Data
1 Disable
select next prev

F17 Capacity Data

1 Disable
select next prev

F17 Capacity Data

2 Enable Default Setting

select next prev

F17 Capacity Data Minimum = 0

3 Zones = (0 - 4) Maximum = 4

select next prev

continued on page -086

Fig. 171 (26375-01)

M4.3-1970-085 TSP 7000 SERIES Crown 2011 PF25326-85 Rev. 6/12

01 Rev. 6/12
274
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Capacity Data Menu

F17 Capacity Data

4 Height 1 = (mm/in) Minimum = 4600 mm (181 in)
Maximum = 17755 mm (699 in)
select next prev

F17 Capacity Data

Minimum = 225 kg (500 lb)
55 Weight
Weight #1
1 ==(kg/lb)
(kg/lb)
Maximum = 1585 kg (3500 lb)
select next prev

F17 Capacity Data

66Height
Height#2
2 ==(mm/in)
(mm/in) Minimum = 4600 mm (181 in)
Maximum = 17755 mm (699 in)
select next prev

F17 Capacity Data

7 Weight 2 = (kg/lb) Minimum = 225 kg (500 lb)
Maximum = 1585 kg (3500 lb)
select next prev

F17 Capacity Data F17 Capacity Data

8 Height 3 = (mm/in) Minimum = 4600 mm (181 in) 11 Weight 4 = (kg/lb)
Maximum = 17755 mm (699 in)
select next prev select next prev

Minimum = 225 kg (500 lb)

Maximum = 1585 kg (3500 lb)
F17 Capacity Data
Minimum = 225 kg (500 lb)
9 Weight 3 = (kg/lb)
Maximum = 1585 kg (3500 lb) F17 Capacity Data
select next prev
99 Escape
select next prev
F17 Capacity Data
goes to FEATURES
10 Height 4 = (mm/in) Minimum = 4600 mm (181 in) F17 CAPACITY DATA
Maximum = 17755 mm (699 in)
select next prev

Fig. 172 (26376-01)

Crown 2011 PF25326-86 Rev. 6/12 TSP 7000 SERIES M4.3-1970-086

01 Rev. 6/12
275
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Wire Guidance and Manual Wire Menus

Features F18 Wire Guidance

F18 Wire Guidance F18.1 No Default Setting
= (Yes/No)
select next prev
select next prev

F18 Wire Guidance

F18.2 Yes
select next prev

F18 Wire Guidance

F18.99 Escape
select next prev

Features F19 Manual Wire

F19 Manual Wire F19.1 Standard Default Setting
= (Standard/Sense & Slow)
select next prev
select next prev

F19 Manual Wire F19.2 Sense & Slow

F19.2 Sense & Slow Distance (m/ft)
select next prev enter change
Minimum = 2 m (5 ft)
Maximum = 6 m (20 ft)

F19 Manual Wire F19.3 Sense & Stop

F19.3 Sense & Stop Distance (m/ft)
select next prev enter change
Minimum = 2 m (5 ft)
Maximum = 6 m (20 ft)

F19 Manual Wire

F19.99 Escape
select next prev

continued on page -088

Fig. 173 (26377-01)

M4.3-1970-087 TSP 7000 SERIES Crown 2011 PF25326-87 Rev. 6/12

01 Rev. 6/12
276
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features End Aisle and Travel Alarm Menus

Default Setting

Default Setting

continued on page -089

Fig. 174 (26378)

Crown 2011 PF25326-88 Rev. 6/12 TSP 7000 SERIES M4.3-1970-088

01 Rev. 6/12
277
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features User Performance and User Codes Menus

Default Setting

Default Setting

continued on page -090 continued on page -090

Fig. 175 (26379)

M4.3-1970-089 TSP 7000 SERIES Crown 2011 PF25326-89 Rev. 6/12

01 Rev. 6/12
278
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features User Codes (cont.) and Cold Condition Menus

continued from page -089

continued from page -089

Default Setting

continued on page -091

Fig. 176 (26380)

Crown 2011 PF25326-90 Rev. 6/12 TSP 7000 SERIES M4.3-1970-090

01 Rev. 6/12
279
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Options Menu

Default
Setting

Default
Setting

continued on page -092 continued on page -092

Fig. 177 (26381)

M4.3-1970-091 TSP 7000 SERIES Crown 2011 PF25326-91 Rev. 6/12

01 Rev. 6/12
280
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Options (cont.) and Front Rail Menus

continued from page -091

continued from page -091 F25 Options F25.3 Location Track

F25.3 Location Track F25.3.1 Disable
select next prev enter next prev
Default
Setting

F25.3 Location Track

F25.3.2 Enable
enter next prev

F25.3 Location Track

F25.3.99 Escape
enter next prev

F25 Options
F25.99 Escape goes to FEATURES F25 OPTIONS
select next prev

Features F26 Front Rail

F26 Front Rail F26.1 Full Default Setting
= (Full/Narrow)
select next prev
select next prev

F26 Front Rail

F26.2 Narrow
select next prev

F26 Front Rail

F26.99 Escape
select next prev

continued on page -093

Fig. 178 (26382-01)

Crown 2011 PF25326-92 Rev. 6/12 TSP 7000 SERIES M4.3-1970-092

01 Rev. 6/12
281
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features Zone Switch and Rack Select Menus

Default
Setting

continued on page -094

Fig. 179 (26383)

M4.3-1970-093 TSP 7000 SERIES Crown 2011 PF25326-93 Rev. 6/12

01 Rev. 6/12
282
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Features User Rack, Screen Setup, and Save Menus

1 Only on trucks with the optional temperature switch and

freezer condition with low temperature hydraulic oil
Features
F29 Not Available

select next prev

Features F30 Screen Setup

F30 Screen Setup F30.1 Fork Height = (OFF/ON)
select next prev
select next prev

F30 Screen Setup F30 Screen Setup 1

F30.2 Load Weight = (OFF/ON) F30.5 Oil Temp = (OFF/ON)

select next prev select next prev

F99 Save F30 Screen Setup F30 Screen Setup

F99.1 No Save F30.3
F30.1Truck
Fork Height
Speed == (OFF/ON)
(OFF/ON) F30.6 Scroll = (OFF/ON)
select next prev select next prev select next prev

F99 Save F30 Screen Setup F30 Screen Setup

F99.2 Yes F30.4 Battery = (OFF/ON) F30.99 Escape
select next prev select next prev select next prev

Fig. 180 (26384-01)

Crown 2011 PF25326-94 Rev. 6/12 TSP 7000 SERIES M4.3-1970-094

01 Rev. 6/12
283
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Hour Meters Menu

continued on page -096

Fig. 181 (26385)

M4.3-1970-095 TSP 7000 SERIES Crown 2011 PF25326-95 Rev. 6/12

01 Rev. 6/12
284
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Event Codes Menus

Fig. 182 (26386)

Crown 2011 PF25326-96 Rev. 6/12 TSP 7000 SERIES M4.3-1970-096

01 Rev. 6/12
285
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance Menu

refer to page -099

refer to page -102

refer to page -105

refer to page -108

refer to page -108

refer to page -108

continued on page -098

Fig. 183 (26387)

M4.3-1970-097 TSP 7000 SERIES Crown 2011 PF25326-97 Rev. 6/12

01 Rev. 6/12
286
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance Menus

refer to page -108

refer to page -109

refer to page -109

refer to page -110

refer to page -112

refer to page -114

refer to page -113

Fig. 184 (26388)

Crown 2011 PF25326-98 Rev. 6/12 TSP 7000 SERIES M4.3-1970-098

01 Rev. 6/12
287
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P1 Setup P1 Menu

Performance
P1 Setup P1

select next prev

P1 Setup P1
Default = 9
P1.1 Travel Accel Minimum = 1
=9 Maximum = 9
select next prev

P1 Setup P1
Default = 7
P1.2 Guide Spd Curve Minimum = 1
=7 Maximum = 9
select next prev

P1 Setup P1 P1.3 Max Trav Speeds

Default = 8.9 kph (5.5 mph)
P1.3 Max Travel Speeds P1.3.1 Free Ranging Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 8.9 kph (5.5 mph)
select next prev select next prev

P1.3 Max Trav Speeds

P1.3.2 Guided Spds
refer to page -100

select next prev

P1.3 Max Trav Speeds

P1.3.3 Center Home
refer to page -100

select next prev

P1.3 Max Trav Speeds

P1.3.3.99 Escape
continued on page -101 select next prev

Fig. 185 (26389-01)

M4.3-1970-099 TSP 7000 SERIES Crown 2011 PF25326-99 Rev. 6/12

01 Rev. 6/12
288
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P1 Setup P1 Menu (continued)

P1.3.2 Guided Spds

Default = 10.4 kph (6.5 mph)
P1.3.2.1 Forks First
Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 10.4 kph (6.5 mph)
select next prev

P1.3.2 Guided Spds

P1.3.2.2 PUF SeatFwd Default = 9.7 kph (6 mph)
Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 9.7 kph (6 mph)
select next prev

P1.3.2 Guided Spds

Default = 12 kph (7.5 mph)
P1.3.2.3 PUF SeatSid Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 12 kph (7.5 mph)
select next prev

P1.3.2 Guided Spds

P1.3.2.99 Escape
select next prev

P1.3.3 Center Home

Default = 4.8 kph (3 mph)
P1.3.3.1 Forks First Minimum = 2.4 kph (1.5 mph)
= (kph/mph) Maximum = 8.9 kph (5.5 mph)
select next prev

P1.3.3 Center Home

P1.3.3.2 PUF Default = 9.7 kph (6 mph)
= (kph/mph) Minimum = 2.4 kph (1.5 mph)
Maximum = 9.7 kph (6 mph)
select next prev

P1.3.3 Center Home

P1.3.3.99 Escape
select next prev

Fig. 186 (26390-01)

Crown 2011 PF25326-100 Rev. 6/12 TSP 7000 SERIES M4.3-1970-100

01 Rev. 6/12
289
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P1 Setup P1 Menu (continued)

continued from page -099

P1 Setup P1 P1.4 Load Handler

Default = 9
P1.4.1 Raise Speed Minimum = 1
P1.4 Load Handler
=9 Maximum = 9
select next prev select next prev

P1.4 Load Handler Default = 9

P1 Setup P1 P1.4.2 Lower Speed Minimum = 1
Default = 8
P1.5 Main Raise Spd Minimum = 1 =9 Maximum = 9
=8 Maximum = 9 select next prev
select next prev

P1.4 Load Handler Default = 7

P1.4.3 Pivot Speed Minimum = 1
P1 Setup P1 =7 Maximum = 9

P1.5.99 Escape select next prev

select next prev

P1.4 Load Handler Default = 7

P1.4.4 Traverse Spd Minimum = 1
=7 Maximum = 9
select next prev

P1.4 Load Handler Default = 5

P1.4.5 Fork Speed Minimum = 1
=5 Maximum = 9
select next prev

P1.4 Load Handler

P1.4.99 Escape
select next prev

Fig. 187 (26391-01)

M4.3-1970-101 TSP 7000 SERIES Crown 2011 PF25326-101 Rev. 6/12

01 Rev. 6/12
290
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P2 Setup P2 Menu

Performance
P2 Setup P2

select next prev

P2 Setup P2
Default = 7
P2.1 Travel Accel Minimum = 1
=7 Maximum = 9
select next prev

P2 Setup P2
Default = 7
P2.2 Guide Spd Curve
Minimum = 1
=7 Maximum = 9
select next prev

P2 Setup P2 P2.3 Max Trav Speeds

P2.3 Max Travel Speeds P2.3.1 Free Ranging Default = 8.9 kph (5.5 mph)
= (kph/mph) Minimum = 1.6 kph (1 mph)
Maximum = 8.9 kph (5.5 mph)
select next prev select next prev

P2.3 Max Trav Speeds

P2.3.2 Guided Spds
refer to page -103

select next prev

P2.3 Max Trav Speeds

P2.3.3 Center Home
refer to page -103

select next prev

P2.3 Max Trav Speeds

P2.3.3.99 Escape
continued on page -104 select next prev

Fig. 188 (26392-01)

Crown 2011 PF25326-102 Rev. 6/12 TSP 7000 SERIES M4.3-1970-102

01 Rev. 6/12
291
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P2 Setup P2 Menu (continued)

P2.3.2 Guided Spds

P2.3.2.1 Forks First Default = 10.4 kph (6.5 mph)
Minimum = 1.6 kph (1 mph)
= (kph/mph)
Maximum = 10.4 kph (6.5 mph)
select next prev

P2.3.2 Guided Spds

P2.3.2.2 PUF SeatFwd Default = 9.7 kph (6 mph)
Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 9.7 kph (6 mph)
select next prev

P2.3.2 Guided Spds

P2.3.2.3 PUF SeatSid Default = 12 kph (7.5 mph)
Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 12 kph (7.5 mph)
select next prev

P2.3.2 Guided Spds

P2.3.2.99 Escape
select next prev

P2.3.3 Center Home

P2.3.3.1 Forks First Default = 4.8 kph (3 mph)
= (kph/mph) Minimum = 2.4 kph (1.5 mph)
Maximum = 8.9 kph (5.5 mph)
select next prev

P2.3.3 Center Home

P2.3.3.2 PUF Default = 9.7 kph (6 mph)
= (kph/mph) Minimum = 2.4 kph (1.5 mph)
Maximum = 9.7 kph (6 mph)
select next prev

P2.3.3 Center Home

P2.3.3.99 Escape
select next prev

Fig. 189 (26393-01)

M4.3-1970-103 TSP 7000 SERIES Crown 2011 PF25326-103 Rev. 6/12

01 Rev. 6/12
292
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P2 Setup P2 Menu (continued)

continued from page -102

P2 Setup P2 P2.4 Load Handler

Default = 7
P2.4.1 Raise Speed
P2.4 Load Handler Minimum = 1
=7 Maximum = 9
select next prev select next prev

P2.4 Load Handler

P2 Setup P2 Default = 9
P2.4.2 Lower Speed Minimum = 1
Default = 5 =9
P2.5 Main Raise Spd Maximum = 9
Minimum = 1
=5 Maximum = 9 select next prev
select next prev

P2.4 Load Handler

Default = 7
P2.4.3 Pivot Speed Minimum = 1
P2 Setup P2 =7 Maximum = 9
P2.5.99 Escape select next prev

select next prev

P2.4 Load Handler

Default = 7
P2.4.4 Traverse Spd Minimum = 1
=7 Maximum = 9
select next prev

P2.4 Load Handler

Default = 5
P2.4.5 Fork Speed Minimum = 1
=5 Maximum = 9
select next prev

P2.4 Load Handler

P2.4.99 Escape
select next prev

Fig. 190 (26394-01)

Crown 2011 PF25326-104 Rev. 6/12 TSP 7000 SERIES M4.3-1970-104

01 Rev. 6/12
293
ELECTRICAL SYSTEM
ACCESS 1 2 3® Performance P3 Setup P3 Menu

Performance
P3 Setup P3

select next prev

P3 Setup P3
Default = 5
P3.1 Travel Accel Minimum = 1
=5 Maximum = 9
select next prev

P3 Setup P3
Default = 3
P3.2 Guide Spd Curve
Minimum = 1
=3 Maximum = 9
select next prev

P3 Setup P3 P3.3 Max Trav Speeds

P3.3 Max Travel Speeds P3.3.1 Free Ranging Default = 7.2 kph (4.5 mph)
Minimum = 1.6 kph (1 mph)
= (kph/mph)
Maximum = 8.9 kph (5.5 mph)
select next prev select next prev

P3.3 Max Trav Speeds

P3.3.2 Guided Spds
refer to page -106

select next prev

P3.3 Max Trav Speeds

P3.3.3 Center Home
refer to page -106

select next prev

P3.3 Max Trav Speeds

P3.3.99 Escape
continued on page -107 select next prev

Fig. 191 (26395-01)

M4.3-1970-105 TSP 7000 SERIES Crown 2011 PF25326-105 Rev. 6/12

01 Rev. 6/12
294
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P3 Setup P3 Menu (continued)

P3.3.2 Guided Spds

Default = 8 kph (5 mph)
P3.3.2.1 Forks First Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 10.4 kph (6.5 mph)
select next prev

P3.3.2 Guided Spds

Default = 7.2 kph (4.5 mph)
P3.3.2.2 PUF SeatFwd Minimum = 1.6 kph (1 mph)
= (kph/mph) Maximum = 9.7 kph (6 mph)
select next prev

P3.3.2 Guided Spds

P3.3.2.3 PUF SeatSid Default = 9.7 kph (6 mph)
= (kph/mph) Minimum = 1.6 kph (1 mph)
Maximum = 12 kph (7.5 mph)
select next prev

P3.3.2 Guided Spds

P3.3.2.99 Escape
select next prev

P3.3.3 Center Home

Default = 4.8 kph (3 mph)
P3.3.3.1 Forks First
Minimum = 2.4 kph (1.5 mph)
= (kph/mph) Maximum = 8.9 kph (5.5 mph)
select next prev

P3.3.3 Center Home

P3.3.3.2 PUF Default = 8 kph (5 mph)
= (kph/mph) Minimum = 2.4 kph (1.5 mph)
Maximum = 9.7 kph (6 mph)
select next prev

P3.3.3 Center Home

P3.3.3.99 Escape
select next prev

Fig. 192 (26396-01)

Crown 2011 PF25326-106 Rev. 6/12 TSP 7000 SERIES M4.3-1970-106

01 Rev. 6/12
295
ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance P3 Setup P3 Menu (continued)

continued from page -105

P3 Setup P3 P3.4 Load Handler

Default = 5
P3.4.1 Raise Speed Minimum = 1
P3.4 Load Handler
=5 Maximum = 9
select next prev select next prev

P3.4 Load Handler

Default = 5
P3 Setup P3 P3.4.2 Lower Speed
Default = 3 Minimum = 1
P3.5 Main Raise Spd Minimum = 1
=5 Maximum = 9
=3 Maximum = 9 select next prev
select next prev

P3.4 Load Handler

Default = 3
P3.4.3 Pivot Speed Minimum = 1
P3 Setup P3 =3 Maximum = 9

P3.5.99 Escape select next prev

select next prev

P3.4 Load Handler

Default = 3
P3.4.4 Traverse Spd Minimum = 1
=3 Maximum = 9
select next prev

P3.4 Load Handler Default = 1

P3.4.5 Fork Speed Minimum = 1
=1 Maximum = 9
select next prev

P3.4 Load Handler

P3.4.99 Escape
select next prev

Fig. 193 (26397-01)

M4.3-1970-107 TSP 7000 SERIES Crown 2011 PF25326-107 Rev. 6/12

01 Rev. 6/12
296
 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance Plug, Coast, Braking, and Free Range Speeds Menus

Performance
Default = 7
P4 Plug Minimum = 1
=7 Maximum = 9
P6 Braking
select next prev Default = 7
P6.1 Braking FF Minimum = 1
=7 Maximum = 9
select next prev

Performance
Default = 9
P5 Coast Minimum = 1 P6 Braking
=9 Maximum = 9 Default = 7
P6.2 Braking PUF Minimum = 1
select next prev =7 Maximum = 9
select next prev

Performance
P6 Braking
P6 Braking
P6.99 Escape
select next prev
select next prev

Performance P7 Free Range Speeds

P7 Free Range Speeds P7.1 Spd Lim Ht 1 mph
= (mm/in)
select next prev select next prev
Default = 17755 mm (699 in)
Minimum = 0
Maximum = 17755 mm (699 in)

P7 Free Range Speeds

P7.2 Spd Lim Ht 0 mph
= (mm/in)
select next prev
Default = 17755 mm (699 in)
Minimum = 0
Maximum = 17755 mm (699 in)

P7 Free Range Speeds

P7.99 Escape
select next prev

Fig. 194 (26398-01)

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ELECTRICAL SYSTEM
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Performance Guided Speeds and BDI Menus

Performance P8 Guided Speeds

P8 Guided Speeds P8.1 Spd Lim Ht 1 mph
= (mm/in)
select next prev select next prev
Default = 17755 mm (699 in)
Minimum = 0
Maximum = 17755 mm (699 in)

P8 Guided Speeds
8.2 Spd Lim Ht 0 mph
= (mm/in)
select next prev
Default = 17755 mm (699 in)
Minimum = 0
Maximum = 17755 mm (699 in)

P8 Guided Speeds
P8.3 Acquire Speed
= (kph/mph)
select next prev
Default = 4 kph (2.5 mph)
Minimum = 2.4 kph (1.5 mph)
Maximum = 4 kph (2.5 mph)
P9 BDI
Default = 5
=5 Minimum = 1
Maximum = 9
select next prev P8 Guided Speeds
P8.99 Escape

select next prev

Fig. 195 (26399-01)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance EAC Setup Menu

Performance P10.1 Mode

P10 EAC Setup P10.1.1 Slowdown

select next prev select next prev

P10 EAC Setup P10.1 Mode

P10.1 EAC Mode
P10.1.2 Slowdn Auto-Resume
= Slowdown
select next prev select next prev

P10 EAC Setup

P10.1 Mode
P10.2 FF Direction refer to page -111
P10.1.3 Slowdn Auto-Stop
select next prev
select next prev

P10 EAC Setup

P10.3 PUF Direction refer to page -111 P10.1 Mode
select next prev P10.1.4 Stop using Motor

select next prev

P10 EAC Setup P10.4 Slowdown Dir

P10.4 Slowdown Dir
P10.4.1 Out of Aisle Only
= P10.1 Mode
select next prev select next prev
P10.1.5 Stop using Brake

select next prev

P10 EAC Setup P10.4 Slowdown Dir
P10.5 Magnet Spread P10.4.2 In & Out of Aisle
= 1
select next prev select next prev P10.1 Mode
P10.1.99 Escape

P10 EAC Setup select next prev

99 Escape
1 Only for P10.1.2 SLOWDN AUTO-RESUME
select next prev
Minimum = 6 m (20 ft)
Maximum = 45.7 m (150 ft)

Fig. 196 (26400-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance EAC Setup Menu (continued)

continued from page -110 continued from page -110

P10.2 FF Direction P10.3 PUF Direction

P10.2.1 EAC Zone Spd P10.3.1 Slowdown Speed
= (kph/mph) = (kph/mph)
select next prev select next prev
Default = 3.2 kph (2 mph) Default = 3.2 kph (2 mph)
Minimum = 1.6 kph (1 mph) Minimum = 1.6 kph (1 mph)
Maximum = 9.7 kph (6 mph) Maximum = 9.7 kph (6 mph)

P10.2 FF Direction P10.3 PUF Direction

P10.2.2 Decel Rate P10.3.2 Decel Rate
=3 =5
select next prev select next prev
Default = 3 Default = 5
Minimum = 1 Minimum = 1
Maximum = 9 Maximum = 9

P10.2 FF Direction P10.3 PUF Direction

P10.2.3 Resume Dist P10.3.3 Resume Dist
= (m/ft) = (m/ft)
select next prev select next prev
Default = 13.7 m (45 ft) Default = 13.7 m (45 ft)
Minimum = 3 m (10 ft) Minimum = 3 m (10 ft)
Maximum = 18.3 m (60 ft) Maximum = 18.3 m (60 ft)

P10.2 FF Direction P10.3 PUF Direction

P10.2.4 Stop Dist P10.3.4 Stop Dist
= (m/ft) = (m/ft)
select next prev select next prev
Default = 6.1 m (20 ft) Default = 6.1 m (20 ft)
Minimum = 0 Minimum = 0
Maximum = 12.2 m (40 ft) Maximum = 12.2 m (40 ft)

P10.2 FF Direction P10.3 PUF Direction

P10.2.99 Escape P10.3.99 Escape

select next prev select next prev

Fig. 197 (26401-01)

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 ELECTRICAL SYSTEM
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Performance Main Hoist R/L Menu

P11.1 Main Hoist Raise

Performance P11.1.1 Max Speed
P11 Main Hoist R/L = N/A
select next prev
select next prev

P11.1 Main Hoist Raise

P11 Main Hoist R/L Default = 6
P11.1.2 Main R Accel
Minimum = 1
P11.1 Main Raise =6 Maximum = 9
select next prev
select next prev

P11.1 Main Hoist Raise

Default = 7
P11 Main Hoist R/L P11.1.3 Main R Decel Minimum = 1
=7 Maximum = 9
P11.2 Main Lower
select next prev
select next prev

P11.1 Main Hoist Raise

P11 Main Hoist R/L Default = 5
P11.1.4 Main R Stage
Minimum = 1
99 Escape =5 Maximum = 9
select next prev TF & TT Masts Only
select next prev

P11.1 Main Hoist Raise

P11.2 Main Hoist Lower
Default = 9 P11.1.99 Escape
P11.2.1 Max Speed Minimum = 1
=9 Maximum = 9 select next prev
select next prev

P11.2 Main Hoist Lower P11.2 Main Hoist Lower Default = 5

Default = 4
P11.2.2 Main L Accel Minimum = 1 P11.2.4 Main L Stage Minimum = 1
=4 Maximum = 9 =5 Maximum = 9
select next prev select next prev TF & TT Masts Only

P11.2 Main Hoist Lower P11.2 Main Hoist Lower

Default = 6
P11.2.3 Main L Decel Minimum = 1 P11.2.99 Escape
=6 Maximum = 9
select next prev select next prev

Fig. 198 (26402-01)

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ELECTRICAL SYSTEM
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Performance Aux Hoist R/L Menu

Performance
P12 Aux Hoist R/L

select next prev

P12 Aux Hoist R/L P12.1 Aux Hoist Raise

P12.1.1 Aux Accel Default = 6
P12.1 Aux Raise =6 Minimum = 1
Maximum = 9
select next prev select next prev

P12.1 Aux Hoist Raise

P12 Aux Hoist R/L Default = 7
P12.1.2 Aux Decel
Minimum = 1
P12.2 Aux Lower =7 Maximum = 9
select next prev
select next prev

P12.1 Aux Hoist Raise

P12 Aux Hoist R/L P12.1.99 Escape
P12.3.99 Escape
select next prev
select next prev

P12.2 Aux Hoist Lower

P12.2.1 Aux L Accel Default = 6
=6 Minimum = 1
Maximum = 9
select next prev

P12.2 Aux Hoist Lower

P12.2.2 Aux L Decel Default = 7
=7 Minimum = 1
Maximum = 9
select next prev

P12.2 Aux Hoist Lower

P12.2.99 Escape

select next prev

Fig. 199 (26403-01)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Performance PDS Setup Menu

Performance P13.1 FF Direction

P13.1.1 Max Speed Default = 6.0
P13 PDS Setup
= 6.0 mph Minimum = 1.0
Maximum = 6.5
select next prev enter next prev

P13 PDS Setup P13.1 FF Direction

P13.1.2 Slowdown Speed Default = 1.5
P13.1 FF Direction Minimum = 1.0
= 1.5 mph
Maximum = 6.0
select next prev select next prev

P13 PDS Setup P13.1 FF Direction

P13.2 PUF Direction P13.1.3 Decel Rate Default = 9
Minimum = 1
=9
select next prev Maximum = 9
select next prev

P13 PDS Setup P13.1 FF Direction

P13.3.99 Escape P13.1.99 Escape
select next prev select next prev

P13.2 PUF Direction

P13.2.1 Max Speed Default = 6.0
= 6.0 mph Minimum = 1.0
Maximum = 7.5
select next prev P13.2 PUF Direction
Default = 9
P13.2.3 Decel Rate
Minimum = 1
=9 Maximum = 9
select next prev
P13.2 PUF Direction
P13.2.2 Slowdown Speed Default = 1.5
= 1.5 mph Minimum = 1.0
Maximum = 6.0
select next prev P13.2 PUF Direction
P13.2.99 Escape

select next prev

Fig. 200 (26404-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®

Utilities Menu

refer to page -116

refer to page -116

refer to page -116

Fig. 201 (26405)

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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Utilities Menu

Utilities Utilities
U2 Activate Tow Mode U4 Truck Lockout
select next prev select next prev

U2 Activate Tow Mode U4 Truck Lockout U4 Truck Lockout

1 Tow Mode 1 Enable Lockout "Key Down to Enable"
select next prev select next prev

When you go into the U2.1 TOW MODE menu,

tow mode is immediately ON. ACCESS 1
shows the message TOW MODE ACTIVATED U4 Truck Lockout
U4 Truck Lockout
KEY DOWN TO REMOVE.
2 Disable Lockout "Key Down to Enable"
select next prev

Utilities
U3 Shipping Mode
U4 Truck Lockout
select next prev 99 Escape
select next prev

U3 Shipping Mode U3 Shipping Mode

1 Enable Ship Mode "Key Down to Enable"
select next prev

U3 Shipping Mode U3 Shipping Mode

2 Disable Ship Mode "Key Down to Enable"
select next prev

U3 Shipping Mode
99 Escape
select next prev

Fig. 202 (26406-01)

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ELECTRICAL SYSTEM
ACCESS 1 2 3®
ANALYZER
The ANALYZER menu lets you look at and do a test of
the system components on the truck. These are the dif-
ferent system components that you can look at and do
a test of in the LEVEL 2 and LEVEL 3 menus:
LEVEL 2:
• A1 (truck status, view only)
• A2 (module inputs)
• A3 (module outputs)
• A4 (not available in this level).
LEVEL 3:
• A1 (truck status, view only)
• A2 (module inputs)
• A3 (not available in this level)
• A4 (test outputs).
ANALYZER Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2. To access LEVEL 3, hold the up
and down arrows and turn the truck ON.
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push ENTER to go into the ANALYZER menu.
A1 STATUS - Shows the status of monitored truck sys-
tems.
A1.1 STEERING = ___ (ENABLED or DISABLED) -
ENABLED = the steering system can operate. DISA-
BLED = the steering system cannot operate, which
could be because of an event code.
A1.2 LIMP TRAVEL = ___ (ENABLED or DISABLED)
- ENABLED = decreased truck travel speed is permit-
M4.3-1970-117 TSP 7000 SERIES
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ted. DISABLED = decreased truck travel speed is not
permitted, which could be because of an event code.
A1.3 FULL TRAVEL = ___ (ENABLED or DISABLED)
- ENABLED = maximum truck travel speed is permit-
ted. DISABLED = maximum truck travel speed is not
permitted, which could be because of an event code.
A1.4 MAIN RAISE = ___ (ENABLED or DISABLED) -
ENABLED = the platform and mast raise system can
operate. DISABLED = the platform and mast raise sys-
tem cannot operate, which could be because of an
event code.
A1.5 MAIN LOWER = ___ (ENABLED or DISABLED)
- ENABLED = the platform and mast lower system can
operate. DISABLED = the platform and mast lower sys-
tem cannot operate, which could be because of an
event code.
A1.6 AUX RAISE = ___ (ENABLED or DISABLED) -
ENABLED = the fork carriage raise system can oper-
ate. DISABLED = the fork carriage raise system cannot
operate, which could be because of an event code.
A1.7 AUX LOWER = ___ (ENABLED or DISABLED) -
ENABLED = the fork carriage lower system can oper-
ate. DISABLED = the fork carriage lower system can-
not operate, which could be because of an event code.
A1.8 TRAVERSE = ___ (ENABLED or DISABLED) -
ENABLED = the auxiliary mast can move from one side
of the platform to the other. DISABLED = the auxiliary
mast cannot move from one side of the platform to the
other, which could be because of an event code.
A1.9 PIVOT = ___ (ENABLED or DISABLED) - ENA-
BLED = the auxiliary mast can turn the fork carriage.
DISABLED = the auxiliary mast cannot turn the fork
carriage, which could be because of an event code.
A1.10 FORK EXTEND = ___ (ENABLED or DISA-
BLED) - This menu is available regardless of how the
F11 FORK TYPE menu is set. ENABLED = the auxil-
iary mast can extend the optional telescopic forks on
the fork carriage. DISABLED = the auxiliary mast can-
not extend the optional telescopic forks on the fork car-
riage, which could be because of an event code.
A1.11 ED CLOSED = ___ (ENABLED or DISABLED) -
ENABLED = the emergency disconnect coil can oper-
ate. DISABLED = the emergency disconnect coil can-
not operate, which could be because of an event code.
Crown 2011 PF25326-117 Rev. 6/12

A1.12 FULL HOIST = ___ (ENABLED or DISABLED) -
ENABLED = the platform and mast raise system can
operate at maximum speed. DISABLED = the platform
and mast raise system cannot operate at maximum
speed, which could be because of an event code.
A1.14 1234567890123 = ___ (ENABLED or DISA-
BLED) - Shows the status of the other 13 menus at one
time. Y is below the menu number if that menu is set to
ENABLED. N is below the menu number if that menu is
set to DISABLED, or is with an event code.
A2 INPUTS - Shows the inputs of monitored truck com-
ponents (encoders, potentiometers, switches, and
temperature sensors) to the control modules.
A2.1 LOAD HANDLER - Shows the auxiliary mast and
fork carriage inputs.
A2.1.1 ECR3 - The input from the auxiliary mast height
encoder has an effect on the fork height.
A2.1.1.1 POSITION = ___ (cm or in) - Shows the fork
height (from the floor to the top of the fork) in cm (the
F2 MEASUREMENT menu is set to METRIC) or in (the
F2 MEASUREMENT menu is set to ENGLISH).
A2.1.1.2 SPEED = ___ (cm/sec or in/sec) - Shows the
rate of fork movement in cm/sec (the F2 MEASURE-
MENT menu is set to METRIC) or in/sec (the F2
MEASUREMENT menu is set to ENGLISH). When you
lower the forks, the value has a negative sign before it.
A2.1.1.3 COUNT = ___ (counts) - Shows the auxiliary
mast height encoder counts. When you lower the forks,
the value has a negative sign before it. The value de-
creases in counts until the forks raise sufficiently to
open the auxiliary height reset switch. After that, the
value does not have a negative sign before it and in-
creases in counts as the forks raise.
A2.1.1.99 ESCAPE - goes to the A2.1.1 ECR3 menu.
A2.1.2 ECR4 - The input from the traverse position en-
coder has an effect on the auxiliary mast position
across the front of the platform.
A2.1.2.1 POSITION = ___ (cm or in) - Shows the aux-
iliary mast position (relative to the center of the plat-
form) in cm (the F2 MEASUREMENT menu is set to
METRIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). When the auxiliary mast moves to the left
of the platform center, the value has a negative sign
before it.
A2.1.2.2 SPEED = ___ (cm/sec or in/sec) - Shows the
rate of auxiliary mast movement in cm/sec (the F2
MEASUREMENT menu is set to METRIC) or in/sec
(the F2 MEASUREMENT menu is set to ENGLISH).
When the auxiliary mast moves to the left of the plat-
form center, the value has a negative sign before it.
Crown 2011 PF25326-118 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
A2.1.2.3 COUNT = ___ (counts) - Shows the traverse
position encoder counts. When the auxiliary mast
moves to the left of the platform center, the value has a
negative sign before it.
A2.1.2.99 ESCAPE - goes to the A2.1.2 ECR4 menu.
A2.1.3 POT5 - The input from the pivot position poten-
tiometer has an effect on the fork carriage position.
A2.1.3.1 POSITION = ___ (deg) - Shows the fork car-
riage position in degrees. 0 degrees = the forks point
fully to the right side of the platform. 90 degrees = the
forks point directly away from the platform. 180 de-
grees = the forks point fully to the left side of the plat-
form.
A2.1.3.2 SPEED = ___ (cm/sec or in/sec) - Shows the
rate of fork movement in deg/sec. When the forks move
to the right, the value has a negative sign before it.
A2.1.3.3 VOLTAGE = ___ (deg) - Shows the voltage
input from the pivot position potentiometer. Approxi-
mately 3.9 V = the forks point fully to the right side of
the platform. Approximately 0.85 V = the forks point
fully to the left side of the platform.
A2.1.3.99 ESCAPE - goes to the A2.1.3 POT5 menu.
A2.1.4 FHSL & FHSR = ___ (SWITCH OPENED or
SWITCH CLOSED) - This menu is available regardless
of how the F11 FORK TYPE menu is set. This menu
shows the condition of the fork home switches on
trucks with optional telescopic forks. SWITCH
CLOSED = the forks are not in the extended position.
SWITCH OPENED = the forks are in the extended po-
sition.
A2.1.5 HGTRS2 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the auxil-
iary height reset switch. SWITCH CLOSED = the forks
are below approximately 21 cm (8.3 in). SWITCH
OPENED = the forks are above approximately 21 cm
(8.3 in).
A2.1.6 TVRS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the traverse reset
switch. SWITCH CLOSED = the auxiliary mast is at the
center of the platform. SWITCH OPENED = the auxil-
iary mast is left or right of the platform center.
A2.1.7 LS = ___ - The input from the load sensor has
an effect on the weight on the forks (to an accuracy of
± 23 kg [50 lb]).
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A2.1.7.1 WEIGHT = ___ (kg or lb) - Shows the weight
on the forks in kg (the F2 MEASUREMENT menu is set
to METRIC) or lb (the F2 MEASUREMENT menu is set
to ENGLISH). In the LEVEL 1 menu (when the fork
height is less than 15 cm [6 in]), ACCESS 1 shows the
message LOAD SENSE DISABLED. In the LEVEL 2 or
LEVEL 3 menus (when the fork height is less than
15 cm [6 in]), the weight defaults to the maximum ca-
pacity (1497 kg [3300 lb]) because the load sense is
DISABLED. Raise the forks more than 15 cm (6 in) and
let the load become stable for an accurate fork weight.
A2.1.7.2 Current = ___ (μA) - Shows the load sense
input in microamperes (μA). Some examples of the
weights in relation to the current values are:
• LOAD SENSE DISABLED (the fork height is less
than 15 cm [6 in]) = 4100 μA.
• LOAD SENSE ENABLED (there is no weight on the
forks) = 5500 μA.
• 767 kg (1690 lb) on the forks = 9100 μA.
• 1522 kg (3355 lb) on the forks = 12800 μA.
A2.1.7.3 Count = ___ (counts) - Shows the load sense
input in counts. Some examples of the weights in rela-
tion to the count values are:
• LOAD SENSE DISABLED (the fork height is less
than 15 cm [6 in]) = 200 counts.
• LOAD SENSE ENABLED (there is no weight on the
forks) = 270 counts.
• 767 kg (1690 lb) on the forks = 462 counts.
• 1522 kg (3355 lb) on the forks = 645 counts.
A2.1.7.99 ESCAPE - goes to the A2.1.7 LS menu.
A2.2 PLATFORM - Shows the inputs from components
on the platform, but not the operator seat.
A2.2.1 ECR5 - The input from the height sense en-
coder has an effect on the platform height.
A2.2.1.1 POSITION = ___ (cm or in) - Shows the plat-
form height (relative to the center of the platform) in cm
(the F2 MEASUREMENT menu is set to METRIC) or in
(the F2 MEASUREMENT menu is set to ENGLISH).
A2.2.1.2 SPEED = ___ (cm/sec or in/sec) - Shows the
rate of platform movement in cm/sec (the F2 MEAS-
UREMENT menu is set to METRIC) or in/sec (the F2
MEASUREMENT menu is set to ENGLISH). When you
lower the platform, the value has a negative sign before
it.
A2.2.1.3 COUNT = ___ (counts) - Shows the height
sense encoder counts. When you lower the platform,
the value has a negative sign before it. The value de-
creases in counts until the platform raises sufficiently to
open the main height reset switch. After that, the value
does not have a negative sign before it and increases
in counts as the platform raises.
A2.2.1.99 ESCAPE - goes to the A2.2.1 ECR5 menu.
A2.2.2 BRS1 & BRS3 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the left
and right brake pedal switches at the front of the plat-
form. The input from the left and right brake pedal
switches goes to ACCESS 4. SWITCH OPENED = the
left or right brake pedal is in operation. SWITCH
CLOSED = the left and right brake pedals are not in
operation.
A2.2.3 CHS1 & CHS2 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the chain
slack switches. SWITCH OPENED = the chains are
loose. SWITCH CLOSED = the chains are not loose.
A2.2.4 CHS3 & CHS4 = ___ (SWITCH OPENED or
SWITCH CLOSED)- Shows the condition of the chain
break switches. SWITCH OPENED = the chains are
broken. SWITCH CLOSED = the chains are not bro-
ken.
A2.2.5 FPS1, 2 & 3 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the foot
presence switches with the floor pedal at the center
and back of the platform. SWITCH OPENED = the floor
pedal is not in operation. SWITCH CLOSED = the floor
pedal is in operation.
A2.2.6 FPS4, 5 & 6 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the foot
presence switches with the floor pedal at the center
and front of the platform. SWITCH OPENED = the floor
pedal is not in operation. SWITCH CLOSED = the floor
pedal is in operation.
A2.2.7 FPS7, 8 & 9 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the foot
presence switches with the floor pedal at the right and
front of the platform. SWITCH OPENED = the floor
pedal is not in operation. SWITCH CLOSED = the floor
pedal is in operation.
A2.2.8 GTSL & GTSR = ___ (SWITCH OPENED or
SWITCH CLOSED) - This menu is available regardless
of how the F26 FRONT RAIL menu is set. This menu
shows the condition of the left and right gate switches.
SWITCH OPENED = the left or right gate is raised.
SWITCH CLOSED = the left and right gates are low-
ered.

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A2.2.9 HGTRS1 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the main
height reset switch. SWITCH OPENED = the forks are
above approximately 42 cm (16.6 in). SWITCH
CLOSED = the platform is below approximately 42 cm
(16.6 in).
A2.2.10 SLS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the seat sense
switch. SWITCH OPENED = the seat is not in position.
SWITCH CLOSED = the seat is in position.
A2.2.11 SPS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the seat position
switch. SWITCH OPENED = the seat is to the left (270
or 300 degrees). SWITCH CLOSED = the seat is for-
ward (0 or 20 degrees).
A2.2.13 ZSSA = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F27 ZONE SWITCH menu is set. This menu shows
the condition of position A of the optional zone select
switch. SWITCH OPENED = the key is not in the A po-
sition. SWITCH CLOSED = the key is in the A position.
A2.2.14 ZSSB = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F27 ZONE SWITCH menu is set. This menu shows
the condition of position B of the optional zone select
switch. SWITCH OPENED = the key is not in the B po-
sition. SWITCH CLOSED = the key is in the B position.
A2.2.15 ZSSC = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F27 ZONE SWITCH menu is set. This menu shows
the condition of position C of the optional zone select
switch. SWITCH OPENED = the key is not in the C po-
sition. SWITCH CLOSED = the key is in the C position.
A2.2.99 ESCAPE - goes to the A2.2 PLATFORM
menu.
A2.3 SEAT CONTROLS - Shows the inputs from com-
ponents on the operator seat.
A2.3.1 ECR1/ECR2 = ___ (counts) - Shows two differ-
ent count values for the steer command encoders.
When you turn the steer tiller clockwise, the value has
a negative sign before it. When you turn the steer tiller
counterclockwise, there is no negative sign before the
value.
A2.3.2 POT1 = ___ (volts) - The input from the traction
command potentiometer has an effect on the travel
speed command. When the right control is in the neu-
tral position, the voltage is 2.3. When the right control
is in the full forward travel position, the voltage is 1.12.
When the right control is in the full reverse travel posi-
tion, the voltage is 3.85.
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ACCESS 1 2 3®
A2.3.3 POT2 = ___ (volts) - The input from the main
raise and lower potentiometer has an effect on the plat-
form and mast direction and speed command. When
the right control is in the neutral position, the voltage is
2.3. When the right control is in the full raise position,
the voltage is 1.2. When the right control is in the full
lower position, the voltage is 3.85.
A2.3.4 POT3 = ___ (volts) - The input from the auxiliary
raise and lower potentiometer has an effect on the fork
carriage direction and speed command. When the left
thumbwheel control is in the neutral position, the volt-
age is 2.58. When the left thumbwheel control is in the
full raise position, the voltage is 1.25. When the left
thumbwheel control is in the full lower position, the volt-
age is 3.75.
A2.3.5 POT4 = ___ (volts) - The input from the traverse
command potentiometer has an effect on the auxiliary
mast direction and speed command. When the right
thumbwheel control is in the neutral position, the volt-
age is 2.46. When the left thumbwheel control is in the
full raise position, the voltage is 1.11. When the left
thumbwheel control is in the full lower position, the volt-
age is 3.75.
A2.3.6 APS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the auto pivot
switch on the left control. SWITCH OPENED = the auto
pivot switch is not in operation. SWITCH CLOSED =
the auto pivot switch is in operation.
A2.3.7 FS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the forward switch
on the right control. SWITCH OPENED = the right con-
trol is in the neutral or reverse travel position. SWITCH
CLOSED = the right control is in the forward travel po-
sition.
A2.3.8 FS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the reverse switch
on the right control. SWITCH OPENED = the right con-
trol is in the neutral or forward travel position. SWITCH
CLOSED = the right control is in the reverse travel po-
sition.
A2.3.9 GUS = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F18 WIRE GUIDANCE menu is set. This menu
shows the condition of the optional guidance switch on
the right armrest. SWITCH OPENED = the guidance
switch is set to the automatic position. SWITCH
CLOSED = the guidance switch is set to the manual
position.
A2.3.10 HNS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the horn switch on
the right control. SWITCH OPENED = the horn switch
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is not in operation. SWITCH CLOSED = the horn
switch is in operation.
A2.3.11 HPSL = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the left hand pres-
ence switch on the left control. SWITCH OPENED =
your hand is not on the left control. SWITCH CLOSED
= your hand is on the left control.
A2.3.12 HPSR = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the right hand pres-
ence switch on the left control. SWITCH OPENED =
your hand is not on the right control. SWITCH CLOSED
= your hand is on the right control.
A2.3.13 ORS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the override switch
on the left control. SWITCH OPENED = the override
switch is not in operation. SWITCH CLOSED = the
override switch is in operation.
A2.3.14 PLS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the pivot left switch
on the left thumbwheel. SWITCH OPENED = the pivot
left switch is not in operation. SWITCH CLOSED = the
pivot left switch is in operation.
A2.3.15 PRS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the pivot right
switch on the left thumbwheel. SWITCH OPENED =
the pivot right switch is not in operation. SWITCH
CLOSED = the pivot right switch is in operation.
A2.3.16 RSS = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the release seat
switch on the right control. SWITCH OPENED = the
release seat switch is not in operation. SWITCH
CLOSED = the release seat switch is in operation.
A2.3.17 SES = ___ (SWITCH OPENED or SWITCH
CLOSED) - Shows the condition of the seat sense
switch on the right control. SWITCH OPENED = the
seat sense switch is not in operation. SWITCH
CLOSED = the seat sense switch is in operation.
A2.3.18 TBS = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F11 FORK TYPE menu is set. This menu shows the
condition of the optional tilt back switch on the right
thumbwheel. SWITCH OPENED = the tilt back switch
is not in operation. SWITCH CLOSED = the tilt back
switch is in operation.
A2.3.19 TDS = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F11 FORK TYPE menu is set. This menu shows the
condition of the optional tilt down switch on the right
thumbwheel. SWITCH OPENED = the tilt down switch
is not in operation. SWITCH CLOSED = the tilt down
switch is in operation.
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A2.3.99 ESCAPE - goes to the A2.3 SEAT CON-
TROLS menu.
A2.4 POWER UNIT - Shows the inputs from compo-
nents on the power unit and mast mainframe.
A2.4.1 ECR6 = ___ (counts) - The input from the steer-
ing feedback encoder has an effect on the drive tire
position. This value has a negative sign before it when
the rear edge of the drive tire points to the right side of
the power unit.
A2.4.2 ECR7 - The input from the traction speed en-
coder has an effect on the speed and direction of the
traction motor. The input from the traction speed en-
coder goes to ACCESS 3 and ACCESS 5.
A2.4.2.1 ACCESS 5 = ___ (rpm) - Shows the input in
rpm to ACCESS 5. This value has a negative sign be-
fore it when the truck moves in reverse.
A2.4.2.2 ACCESS 5 = ___ (counts) - Shows the input
in counts to ACCESS 5.
A2.4.2.3 ACCESS 3 = ___ (rpm) - Shows the input in
rpm to ACCESS 3. This value has a negative sign be-
fore it when the truck moves in reverse.
A2.4.2.99 ESCAPE - goes to the A2.4.2 ECR7 menu.
A2.4.3 ECR8 = ___ (rpm) - The input from the pump
motor encoder has an effect on the speed and direction
of the pump motor. This value has a plus sign before it
for most functions, but not when the platform or mast
lowers. When the platform or mast lowers, the value
has a negative sign before it.
A2.4.4 CS1 = ___ (amps) - Shows the input from the
current monitor in A.
A2.4.5 GS1 STEER - This menu is available regard-
less of how the F18 WIRE GUIDANCE menu is set.
This is the optional guidance sensor bar at the drive tire
end of the truck.
A2.4.5.1 GS1 RAW = ___ (%) - Shows four different
values in %. Raw values are values that the wire guid-
ance system does not adjust. These four values are
from the four different sensor coils in the guidance sen-
sor bar. Each raw value increases when the each sen-
sor coil of the truck moves across the guide wire. Each
raw value decreases as each sensor coil moves away
from the guide wire.
A2.4.5.2 GS1 SCALED = ___ (%) - Shows four differ-
ent values in %. Scaled values are raw values that
change. The wire guidance system adds to the raw
value of each sensor coil. The function of this is to
make all four sensor coil inputs as equal as possible.
A2.4.5.99 ESCAPE - goes to the A2.4.5 GS1 STEER
menu.
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A2.4.6 GS2 LOAD - This menu is available regardless
of how the F18 WIRE GUIDANCE menu is set. This is
the optional guidance sensor bar at the load wheel end
of the truck.
A2.4.6.1 GS2 RAW = ___ (%) - Shows four different
values in %. Raw values are values that the wire guid-
ance system does not adjust. These four values are
from the four different sensor coils in the guidance sen-
sor bar. Each raw value increases when the each sen-
sor coil of the truck moves across the guide wire. Each
raw value decreases as each sensor coil moves away
from the guide wire.
A2.4.6.2 GS2 SCALED = ___ (%) - Shows four differ-
ent values in %. Scaled values are raw values that
change. The wire guidance system adds to the raw
value of each sensor coil. The function of this is to
make all four sensor coil inputs as equal as possible.
A2.4.6.99 ESCAPE - goes to the A2.4.6 GS2 LOAD
menu.
A2.4.7 EAC - This menu is available regardless of how
the F20 END AISLE menu is set. This menu shows
data related to the optional end aisle control.
A2.4.7.1 EACA1 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the digital
switch input from the A1 sensor to CA602-5 on AC-
CESS 6. SWITCH OPENED = the A1 sensor does not
sense the floor magnet. SWITCH CLOSED = the A1
sensor senses the floor magnet.
A2.4.7.2 EACA2 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the digital
switch input from the A2 sensor to CA602-8 on
ACCESS 6. SWITCH OPENED = the A2 sensor does
not sense the floor magnet. SWITCH CLOSED = the
A2 sensor senses the floor magnet.
A2.4.7.3 EACB1 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the digital
switch input from the B1 sensor to CA602-11 on AC-
CESS 6. SWITCH OPENED = the B1 sensor does not
sense the floor magnet. SWITCH CLOSED = the B1
sensor senses the floor magnet.
A2.4.7.4 EACB2 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the digital
switch input from the B2 sensor to CA602-14 on
ACCESS 6. SWITCH OPENED = the B2 sensor does
not sense the floor magnet. SWITCH CLOSED = the
B2 sensor senses the floor magnet.
A2.4.7.5 SIGNAL = ___ (percent) - Shows the analog
signal input to ACCESS 6 from the sensors in %. A
value between 0 and 99% is the % of the 5 V supply
that the sensors sense. This value must be 80% or
more when the truck moves across the floor magnets.
Crown 2011 PF25326-122 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
A2.4.7.99 ESCAPE - goes to the A2.4.7 EAC menu.
A2.4.8 BRES = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F4.3 BATTERY RETAIN menu is set. This menu
shows the condition of the optional battery restraint
switch. SWITCH OPENED = the battery restraint is not
in position. SWITCH CLOSED = the battery restraint is
in position.
A2.4.9 CTS = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu shows as (NOT AVAILABLE) if
the F7 MAST TYPE menu is not set to TF. This menu
shows the condition of the cable tension switch on a TF
mast. SWITCH OPENED = the hose take-up cable is
loose. SWITCH CLOSED = the hose take-up cable is
not loose.
A2.4.11 RGS = ___ (SWITCH OPENED or SWITCH
CLOSED) - This menu is available regardless of how
the F18 WIRE GUIDANCE menu is set. This menu
shows the condition of the optional rail guide switches
that operate with the rail guide wheels. SWITCH
OPENED = the rail guide switches are not in operation.
SWITCH CLOSED = the rail guide switches are in op-
eration.
A2.4.12 BRS2 & BRS4 = ___ (SWITCH OPENED or
SWITCH CLOSED) - Shows the condition of the left
and right brake pedal switches at the front of the plat-
form. The input from the left and right brake pedal
switches goes to ACCESS 5. SWITCH OPENED = the
left or right brake pedal is in operation. SWITCH
CLOSED = the left and right brake pedals are not in
operation.
A2.4.13 VOLTAGES - Shows the battery voltage at the
inputs to ACCESS 5.
A2.4.13.1 BATTERY = ___ (volts) - Shows the battery
voltage after FU2 to CA403-25 on ACCESS 5.
A2.4.13.2 STEERING = ___ (volts) - Shows the battery
voltage to ACCESS 5 after FU13.
A2.4.13.3 BRK INNER = ___ (volts) - Shows the bat-
tery voltage after FU9 to CA403-7 on ACCESS 5.
A2.4.13.4 BRK OUTER = ___ (volts) - Shows the bat-
tery voltage after FU10 to CA403-9 on ACCESS 5.
A2.4.13.99 ESCAPE - goes to the A2.4.13 VOLTAGES
menu.
A2.4.14 PDS - The optional pedestrian detection sys-
tem is only available on EU trucks.
A2.4.15 CHS5 & CHS6 = ___ (SWITCH OPENED or
SWITCH CLOSED) - This menu shows as (NOT
AVAILABLE) if the F7 MAST TYPE menu is not set to
TT. This menu shows the condition of the chain slack
switches on a TT mast. SWITCH OPENED = the
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chains are loose. SWITCH CLOSED = the chains are
not loose.
A2.4.16 CHS7 & CHS8 = ___ (SWITCH OPENED or
SWITCH CLOSED) - This menu shows as (NOT
AVAILABLE) if the F7 MAST TYPE menu is not set to
TT. This menu shows the condition of the chain break
switches on a TT mast. SWITCH OPENED = the
chains broke. SWITCH CLOSED = the chains did not
break.
A2.4.17 ACCESS 2 TEMP = ___ (Degrees C) - Shows
the temperature of the ACCESS 2 heatsink in °C.
A2.4.18 M2 TEMP = ___ (Degrees C) - Shows the in-
put from the temperature switch in the hydraulic pump
motor in °C.
A2.4.19 ACCESS 3 TEMP = ___ (Degrees C) - Shows
the temperature of the ACCESS 3 heatsink in °C.
A2.4.20 M1 TEMP = ___ (Degrees C) - Shows the in-
put from the temperature switch in the traction motor in
°C.
A2.4.21 HYDR OIL TMP = ___ (Degrees C) - This
menu shows as (NOT AVAILABLE) if you do not install
the low temperature freezer condition software. This
menu shows the input from the optional temperature
switch for freezer condition trucks with low temperature
hydraulic oil in the reservoir.
A2.4.99 ESCAPE - goes to the A2.4 POWER UNIT
menu.
A3 OUTPUTS - Shows the outputs from the control
modules to the truck components that you operate.
A3.1 LOAD HANDLER - Shows the auxiliary mast and
fork carriage outputs. The components in this menu are
solenoid valves. Many of the solenoid valves are iden-
tified as proportional valves.
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Note: The output values in this section are with the
truck in the P1 PERFORMANCE LEVEL with all P1.4
LOAD HANDLER menus set to 9. If you operate in the
P2 or P3 PERFORMANCE LEVELS, or with the P1.4
LOAD HANDLER menus set to less than 9, your duty
cycle and current values are lower.
A3.1.1 PVAL - Shows the output from ACCESS 7 to
the proportional auxiliary lower valve.
A3.1.1.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 23% as the operator input
command for auxiliary lower changes from no input to
maximum input.
A3.1.1.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional auxiliary lower valve coil
circuit in mA. The output changes from approximately -
5 mA to 399 mA as the operator input command for
auxiliary lower changes from no input to maximum in-
put.
A3.1.1.99 ESCAPE - goes to the A3.1.1 PVAL menu.
A3.1.2 PVAR - Shows the output from ACCESS 7 to
the proportional auxiliary raise valve.
A3.1.2.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 22% as the operator input
command for auxiliary raise changes from no input to
maximum input.
A3.1.2.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional auxiliary raise valve coil
circuit in mA. The output changes from approximately
2 mA to 399 mA as the operator input command for
auxiliary raise changes from no input to maximum in-
put.
A3.1.2.3 RESISTANCE = ___ (ohms) - Shows the re-
sistance of the proportional auxiliary raise valve coil in
Ω.
A3.1.2.99 ESCAPE - goes to the A3.1.2 PVAR menu.
A3.1.3 PVLH - Shows the output from ACCESS 7 to
the proportional relief valve. This component is a relief
valve for all auxiliary hydraulic functions that you adjust
electronically.
A3.1.3.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 30% as the operator input
command for an auxiliary function changes from no in-
put to maximum input.
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A3.1.3.2 FET VOLTAGE = ___ (volts) - Shows the volt-
age supplied to the proportional relief valve coil circuit,
minus the voltage drop across that coil. For example:
the voltage supplied to the coil circuit is approximately
51 V without a load. With no hydraulic function in oper-
ation, there is a drop across the proportional relief
valve coil of approximately 3 V. In this situation,
ACCESS 1 shows 48 V. If you operate an auxiliary hy-
draulic function (pivot right), the voltage drop across
the proportional relief valve coil increases to approxi-
mately 7 V, and ACCESS 1 shows 44 V.
A3.1.3.99 ESCAPE - goes to the A3.1.3 PVLH menu.
A3.1.4 PVT1 - There are two coils on one valve spool
on the proportional traverse valve. This component is
the first coil. This menu shows the output from
ACCESS 7 to the coil that causes the traverse left func-
tion.
A3.1.4.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 37% as the operator input
command for traverse left changes from no input to
maximum input.
A3.1.4.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional traverse valve coil circuit
in mA. The output changes from 0 mA to approximately
473 mA as the operator input command for traverse left
changes from no input to maximum input.
A3.1.4.99 ESCAPE - goes to the A3.1.4 PVT1 menu.
A3.1.5 PVT2 - There are two coils on one valve spool
on the proportional traverse valve. This component is
the second coil. This menu shows the output from
ACCESS 7 to the coil that causes the traverse right
function.
A3.1.5.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 33% as the operator input
command for traverse right changes from no input to
maximum input.
A3.1.5.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional traverse valve coil circuit
in mA. The output changes from 0 mA to approximately
416 mA as the operator input command for traverse
right changes from no input to maximum input.
A3.1.5.99 ESCAPE - goes to the A3.1.5 PVT2 menu.
A3.1.6 PVF1 - This menu is available regardless of
how the F11 FORK TYPE menu is set. There are two
coils on one valve spool on the proportional fork valve.
This component is the first coil. This menu shows the
output from ACCESS 7 to the coil that causes the forks
to extend.
Crown 2011 PF25326-124 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
A3.1.6.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 39% as the operator input
command for fork extend changes from no input to
maximum input.
A3.1.6.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional fork valve coil circuit in
mA. The output changes from 0 mA to approximately
481 mA as the operator input command for fork extend
changes from no input to maximum input.
A3.1.6.99 ESCAPE - goes to the A3.1.6 PVF1 menu.
A3.1.7 PVF2 - This menu is available regardless of
how the F11 FORK TYPE menu is set. There are two
coils on one valve spool on the proportional fork valve.
This component is the second coil. This menu shows
the output from ACCESS 7 to the coil that causes the
forks to retract.
A3.1.7.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 39% as the operator input
command for fork retract changes from no input to
maximum input.
A3.1.7.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional fork valve coil circuit in
mA. The output changes from 0 mA to approximately
481 mA as the operator input command for fork retract
changes from no input to maximum input.
A3.1.7.99 ESCAPE - goes to the A3.1.7 PVF2 menu.
A3.1.8 PVP1 - There are two coils on one valve spool
on the proportional pivot valve. This component is the
first coil. This menu shows the output from ACCESS 7
to the coil that causes the pivot left function.
A3.1.8.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 47% during the pivot left
command.
A3.1.8.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional pivot valve coil circuit in
mA. The output changes from 0 mA to approximately
600 mA during the pivot left command.
A3.1.8.99 ESCAPE - goes to the A3.1.8 PVP1 menu.
A3.1.9 PVP2 - There are two coils on one valve spool
on the proportional pivot valve. This component is the
second coil. This menu shows the output from
ACCESS 7 to the coil that causes the pivot right func-
tion.
A3.1.9.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 40% during the pivot right
command.
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A3.1.9.2 CURRENT = ___ (mA) - Shows the current
flow through the proportional pivot valve coil circuit in
mA. The output changes from 0 mA to approximately
530 mA during the pivot right command.
A3.1.9.99 ESCAPE - goes to the A3.1.9 PVP2 menu.
A3.1.10 SVAL - Shows the output from ACCESS 7 to
the auxiliary lower solenoid valve. This component is a
velocity fuse. If the lower speed indication from the
auxiliary height encoder is more than 36.5 m/min
(120 ft/min), the auxiliary lower solenoid valve is de-en-
ergized. As a result, the auxiliary lift cylinder does not
lower.
A3.1.10.1 DUTY CYCLE = ___ (percent) - Shows the
ON time of the output driver circuit. The output changes
from 0% to approximately 46% during the auxiliary
lower command.
A3.1.10.2 FET VOLTAGE = ___ (volts) - Shows the
voltage supplied to the coil circuit, minus the voltage
drop across that coil. For example: the voltage supplied
to the coil circuit is approximately 51 V without a load.
When you do not operate auxiliary lower, there is no
voltage drop across the auxiliary lower solenoid valve
coil. In this situation, ACCESS 1 shows 51 V. When
you operate auxiliary lower, the voltage drop across the
auxiliary lower solenoid valve coil increases to approx-
imately 23 V, and ACCESS 1 shows 28 V.
A3.1.10.99 ESCAPE - goes to the A3.1.10 SVAL
menu.
A3.2 PLATFORM - Shows the outputs to components
on the platform, but not the operator seat.
A3.2.1 ALM1 = ___ (OFF or ON) - Shows the output to
the status alarm. OFF = the status alarm is not in oper-
ation. ON (steady) = the status alarm is in continuous
operation. OFF/ON (alternately) = the alarm is in inter-
mittent operation.
A3.2.2 EML = ___ (percent) - Shows the output in %
from ACCESS 4 to the seat locking solenoid coil that
holds the operator seat in position. 0% = there is no
output, the operator seat does not turn. 99% (briefly),
then 9% = the operator seat turns.
A3.2.99 ESCAPE - goes to the A3.2 PLATFORM
menu.
A3.3 SEAT CONTROLS - Shows the outputs to com-
ponents on the operator seat.
A3.3.1 CC1 DUTY CYCL = ___ (percent) - This menu
is available regardless of how the F24 COLD CONDI-
TION menu is set. This menu shows the % of output
from ACCESS 8 to the optional heater for the emer-
gency disconnect switch on freezer condition trucks.
A3.3.99 ESCAPE - goes to the A3.3 SEAT CON-
TROLS menu.
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A3.4 POWER UNIT - Shows the outputs to compo-
nents on the power unit and mast mainframe.
A3.4.1 SVML DUTY CYC = ___ (percent) - Shows the
% of output from ACCESS 2 to the main lower solenoid
valve. 0% = the platform and mast lower function is not
in operation. 49% (briefly), then 20% = the platform and
mast lower function is in operation.
A3.4.2 SVMR DUTY CYC = ___ (percent) - Shows the
% of output from ACCESS 2 to the main raise solenoid
valve. 0% = the platform and mast raise function is not
in operation. 50% (briefly), then 25% = the platform and
mast raise function is in operation.
A3.4.3 SVA DUTY CYCL = ___ (percent) - Shows the
% of output from ACCESS 2 to the auxiliary solenoid
valve. 0% = the auxiliary mast and fork carriage func-
tion is not in operation. 25% = each auxiliary mast and
fork carriage function but fork carriage lower is in oper-
ation.
A3.4.4 PVML DUTY CYC = ___ (percent) - Shows the
% of output from ACCESS 2 to the main lower propor-
tional valve. 0% = the platform and mast lower function
is not in operation. 50% (briefly), then 25% = the plat-
form and mast lower function is in operation.
A3.4.5 ED - Shows the outputs from ACCESS 3 and
ACCESS 5 to the coil of the emergency disconnect
contactor.
A3.4.5.1 ACCESS 5 = ___ (OFF or ON) - Shows the
condition of the driver circuit output to the emergency
disconnect coil from ACCESS 5. OFF = the ACCESS 5
driver is OFF. ON = the ACCESS 5 driver is ON.
A3.4.5.2 ACCESS 3 = ___ (percent) - Shows the con-
dition of the driver circuit output to the emergency dis-
connect coil from ACCESS 3. 0% = the ACCESS 3
driver is OFF. 39.5% = the ACCESS 3 driver is ON.
A3.4.5.99 ESCAPE - goes to the A3.4.5 ED menu.
A3.4.6 ALM2 DUTY CYC = ___ (percent) - Shows the
% of operation of the ACCESS 3 driver to the optional
travel alarm.
A3.4.7 HN = ___ (OFF or ON) - Shows the condition of
the ACCESS 2 horn driver output. OFF = the horn is
not in operation. ON = the horn is in operation.
A3.4.8 M1 CURRENT = ___ (amps) - Shows the cur-
rent flow in the ACCESS 3 and traction motor loop. In
this closed loop, the system output changes as the op-
erator input command for travel changes. During full
forward travel, there are approximately 0.2 to 247 A.
During full reverse travel, there are approximately 0.2
to 227 A.
A3.4.9 M2 CURRENT = ___ (amps) - Shows the cur-
rent flow in the ACCESS 2 and hydraulic pump motor
loop. In this closed loop, the system output changes as
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the operator input command for raise changes. With
the truck ON and the emergency disconnect contactor
open, there are approximately 0.2 A. With the truck ON
and the emergency disconnect contactor closed, there
are approximately 70 A. During full fork carriage raise,
there are approximately 70 to 290 A. During full plat-
form and mast raise, there are approximately 70 to 525
A. During full platform and mast lower, there are ap-
proximately 70 to 210 A.
A3.4.10 M3 DUTY CYCLE = ___ (percent) - Shows the
driver output from ACCESS 5 to the steer motor in %.
The driver output changes as the steer input command
changes. 0% = there is no steer output. 95% = maxi-
mum steer is available.
A3.4.11 BRK INNER - Shows the output from
ACCESS 5 to the inner coil of the traction motor brake.
A3.4.11.1 PWM = ___ (percent) - Shows the % of
ACCESS 5 pulse width modulation output to the inner
coil. 0% = you apply the traction motor brake. 26%
(briefly), then 10% = you release the traction motor
brake.
A3.4.11.2 CURRENT = ___ (amps) - Shows the cur-
rent flow in the loop of ACCESS 5 and the inner coil of
the traction motor brake. 0 A = you apply the traction
motor brake. 5.3 A (briefly), then 1.9 A = you release
the traction motor brake.
A3.4.11.3 RESISTANCE = ___ (ohms) - Shows the re-
sistance of the inner coil of the traction motor brake in
Ω.
A3.4.11.99 ESCAPE - goes to the A3.4.11 BRK INNER
menu.
A3.4.12 BRK OUTER - Shows the output from
ACCESS 5 to the outer coil of the traction motor brake.
A3.4.12.1 PWM = ___ (percent) - Shows the % of
ACCESS 5 pulse width modulation output to the outer
coil. 0% = you apply the traction motor brake. 26%
(briefly), then 8% = you release the traction motor
brake.
A3.4.12.2 CURRENT = ___ (amps) - Shows the cur-
rent flow in the loop of ACCESS 5 and the outer coil of
the traction motor brake. 0 A = you apply the traction
motor brake. 13.7 A (briefly), then 4.3 A = you release
the traction motor brake.
A3.4.12.3 RESISTANCE = ___ (ohms) - Shows the re-
sistance of the outer coil of the traction motor brake in
Ω.
A3.4.12.99 ESCAPE - goes to the A3.4.12 BRK
OUTER menu.
A3.4.13 FAN3 = ___ (percent) - Shows the % of output
from ACCESS 2 to the cooling fan in %. 0% = the cool-
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ELECTRICAL SYSTEM
ACCESS 1 2 3®
ing fan driver is OFF. 99% = the cooling fan driver is
ON.
A3.4.99 ESCAPE - goes to the A3.4 POWER UNIT
menu.
A3.4.14 PDS - The optional pedestrian detection sys-
tem is only available on EU trucks.
Note: In the A4 TEST OUTPUTS menus, ENTER is
identified as TEST. When you push and hold TEST, it
energizes the applicable circuit and ACCESS 1 shows
the message TEST OUTPUT ACTIVE. After three sec-
onds, the applicable circuit is de-energized and
ACCESS 1 shows the message TEST OUTPUT COM-
PLETE. When you release TEST, ACCESS 1 goes out
of the menu it was in and you must push TEST again
to go into the same menu.
A4 TEST OUTPUTS - Gives an output to a specified
component on command. When you do a test on the
output to a valve, a digital volt-ohm multimeter
(DVOM), set to read DC V, must be across the coil to
make sure that the coil and coil driver circuit operate
correctly. Do not use an analog volt-ohm multimeter.
A4.1 LOAD HANDLER - The load handler includes the
auxiliary mast and fork carriage. This menu does a test
of the outputs to the auxiliary mast and fork carriage
components.
A4.1.1 PVAL - Does a test of the output from
ACCESS 7 to the proportional auxiliary lower valve.
With a digital volt-ohm multimeter across the coil of the
proportional auxiliary lower valve, push and hold TEST.
The digital volt-ohm multimeter must show approxi-
mately 24 V during TEST OUTPUT ACTIVE.
A4.1.2 PVAR - Does a test of the output from
ACCESS 7 to the proportional auxiliary raise valve.
With a digital volt-ohm multimeter across the coil of the
proportional auxiliary raise valve, push and hold TEST.
The digital volt-ohm multimeter must show approxi-
mately 24 V during TEST OUTPUT ACTIVE.
A4.1.3 PVLH - Does a test of the output from
ACCESS 7 to the proportional relief valve. With a digi-
tal volt-ohm multimeter across the coil of the propor-
tional relief valve, push and hold TEST. The digital volt-
ohm multimeter must show approximately 24 V during
TEST OUTPUT ACTIVE.
A4.1.4 PVT1 - Does a test of the output from
ACCESS 7 to the first proportional traverse valve. With
a digital volt-ohm multimeter across the coil of the first
proportional traverse valve, push and hold TEST. The
digital volt-ohm multimeter must show approximately
24 V during TEST OUTPUT ACTIVE.
A4.1.5 PVT2 - Does a test of the output from
ACCESS 7 to the second proportional traverse valve.
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With a digital volt-ohm multimeter across the coil of the
second proportional traverse valve, push and hold
TEST. The digital volt-ohm multimeter must show ap-
proximately 24 V during TEST OUTPUT ACTIVE.
A4.1.6 PVF1 - Does a test of the output from
ACCESS 7 to the first proportional fork valve. With a
digital volt-ohm multimeter across the coil of the first
proportional fork valve, push and hold TEST. The digi-
tal volt-ohm multimeter must show approximately 24 V
during TEST OUTPUT ACTIVE.
A4.1.7 PVF2 - Does a test of the output from
ACCESS 7 to the second proportional fork valve. With
a digital volt-ohm multimeter across the coil of the sec-
ond proportional fork valve, push and hold TEST. The
digital volt-ohm multimeter must show approximately
24 V during TEST OUTPUT ACTIVE.
A4.1.8 PVP1 - Does a test of the output from
ACCESS 7 to the first proportional pivot valve. With a
digital volt-ohm multimeter across the coil of the first
proportional pivot valve, push and hold TEST. The dig-
ital volt-ohm multimeter must show approximately 24 V
during TEST OUTPUT ACTIVE.
A4.1.9 PVP2 - Does a test of the output from
ACCESS 7 to the second proportional pivot valve. With
a digital volt-ohm multimeter across the coil of the sec-
ond proportional pivot valve, push and hold TEST. The
digital volt-ohm multimeter must show approximately
24 V during TEST OUTPUT ACTIVE.
A4.1.10 SVAL - Does a test of the output from
ACCESS 7 to the auxiliary lower solenoid valve. With a
digital volt-ohm multimeter across the coil of the auxil-
iary lower solenoid valve, push and hold TEST. The
digital volt-ohm multimeter must show approximately
24 V during TEST OUTPUT ACTIVE.
A4.1.99 ESCAPE - goes to the A4.1 LOAD HANDLER
menu.
A4.2 PLATFORM - Does a test of the outputs to the
components on the platform, but not the operator seat.
A4.2.1 ALM1 - Does a test of the output from
ACCESS 1 to the status alarm. Push and hold TEST.
The status alarm must operate continuously during
TEST OUTPUT ACTIVE.
A4.2.2 EML - Does a test of the output from ACCESS 4
to the seat locking solenoid that holds the operator seat
in position. Push and hold TEST. The seat locking so-
lenoid must unlock the operator seat during TEST
OUTPUT ACTIVE.
A4.2.99 ESCAPE - goes to the A4.2 PLATFORM
menu.
A4.3 SEAT CONTROLS - Does a test of the outputs to
the components on the operator seat.
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A4.3.1 SEAT/CC - This menu is available regardless of
how the F24 COLD CONDITION menu is set. This
menu does a test of the output from ACCESS 8 to the
optional heater for the emergency disconnect switch
on freezer condition trucks. Push and hold TEST.
A4.3.99 ESCAPE - goes to the A4.3 SEAT CON-
TROLS menu.
A4.4 POWER UNIT - Does a test of the outputs to the
components on the power unit and mast mainframe.
A4.4.1 SVML - Does a test of the output from
ACCESS 2 to the main lower solenoid valve. With a
digital volt-ohm multimeter across the coil of the main
lower solenoid valve, push and hold TEST. The digital
volt-ohm multimeter must show approximately 15 V
during TEST OUTPUT ACTIVE.
A4.4.2 SVMR - Does a test of the output from
ACCESS 2 to the main raise solenoid valve. With a dig-
ital volt-ohm multimeter across the coil of the main
raise solenoid valve, push and hold TEST. The digital
volt-ohm multimeter must show approximately 17 V
during TEST OUTPUT ACTIVE.
A4.4.3 SVA - Does a test of the output from ACCESS 2
to the auxiliary solenoid valve. With a digital volt-ohm
multimeter across the coil of the auxiliary solenoid
valve, push and hold TEST. The digital volt-ohm multi-
meter must show 17 to 18 V during TEST OUTPUT
ACTIVE.
A4.4.4 PVML - Does a test of the output from
ACCESS 2 to the main lower proportional valve. With
a digital volt-ohm multimeter across the coil of the main
lower proportional valve, push and hold TEST. The dig-
ital volt-ohm multimeter must show 17 to 18 V during
TEST OUTPUT ACTIVE.
A4.4.5 ED - Does a test of the outputs from ACCESS 3
and ACCESS 5 to the coil of the emergency disconnect
contactor.
A4.4.5.1 ACCESS 5 - Does a test of the positive output
driver from ACCESS 5 to the coil of the emergency dis-
connect contactor. With a digital volt-ohm multimeter
across the positive side of the coil of the emergency
disconnect contactor and BNEG, push and hold TEST.
The digital volt-ohm multimeter must show approxi-
mately 48 V during TEST OUTPUT ACTIVE.
A4.4.5.2 ACCESS 3 - Does a test of the negative out-
put driver from ACCESS 3 to the coil of the emergency
disconnect contactor. With a digital volt-ohm multime-
ter across a positive 48 V source and the negative side
of the coil of the emergency disconnect contactor, push
and hold TEST. The digital volt-ohm multimeter must
show approximately 48 V during TEST OUTPUT AC-
TIVE.
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A4.4.5.3 BOTH - Does a test of the ACCESS 3 and
ACCESS 5 output drivers to the coil of the emergency
disconnect contactor. With a digital volt-ohm multime-
ter across the coil of the emergency disconnect contac-
tor, push and hold TEST. The digital volt-ohm
multimeter must show approximately 42 V during
TEST OUTPUT ACTIVE.
A4.4.5.99 ESCAPE - goes to the A4.4.5 ED menu.
A4.4.6 ALM2 - Does a test of the output from
ACCESS 3 to the optional travel alarm. Push and hold
TEST. The travel alarm must operate continuously dur-
ing TEST OUTPUT ACTIVE.
A4.4.7 HN - Does a test of the output from ACCESS 2
to the horn. Push and hold TEST. The horn must oper-
ate continuously during TEST OUTPUT ACTIVE.
A4.4.8 M1 - Does a test of the output from ACCESS 3
to the traction motor. With a digital volt-ohm multimeter
on the U-phase nut on the traction motor and BNEG,
push and hold TEST. The digital volt-ohm multimeter
must show 1/2 of the +BV during TEST OUTPUT AC-
TIVE.
A4.4.9 M2 - Does a test of the output from ACCESS 3
to the hydraulic pump motor. With a digital volt-ohm
multimeter on the U-phase nut on the hydraulic pump
motor and BNEG, push and hold TEST. The digital volt-
ohm multimeter must show 1/2 of the +BV during TEST
OUTPUT ACTIVE.
A4.4.10 M3 - Does a test of the output from ACCESS 5
to the steer motor.
A4.4.10.1 CLOCKWISE - Push and hold TEST. The
drive tire must turn clockwise during TEST OUTPUT
ACTIVE.
A4.4.10.2 CCWISE - Push and hold TEST. The drive
tire must turn counter-clockwise during TEST OUTPUT
ACTIVE.
A4.4.10.99 ESCAPE - goes to the A4.4.10 M3 menu.
A4.4.11 BRK INNER - Does a test of the output from
ACCESS 5 to the inner coil of the traction motor brake.
With a digital volt-ohm multimeter between CA407-2
(blue wire - positive supply) and CA407-3 (yellow wire
- negative supply), push and hold TEST. The digital
volt-ohm multimeter must show approximately 3.4 V
during TEST OUTPUT ACTIVE.
A4.4.12 BRK OUTER - Does a test of the output from
ACCESS 5 to the outer coil of the traction motor brake.
With a digital volt-ohm multimeter between CA407-1
(white wire - positive supply) and CA407-4 (orange
wire - negative supply), push and hold TEST. The digi-
tal volt-ohm multimeter must show approximately 4.4 V
during TEST OUTPUT ACTIVE.
Crown 2011 PF25326-128 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
A4.4.13 FAN3 - Does a test of the output from
ACCESS 2 to the cooling fan. Push and hold TEST.
The cooling fan must operate during TEST OUTPUT
ACTIVE.
A4.4.14 PDS - The optional pedestrian detection sys-
tem is only available on EU trucks.
A4.4.99 ESCAPE - goes to the A4.4 POWER UNIT
menu.
A99 ESCAPE - goes out of the ANALYZER menu.
CALIBRATION
The software in the control modules contains parame-
ters for the operation of different truck functions. When
you do the steps in the CALIBRATION menus, this lets
the software:
• Sense the voltage feedback from the command po-
tentiometers in the multi-task control handles dur-
ing the C1 HANDLES calibration.
• Sense the counts feedback from different sensor
bearing encoders.
• Sense the counts feedback from the weight sensor.
• Sense the potentiometer voltage feedback during
pivot calibration.
• Keep the position and type of cutouts during the C3
HEIGHT CUTOUTS calibration (these are in
ACCESS 1).
• Adjust the wire guidance steer operation.
When to Calibrate the Truck
• Do all C1 HANDLES calibrations when you replace
ACCESS 8.
• Do the necessary C3 HEIGHT CUTOUTS calibra-
tions (if you have cutouts) when you replace
ACCESS 1.
• Do the C4 STEER ENCODER calibration when you
replace ACCESS 5.
• Do the C5 WIRE GUIDANCE calibration when you
replace ACCESS 6.
• Do the C2.4 MAIN HGT SENSE, C2.11 AUX RAISE
VALVE, and C2.13 AUX L VALVE calibrations when
you replace ACCESS 4.
• Do these calibrations when you replace
ACCESS 7:
– C2.1 PVLH AUX RELIEF
– C2.2 TRAVERSE SENSE
– C2.3 PIVOT SENSE
– C2.8 TRAVERSE VALVE
– C2.9 PIVOT VALVE
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ACCESS 1 2 3®
– C2.10 EXTEND VALVE (optional - telescopic
forks)
– C2.12 WEIGHT SENSE
– C2.14 AUX HGT SENSE
– C2.15 TILT VALVE (optional - tilt forks)
– C2.16 FRK POS VALV (optional - fork posi-
tioner).
• Do the C1.1 TRACTION, C1.2 MAIN R/L, and C1.3
TRAVERSE calibrations when you replace, assem-
ble, or disassemble the right multi-task control han-
dle.
• Do the C1.4 AUX RAISE/LOWER calibration when
you replace, assemble, or disassemble the left
multi-task control handle.
• Do the C2.1 PVLH AUX RELIEF calibration when
you replace the proportional relief valve.
• Do the C2.2 TRAVERSE SENSE calibration when
you replace the traverse position encoder or the
traverse reset switch, or when you install the auxil-
iary mast or the fork carriage.
• Do the C2.3 PIVOT SENSE calibration when you
replace the pivot position potentiometer.
• Do the C2.4 MAIN HGT SENSE calibration when
you replace the height sense encoder or the main
height reset switch.
• Do the C2.8 TRAVERSE VALVE calibration when
you replace the proportional traverse valves.
• Do the C2.9 PIVOT VALVE calibration when you re-
place the proportional pivot valves.
• Do the C2.10 EXTEND VALVE calibration when
you replace the proportional fork valves.
• Do the C2.11 AUX RAISE VALVE calibration when
you replace the proportional auxiliary raise valve.
• Do the C2.12 WEIGHT SENSE calibration when
you replace the load sense.
• Do the C2.13 AUX L VALVE calibration when you
replace the proportional auxiliary lower valve.
• Do the C2.14 AUX HGT SENSE calibration when
you replace the auxiliary mast height encoder or the
auxiliary height reset switch.
• Do the C3 HEIGHT CUTOUTS calibration when
you replace the height sense encoder.
• Do the C4 STEER ENCODER calibration when you
replace the steering feedback encoder.
• Do the C5 WIRE GUIDANCE calibration when you
replace the steering feedback encoder or the sen-
sor bars.
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CALIBRATION Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2 (you can only access the CALI-
BRATION menu in LEVEL 2).
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push the down arrow to go to the CALIBRATION
menu.
5. Push ENTER to go into the CALIBRATION menu.
C1 HANDLES - Lets ACCESS 8 sense the voltage
range across these components and compare the
range with the parameters:
• The traction command potentiometer
• The main raise and lower potentiometer
• The auxiliary raise and lower potentiometer
• The traverse command potentiometer.
C1.1 TRACTION - Calibrates the traction command
potentiometer.
Note: During the C1.1 TRACTION calibration, if the
voltage feedback from the traction command potenti-
ometer is not in the correct parameters, ACCESS 1
shows INVALID CALIBRATION. This is a problem with
the traction command potentiometer, ACCESS 8, the
wires between the two, or the mechanical movement of
the multi-task control handle.
FORWARD = ___ (V) - Move the right multi-task con-
trol handle to the full forward travel position and hold it
there. Make sure that you move the multi-task control
handle as far as it mechanically can be. The traction
command potentiometer voltage must be approxi-
mately 1.08 V. Push ENTER to record the voltage, and
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if the voltage is in the correct parameters, ACCESS 1
changes to the next message.
REVERSE = ___ (V) - Move the right multi-task control
handle to the full reverse travel position and hold it
there. Make sure that you move the multi-task control
handle as far as it mechanically can be. The traction
command potentiometer voltage must be approxi-
mately 3.85 V. Push ENTER to record the voltage, and
if the voltage is in the correct parameters, ACCESS 1
changes to the next message.
CENTER = ___ (V) - Release the right multi-task con-
trol handle and let it go to the neutral position. The trac-
tion command potentiometer voltage must be
approximately 2.32 V. Push ENTER to record the volt-
age, and if the voltage is in the correct parameters,
ACCESS 1 goes to the C1.1 TRACTION menu.
C1.2 MAIN R/L - Calibrates the main raise and lower
potentiometer.
Note: During the C1.2 MAIN R/L calibration, if the volt-
age feedback from the main raise and lower potentiom-
eter is not in the correct parameters, ACCESS 1 shows
INVALID CALIBRATION. This is a problem with the
main raise and lower potentiometer, ACCESS 8, the
wires between the two, or the mechanical movement of
the multi-task control handle.
RAISE = ___ (V) - Move the right multi-task control
handle to the full raise position and hold it there. Make
sure that you move the multi-task control handle as far
as it mechanically can be. The main raise and lower
potentiometer voltage must be approximately 1.06 V.
Push ENTER to record the voltage, and if the voltage
is in the correct parameters, ACCESS 1 changes to the
next message.
LOWER = ___ (V) - Move the right multi-task control
handle to the full lower position and hold it there. Make
sure that you move the multi-task control handle as far
as it mechanically can be. The main raise and lower
potentiometer voltage must be approximately 3.58 V.
Push ENTER to record the voltage, and if the voltage
is in the correct parameters, ACCESS 1 changes to the
next message.
CENTER = ___ (V) - Release the right multi-task con-
trol handle and let it go to the neutral position. The main
raise and lower potentiometer voltage must be approx-
imately 2.31 V. Push ENTER to record the voltage, and
if the voltage is in the correct parameters, ACCESS 1
goes to the C1.2 MAIN R/L menu.
C1.3 TRAVERSE - Calibrates the traverse command
potentiometer.
Note: During the C1.3 TRAVERSE calibration, if the
voltage feedback from the traverse command potenti-
ometer is not in the correct parameters, ACCESS 1
Crown 2011 PF25326-130 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
shows INVALID CALIBRATION. This is a problem with
the traverse command potentiometer, ACCESS 8, the
wires between the two, or the mechanical movement of
the thumbwheel on the multi-task control handle.
RIGHT = ___ (V) - Move the thumbwheel on the right
multi-task control handle to the full traverse right posi-
tion and hold it there. Make sure that you move the
thumbwheel as far as it mechanically can be. The trav-
erse command potentiometer voltage must be approx-
imately 3.93 V. Push ENTER to record the voltage, and
if the voltage is in the correct parameters, ACCESS 1
changes to the next message.
LEFT = ___ (V) - Move the thumbwheel on the right
multi-task control handle to the full traverse left position
and hold it there. Make sure that you move the thumb-
wheel as far as it mechanically can be. The traverse
command potentiometer voltage must be approxi-
mately 1.11 V. Push ENTER to record the voltage, and
if the voltage is in the correct parameters, ACCESS 1
changes to the next message.
CENTER = ___ (V) - Release the thumbwheel on the
right multi-task control handle and let it go to the neutral
position. The traverse command potentiometer voltage
must be approximately 2.41 V. Push ENTER to record
the voltage, and if the voltage is in the correct parame-
ters, ACCESS 1 goes to the C1.3 TRAVERSE menu.
C1.4 AUX RAISE/LOWER - Calibrates the auxiliary
raise and lower potentiometer.
Note: During the C1.4 AUX RAISE/LOWER calibra-
tion, if the voltage feedback from the auxiliary raise and
lower potentiometer is not in the correct parameters,
ACCESS 1 shows INVALID CALIBRATION. This is a
problem with the auxiliary raise and lower potentiome-
ter, ACCESS 8, the wires between the two, or the me-
chanical movement of the thumbwheel on the multi-
task control handle.
RAISE = ___ (V) - Move the thumbwheel on the left
multi-task control handle to the full raise position and
hold it there. Make sure that you move the thumbwheel
as far as it mechanically can be. The auxiliary raise and
lower potentiometer voltage must be approximately
1.25 V. Push ENTER to record the voltage, and if the
voltage is in the correct parameters, ACCESS 1
changes to the next message.
LOWER = ___ (V) - Move the thumbwheel on the left
multi-task control handle to the full lower position and
hold it there. Make sure that you move the thumbwheel
as far as it mechanically can be. The auxiliary raise and
lower potentiometer voltage must be approximately
3.78 V. Push ENTER to record the voltage, and if the
voltage is in the correct parameters, ACCESS 1
changes to the next message.
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CENTER = ___ (V) - Release the thumbwheel on the and the gauge pressure continues to increase. Keep
left multi-task control handle and let it go to the neutral one of the three large floor pedals pushed and monitor
position. The auxiliary raise and lower potentiometer the pressure on the gauge. When the pressure on the
voltage must be approximately 2.63 V. Push ENTER to gauge is at 3500 psi (241 bar), push ENTER.
record the voltage, and if the voltage is in the correct CALIBRATION ACCEPTED
parameters, ACCESS 1 goes to the C1.4 AUX RAISE/ AT 3500 PSI - The pump motor stops and, if the pres-
LOWER menu. sures and current values are in the correct parameters,
C1.99 SAVE HANDLES - Push the up and down ar- this message shows momentarily. If the message CAL-
rows to go through these menus: IBRATION FAILED shows, then find and repair the
• C1.99.1 NO SAVE problem.
• C1.99.2 YES, SAVE VALUES Note: Disconnect the gauge from the load handler
manifold before you continue.
• C1.99.3 LOAD DEFAULTS.
Push ENTER to make a selection and go to the C1
HANDLES menu.
C2 HYDRAULICS - Lets the system sense count feed-
back and current flow values during some hydraulic
function operation.
C2.1 PVLH AUX RELIEF - The proportional relief valve
is for the auxiliary hydraulic functions. This calibration
lets ACCESS 7 sense the quantity of current flow that
is necessary (through the proportional relief valve coil)
to let the proportional relief valve go against some
pressures. This gives smooth operation of the auxiliary
hydraulic functions during usual operation.
Note: You must connect a 0 to 5000 psi (344.73 bar)
gauge to the male quick-disconnect fitting in Port G of
the load handler manifold.
STAY ATTENDED - Shows if you are not on one of the
three large floor pedals when you go into the C2.1
PVLH AUX RELIEF menu. This message also shows if
you move off of the floor pedal during the C2.1 PVLH
AUX RELIEF calibration.
CONNECT GAUGE,
THEN PRESS ENTER - This message, which makes
sure that you have a gauge connected, shows when
you are on a floor pedal. If you have a gauge con-
nected, push ENTER.
PRESS ENTER WHEN
AT 700 PSI - The pump motor starts to operate and the
gauge pressure starts to increase. Keep one of the
three large floor pedals pushed and monitor the pres-
sure on the gauge. When the pressure on the gauge is
at 700 psi (48 bar), push ENTER.
PRESS ENTER WHEN
AT 1700 PSI - The pump motor continues to operate
and the gauge pressure continues to increase. Keep
one of the three large floor pedals pushed and monitor
the pressure on the gauge. When the pressure on the
gauge is at 1700 psi (117 bar), push ENTER.
PRESS ENTER WHEN
AT 3500 PSI - The pump motor continues to operate

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C2.2 TRAVERSE SENSE - You must set the F10.1
TRAVERSE FRAME WIDTH menu correctly before
you do the C2.2 TRAVERSE SENSE calibration. This
calibration lets ACCESS 7 sense the traverse position
encoder counts from the platform center to the full right
and left positions. It also senses when the traverse re-
set switch changes condition at the platform center.
The traverse position encoder counts have a minus
sign before them when the auxiliary mast and fork car-
riage is left of the platform center.
TRAVERSE FULLY RIGHT
THEN 8 -___ (counts) - With hands in position on the
two multi-task control handles, operate traverse right
until the auxiliary mast and fork carriage traverses fully
to the right side of the platform. Push ENTER.
TRAVERSE FULLY LEFT
THEN 8 ___ (counts) - With hands in position on the
two multi-task control handles, operate traverse left un-
til the auxiliary mast and fork carriage traverses fully to
the left side of the platform. Push ENTER.
TRAVERSE FULLY RIGHT
THEN 8 ___ (counts) - With hands in position on the
two multi-task control handles, operate traverse right
until the auxiliary mast and fork carriage traverses fully
to the right side of the platform. Push ENTER.
CALIBRATION ACCEPTED - If the traverse position
encoder counts and the traverse reset switch ON and
OFF point are in the correct parameters, this message
shows momentarily. If you did not set the F10.1 TRAV-
ERSE FRAME WIDTH menu correctly, ACCESS 1
could show FAILED, INVALID RANGE.
C2.3 PIVOT SENSE - This calibration lets ACCESS 7
sense the voltage across the pivot position potentiom-
eter when the fork carriage is fully right and left. The
Access 1 2 3® system uses these voltage values to
know when to show the message PIVOT NOT HOME
and to slow truck travel.
PIVOT FULLY LEFT
THEN 8 ___ (V) - With hands in position on the two
multi-task control handles, operate pivot left until the
auxiliary mast and fork carriage traverses fully to the
left (the forks are to the left of the platform). Push EN-
TER.
PIVOT FULLY RIGHT
THEN 8 ___ (V) - With hands in position on the two
multi-task control handles, operate pivot right until the
auxiliary mast and fork carriage traverses fully to the
right (the forks are to the right of the platform). Push
ENTER.
CALIBRATION ACCEPTED - If the pivot position po-
tentiometer voltages are in the correct parameters, this
message shows momentarily.
Crown 2011 PF25326-132 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
C2.4 MAIN HGT SENSE - This calibration sets a max-
imum lift height. It lets ACCESS 4 record the number of
height sense encoder counts at the maximum lift height
and at fully lowered. It also senses when the main
height reset switch opens (the number of height sense
encoder counts).
RESTRICT CAL HEIGHT
TO 426", ↓ YES ↑ NO - For calibration in a factory.
Push NO when you calibrate the truck in a factory for
calibration to full height.
LOWER BELOW RESET
___ (counts) - This message shows if the platform is
above the point that the main height reset switch
opens. Lower the platform to the minimum height.
RAISE ABOVE RESET
-___ (counts) - Raise the platform. The counts have a
minus sign before them until the platform is at the point
that the main height reset switch opens.
LOWER TO MIN, THEN
PRESS 8 ___ (counts) - Lower the platform to the
minimum height. This message shows when the main
height reset switch closes. Push ENTER.
RAISE TO MAX, THEN
PRESS 8 ___ (in) - Raise the platform to the maxi-
mum height or to the maximum allowable height. The
height value does not include the fork height. Push EN-
TER.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.8 TRAVERSE VALVE - This calibration lets
ACCESS 7 sense how much current flow through the
two coils on the proportional traverse valve is neces-
sary for traverse movement in each direction.
TRAVERSE LEFT OR RT
TO BEGIN - With hands in position on the two multi-
task control handles, operate the traverse function to
the left or right.
MAINTAIN COMMAND
___ (mA) - Continue to operate the traverse function.
STOP COMMAND - Do not operate the traverse func-
tion.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.9 PIVOT VALVE - This calibration lets ACCESS 7
sense how much current flow through the two coils on
the proportional pivot valve is necessary for pivot
movement in each direction.
PIVOT LEFT OR RT
TO BEGIN - With hands in position on the two multi-
task control handles, operate the pivot function to the
left or right.
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MAINTAIN COMMAND
___ (mA) - Continue to operate the pivot function.
STOP COMMAND - Do not operate the pivot function.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.10 EXTEND VALVE - If the F11 FORK TYPE menu
is not set to TELESCOPIC, this menu is C2.10 FORK
EXTEND (N/A). This calibration lets ACCESS 7 sense
how much current flow through the two coils on the pro-
portional fork valve is necessary for fork movement in
each direction.
TRAVERSE LEFT OR RT
TO BEGIN - With hands in position on the two multi-
task control handles, operate the traverse function to
the left or right.
MAINTAIN COMMAND
___ (mA) - Continue to operate the traverse function.
STOP COMMAND - Do not operate the traverse func-
tion.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.11 AUX RAISE VALVE - This calibration lets
ACCESS 7 sense the breakout point to raise the fork
carriage. It also senses the quantity of current flow
through the proportional auxiliary raise valve that is
necessary for five lift speeds. This calibration is in
ACCESS 4.
LOWER TO MIN, RAISE
TO BEGIN ___ (in) - With hands in position on the two
multi-task control handles, lower the forks fully, then
raise the fork carriage.
FINDING BREAKOUT
MAINTAIN ___ (mA) - Continue to raise the fork car-
riage.
FINDING SPEED 1 (or 2 through 5)
MAINTAIN ___ (mA) - Continue to raise the fork car-
riage.
PAUSED - LOWER, RAISE
TO CONT ___ (mA) - This message shows if you did
not continue to raise the fork carriage. It also shows
when the fork carriage is at the maximum height. Con-
tinue to raise the fork carriage, or fully lower the fork
carriage and then raise the fork carriage again.
STOP COMMAND - Do not raise the fork carriage.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.12 WEIGHT SENSE - Weight on the forks is not
necessary for this calibration. This calibration lets
ACCESS 7 sense the output counts from the load
M4.3-1970-134 TSP 7000 SERIES
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sense with no weight on the forks. This is a measure-
ment for accurate weight.
EMPTY & LOWER FORKS
THEN  ___ (in) - With hands in position on the two
multi-task control handles, lower the forks fully, and
make sure that the forks are empty. Push ENTER.
SLOWLY RAISE AUX
___ (mA) - Raise the fork carriage.
STOP AUX FUNCTION
___ (mA) - Do not raise the fork carriage.
WAITING TO STABILIZE
___ (mA) - This message shows momentarily.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.13 AUX L VALUE - This calibration lets ACCESS 7
sense the breakout point to lower the fork carriage. It
also senses the quantity of current flow through the
proportional auxiliary raise valve that is necessary for
six lift speeds. This calibration is in ACCESS 4. A
weight of 91 to 227 kg (200 to 500 lb) must be on the
forks during this calibration.
RAISE TO MAX, LOWER
TO BEGIN ___ (in) - With hands in position on the two
multi-task control handles, raise the forks fully, then
lower the fork carriage.
FINDING BREAKOUT
MAINTAIN ___ (mA) - Continue to lower the fork car-
riage.
FINDING SPEED 1 (or 2 through 6)
MAINTAIN ___ (mA) - Continue to lower the fork car-
riage.
PAUSED - RAISE, LOWER
TO CONT ___ (mA) - This message shows if you did
not continue to lower the fork carriage. It also shows
when the fork carriage is at the minimum height. Con-
tinue to lower the fork carriage, or fully raise the fork
carriage and then lower the fork carriage again.
STOP COMMAND - Do not lower the fork carriage.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.14 AUX HGT SENSE - This calibration lets
ACCESS 7 record the number of auxiliary mast height
encoder counts at the maximum fork carriage lift
height. It also senses when the fork carriage is fully
lowered and when the auxiliary height reset switch
opens (the number of auxiliary mast height encoder
counts).
LOWER BELOW RESET
-___ (counts) - This message shows if the forks start
above where the auxiliary height reset switch opens.
Crown 2011 PF25326-133 Rev. 6/12

Lower the fork carriage. The counts have a minus sign
before them until the fork carriage is at the point that
the auxiliary height reset switch opens.
RAISE ABOVE RESET
-___ (counts) - Raise the fork carriage. The counts
have a minus sign before them until the fork carriage is
at the point that the auxiliary height reset switch opens.
LOWER TO MIN, THEN
PRESS  -___ (counts) - Lower the fork carriage to the
minimum height. This message shows when the auxil-
iary height reset switch closes. Push ENTER.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.15 TILT VALVE - If the F11 FORK TYPE menu is
not set to TILTING, this menu is C2.15 TILT VALVE (N/
A). This calibration is for trucks with optional tilt forks.
SELECT TILT
UP OR DOWN TO BEGIN - With hands in position on
the right thumbwheel, tilt the forks up or down.
SUSPENDED
USE TILT TO CONT - This message shows if you did
not tilt the forks. Continue to tilt the forks.
TILT CAL
MAINTAIN ___ (mA) - Continue to tilt the forks.
TILT UP CAL
MAINTAIN ___ (mA) - Tilt the forks up.
TILT DOWN CAL
MAINTAIN ___ (mA) - Tilt the forks down.
STOP TILT - Do not tilt the forks.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.16 FRK POS VALVE - If the F11 FORK TYPE menu
is not set to FORK POSITION, this menu is C2.16 FRK
POS VALVE (N/A). This calibration is for trucks with the
optional fork positioner.
SELECT FORK POSITIONER
UP OR DOWN TO BEGIN - With hands in position on
the right thumbwheel, operate the fork positioner.
SUSPENDED
USE FORK POS TO CONT - This message shows if
you did not operate the fork positioner. Continue to op-
erate the fork positioner.
FORK POSITIONER
MAINTAIN - Continue to operate the fork positioner.
FORK POS OPEN CAL
MAINTAIN ___ (mA) - Open the fork positioner.
FORK POS CLOSED CAL
MAINTAIN ___ (mA) - Close the fork positioner.
Crown 2011 PF25326-134 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
STOP FORK POSITIONER - Do not operate the fork
positioner.
CALIBRATION ACCEPTED - This message shows
momentarily.
C2.99 SAVE HYDR CAL - Push the up and down ar-
rows to go through these menus:
• C2.99.1 NO SAVE
• C2.99.2 YES, SAVE VALUES
• C2.99.3 LOAD DEFAULTS.
Push ENTER to make a selection and go to the C2 HY-
DRAULICS menu.
C3 HEIGHT CUTOUTS - Lets you set a maximum of
six raise and lower cutouts for the platform and mast.
These cutouts are in ACCESS 1.
C3.1 CUTOUT 1 - This is the first of six possible cut-
outs. For cutouts two through six, do the steps below.
R/L TO CUTOUT 1
 SET ___ (in) - The height is in mm (the F2 MEAS-
UREMENT menu is set to METRIC) or in (the F2
MEASUREMENT menu is set to ENGLISH). Raise or
lower the platform or mast to the cutout height. Push
ENTER to set the cutout height.
TYPE: ___
 SET ↓ ↑ CHANGE - Push the up and down arrows
to show the type of cutout and push ENTER to make
the selection. The types of cutouts are:
• PCT = positive cutout. This cutout occurs when you
raise the platform or mast. You can override this
cutout with the override switch.
• PST = positive stop. This cutout occurs when you
raise the platform or mast. You cannot override this
cutout.
• NCT = negative cutout. This cutout occurs when
you lower the platform or mast. You can override
this cutout with the override switch.
• NONE = no cutout.
WHEN? ___
SET ↓ ↑ CHANGE - Push the up and down arrows
to show when the cutout is ON and push ENTER to
make the selection. The types of cutout times are:
• ALWAYS = the cutout is always ON.
• FR ONLY = The cutout is only ON when you oper-
ate the truck in free range (with the guidance switch
set to the manual position and not in a guide aisle).
ZONE? ___
 SET ↓ ↑ CHANGE - This message shows if F27
ZONE SWITCH is set to YES (the truck has the op-
tional zone select switch). Push the up and down ar-
rows to show in which zone the cutout is ON and push
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ENTER to make the selection. The types of zone cut- down arrows to show a value between 1 and 9. Push
outs are: ENTER to make a selection.
• ALL ZONES = the cutout is always ON. C5.1.2 SENSOR COIL - This calibration sets the fre-
• ZONE A = the cutout is only ON when the zone se- quency and amplitude of the floor signal, and how re-
lect switch is in position A. active the coils are.
• ZONE B = the cutout is only ON when the zone se- SWITCH TO MANUAL - This message shows if the
lect switch is in position B. guidance switch is set to the automatic position. Set the
guidance switch to the manual position.
• ZONE C = the cutout is only ON when the zone se-
lect switch is in position C. GO TO AUTO WHEN DONE - Operate the truck
across a guide wire at an angle of a minimum of five
C3.7 SAVE CUTOUTS - Push the up and down arrows
degrees. The coils in the two guidance sensor bars
to go through these menus:
must move directly across the guide wire a minimum of
• C3.7.1 NO SAVE two times. You must do this calibration on a guide wire
• C3.7.2 YES, SAVE VALUES with a high field strength. After you move across the
• C3.7.3 CLEAR ALL. guide wire, operate the truck to the center of the aisle,
stop the truck, and set the guidance switch to the auto-
Push ENTER to make a selection. After the selection,
matic position.
the message SAVING TO MODULES PLEASE
STANDBY shows, and then ACCESS 1 goes to the C3 C5.1.3 WHEEL ANGLE - This calibration sets the
HEIGHT CUTOUTS menu. steered wheel position for the truck to move in a
straight line. The truck must move a minimum of 18 m
C4 STEER ENCODER - This calibration makes sure
(60 ft) in the two directions. The truck moves at a de-
that when the steering of the truck is at mechanical
creased speed during this calibration.
center, the steering feedback encoder sends 5 V to
ACCESS 5. This is important for the correct steering TRAVEL ON WIRE
operation and in a guide aisle. If you do not correctly AUTO WIRE GUIDE - With the guidance switch set to
align the steering feedback encoder: the automatic position, operate the truck in one direc-
tion or the other.
• The power unit end of the truck could move from
side to side.
• The truck does not steer or follow the guide wire
correctly.
• The steering position indicators on ACCESS 1 are
not as accurate as possible.
To align the steering feedback encoder, refer to the
STEERING > Steering Feedback > Steering Encoder
Alignment section.
C5 WIRE GUIDANCE - This calibration is necessary
for the correct performance and operation in a guide
aisle.
C5.1 CALIBRATE - This calibration lets the wire guid-
ance system:
• Sense the input from the four sensors on the guid-
ance sensor bars.
• Find the steer tire position that is necessary to keep
the steering feedback encoder at or near index.
• Compare the input from the guidance sensor bars
to find out if the truck moves in a straight line.
C5.1.1 SET RESPONSE - This value sets how reactive
the steering is to a change in input from the sensors in
the guidance sensor bars. The range is 1 for the least
reactive and 9 for the most reactive. Push the up and

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FORKS TRAILING ___ (%)
CHANGE DIRECTION - This message shows and the
status alarm operates when the truck moves 18 m
(60 ft) in the forks trailing direction. Change the truck
direction of travel.
FORKS LEADING ___ (%)
COME TO STOP - This message shows and the status
alarm operates when the truck moves 18 m (60 ft) in
the forks leading direction. If the truck moves 18 m
(60 ft) in the other direction, the system senses this and
ACCESS 1 shows the message COME TO STOP.
SWITCH TO MANUAL - This message shows when
the truck stops. Set the guidance switch to the manual
position to temporarily keep the wheel angle values.
SWITCH TO AUTO - This message shows after you
set the guidance switch to the manual position. Set the
guidance switch to the automatic position.
C5.1.4 TRUCK ANGLE - During this calibration, the
system compares feedback from the two guidance
sensor bars to find out if the truck moves in a straight
line. The truck must move a minimum of 18 m (60 ft) in
the two directions. The truck moves at a decreased
speed during this calibration.
TRAVEL ON WIRE
AUTO WIRE GUIDE - With the guidance switch set to
the automatic position, operate the truck in one direc-
tion or the other.
FORKS TRAILING ___ (%)
CHANGE DIRECTION - This message shows and the
status alarm operates when the truck moves 18 m
(60 ft) in the forks trailing direction. Change the truck
direction of travel.
FORKS LEADING ___ (%)
COME TO STOP - This message shows and the status
alarm operates when the truck moves 18 m (60 ft) in
the forks leading direction. If the truck moves 18 m
(60 ft) in the other direction, the system senses this and
ACCESS 1 shows the message COME TO STOP.
SWITCH TO MANUAL - This message shows when
the truck stops. Set the guidance switch to the manual
position to temporarily keep the truck angle values.
SWITCH TO AUTO - This message shows after you
set the guidance switch to the manual position. Set the
guidance switch to the automatic position.
C5.2 ADJUST X-OFFSET - Consult with Crown Ser-
vice if it is necessary to do this calibration. If the truck
does not move directly across the guide wire, but
moves to one side of the guide wire, do this calibration.
Before you do this calibration, put a mark for truck me-
chanical center on the platform end of the truck. Moni-
tor this mark from the operator position to refer to the
Crown 2011 PF25326-136 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
guide wire in the floor during travel in the two direc-
tions.
SWITCH TO AUTO - Set the guidance switch to the
automatic position.
TRAVEL ON WIRE - Operate the truck in one direction
or the other. Monitor and compare the mark on the
center of the platform end of the truck to the guide wire
in the floor. The truck must move a minimum of 12 m
(40 ft) in the necessary direction. The truck does not
move at a decreased speed during this calibration.
FORKS TRAILING ___ (%) or
FORKS LEADING ___ (%)
DISTANCE REACHED - This message shows and the
status alarm operates when the truck moves 12 m
(40 ft) in the necessary direction. Stop the truck.
MOVE TRUCK LEFT or MOVE TRUCK RIGHT - This
message shows when the truck stops. If, during travel,
the truck moves more (or always) to the right side of the
guide wire, do the X-OFFSET adjustment to the left. If
the truck moves more (or always) to the left side of the
guide wire, do the X-OFFSET adjustment to the right.
___ 16THS IN or ___ MM - Shows the X-OFFSET
value in mm (the F2 MEASUREMENT menu is set to
METRIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). This message lets you set an X-OFFSET
distance, one digit at a time. The maximum quantity
that you can set is 50 mm (32/16 in).
TRAVEL TO CONTINUE - If you adjust the X-OFFSET
in one direction of travel, you must operate the truck in
the other direction. Monitor and compare the mark on
the center of the platform end of the truck to the guide
wire in the floor. Make sure that the truck moves in a
straight line across the center of the guide wire.
C5.99 SAVE GUIDANCE - Push the up and down ar-
rows to go through these menus:
• C5.99.1 NO SAVE
• C5.99.2 YES, SAVE VALUES
• C5.99.3 LOAD DEFAULTS.
Push ENTER to make a selection and go to the C5
WIRE GUIDANCE menu.
C99 ESCAPE - goes out of the CALIBRATION menu.
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ELECTRICAL SYSTEM
ACCESS 1 2 3®
FEATURES
The FEATURES menu lets you ENABLE, DISABLE,
and set parameters for truck features. You must set
other features by the data on the data plate, the capac-
ity plate, and the specification sheet. Refer to the IN-
TRODUCTION section for a description of the data
plate.
FEATURES Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2. To access LEVEL 3, hold the up
and down arrows and turn the truck ON.
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push the down arrow to go to the FEATURES
menu.
5. Push ENTER to go into the FEATURES menu.
F1 LANGUAGE = ___ - Sets the language on the
ACCESS 1 display screen. The available selections
are:
• F1.1 ENGLISH
• F1.2 DEUTSCH (GERMAN)
• F1.3 FRANCAIS (FRENCH)
• F1.4 ESPANOL (SPANISH)
• F1.5 NEDERLANDS (DUTCH)
• F1.6 ITALIANO (ITALIAN)
• F1.99 ESCAPE.
F2 MEASUREMENT = ___ - Sets the system for
weights and measures. The available selections are:
• F2.1 METRIC
• F2.2 ENGLISH
M4.3-1970-137 TSP 7000 SERIES
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• F2.99 ESCAPE.
F3 TRUCK MODEL = ___ - Consult the data plate or
capacity plate for the applicable truck model. The avail-
able selections are:
• F3.1 TSP6500/7000-33
• F3.2 TSP6500/7000-1.00
• F3.3 TSP6500/7000-1.25
• F3.4 TSP6500/7000-1.50
• F3.99 ESCAPE.
F4 BATTERY SETUP - Sets the correct truck battery
data.
F4.1 BATT VOLTAGE = ___ (Volts) - Sets the truck
battery voltage. Consult the truck data number on the
data plate for the applicable battery voltage. If you do
not set the battery voltage correctly, you will get an
event code. The available selections are:
• F4.1.1 48 VOLTS
• F4.1.2 72 VOLTS. If the F3 TRUCK MODEL menu
is set to F3.2 - TSP6500/7000-1.00 or F3.3 -
TSP6500/7000-1.25, then (NOT AVAILABLE)
shows.
• F4.1.3 80 VOLTS
• F4.1.99 ESCAPE.
F4.2 BATTERY BOX = ___ (mm or in) - The dimen-
sion is in mm (the F2 MEASUREMENT menu is set to
METRIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). This menu sets the battery compartment
dimension. Consult the truck data number on the data
plate for the applicable battery compartment dimen-
sion. Use the battery compartment dimension for the
applicable height and speed curves of your truck, and
for the truck length. If the battery compartment dimen-
sion is incorrect, the wire guidance system does not
operate correctly, which stops the truck during wire
guidance travel. The battery compartment dimension
also has an effect on the F19 MANUAL WIRE SENSE
menu. How the F3 TRUCK MODEL and F4.1 BATT
VOLTAGES menus are set have an effect on which
battery compartment dimensions are available. Refer
to the Battery Compartment Chart. The available selec-
tions are:
• F4.2.1 AA 550 MM (21.6 IN)
• F4.2.2 A 634 MM (25 IN)
• F4.2.3 B 721 MM (28 IN)
• F4.2.4 C 865 MM (34 IN)
• F4.2.5 D 1010 MM (39.75 IN)
• F4.2.99 ESCAPE.
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 ELECTRICAL SYSTEM
ACCESS 1 2 3®

Battery Compartment Chart

And the F4.1 BATT VOLTAGE menu Then the F4.2 BATTERY BOX menu
If the F3 TRUCK MODEL menu is:
is: available is:
48 VOLTS AA 550 MM (21.6 IN), A 634 MM (25
-33 IN), B 721 MM (28 IN), or C 865 mm
(34 IN)
B 721 MM (28 IN), C 865 mm (34
-33 72 VOLTS
IN), or D 1010 MM (39.75 IN)
80 VOLTS A 634 MM (25 IN), B 721 MM (28
-33 IN), C 865 mm (34 IN), or D 1010
MM (39.75 IN)
-1.00 48 VOLTS AA 550 MM (21.6 IN)
-1.00 80 VOLTS A 634 MM (25 IN)
Any voltage A 634 MM (25 IN), B 721 MM (28
-1.25
IN), or C 865 mm (34 IN)
48 VOLTS B 721 MM (28 IN), or C 865 mm (34
-1.50
IN)
72 or 80 VOLTS B 721 MM (28 IN), C 865 mm (34
-1.50
IN), or D 1010 MM (39.75 IN)

F4.3 BATT RETAIN = ___ (no or yes) - Sets the op-
tional battery restraint switch. The available selections
are:
• F4.3.1 NO
• F4.3.2 YES
• F4.3.99 ESCAPE.
If this menu is set to YES, and ACCESS 3 does not
sense input from the battery restraint switch:
• The status alarm operates.
• ACCESS 1 shows the message NO BATTERY RE-
STRAINT.
• Traction and all hydraulic functions are not availa-
ble.
F4.99 ESCAPE - goes to the F4 BATTERY SETUP
menu.
F5 TRUCK WEIGHT = ___ (kg or lb) - The truck
weight is in kg (the F2 MEASUREMENT menu is set to
METRIC) or lb (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble truck weight with the maximum battery, which is the
value that you must put in. The minimum value is
6350 kg (14000 lb), and the maximum value is
15000 kg (33000 lb). The truck weight has an effect on
plugging and the traction motor brake (electromechan-
ical and regenerative). If the value is incorrect, the truck
could move the drive tire when you stop, or not stop in
the correct distance. To put in the truck weight:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct truck weight is set.
ACCESS 1 goes to the F5 TRUCK WEIGHT menu.
F6 MAX LOAD = ___ (kg or lb) - The maximum lift
capacity of the truck is in kg (the F2 MEASUREMENT
menu is set to METRIC) or lb (the F2 MEASUREMENT
menu is set to ENGLISH). Consult the capacity plate
for the applicable maximum lift capacity of the truck,
which is the value that you must put in. The minimum
value is 225 kg (500 lb), and the maximum value is
1500 kg (3300 lb). The maximum lift capacity and the
truck weight set up the parameters for plugging and the
traction motor brake (electromechanical and regenera-
tive). To put in the maximum lift capacity:
• Push the up and down arrows to go through the dig-
its and then push ENTER.

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• Do the last step one digit at a time from the left side
to the right side until the correct maximum lift ca-
pacity is set. ACCESS 1 goes to the F6 MAX LOAD
menu.
F7 MAST TYPE = ___ - There are three different types
of masts. Consult the truck data number on the data
plate for the applicable mast types. The available se-
lections are:
• F7.1 TN MAST
• F7.2 TF MAST
• F7.3 TT MAST
• F7.99 ESCAPE.
F8 MAST HEIGHT - Sets the correct heights for the
mast.
F8.1 LIFT HEIGHT = ___ (mm or in) - The lift height is
in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). The F7 MAST TYPE selection has an ef-
fect on the maximum value for this menu. This value is
the measurement from the floor to the top of the forks
with the mast in the full raise position. This value also
sets the correct cushion (the decrease in speed) before
the mast is at the maximum lift height. The minimum
value is 4600 mm (181 in), and the maximum value is
17755 mm (699 in). Consult the truck data number on
the data plate or the capacity plate for the applicable lift
height. To put in the lift height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct lift height is set.
ACCESS 1 goes to the F8.1 LIFT HEIGHT menu.
F8.2 COLLAPSED HT = ___ (mm or in) - The col-
lapsed height is in mm (the F2 MEASUREMENT menu
is set to METRIC) or in (the F2 MEASUREMENT menu
is set to ENGLISH). This value is the height of the truck
with the mast in the full lower position. When you put in
a value for the F8.1 LIFT HEIGHT menu, the truck soft-
ware automatically calculates the collapsed height.
F8.99 ESCAPE - goes to the F8 MAST HEIGHT menu.
F9 AUX MAST HEIGHT = ___ (mm or in) - The auxil-
iary mast height is in mm (the F2 MEASUREMENT
menu is set to METRIC) or in (the F2 MEASUREMENT
menu is set to ENGLISH). This value is the distance
that the forks move when you raise the fork carriage.
The measurement is from the bottom of the forks to the
floor (subtract 25 mm [1 in]). The minimum value is
1750 mm (69 in), and the maximum value is 2895 mm
(114 in). To put in the auxiliary mast height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
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• Do the last step one digit at a time from the left side
to the right side until the correct auxiliary mast
height is set. ACCESS 1 goes to the F9 AUX MAST
HEIGHT menu.
F10 TRAVERSE FRAME = ___ - Sets the correct val-
ues for traverse operation.
F10.1 FRAME WIDTH = ___ (mm or in) - The frame
width is in mm (the F2 MEASUREMENT menu is set to
METRIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). This value is the maximum distance that
the auxiliary mast and fork carriage moves during trav-
erse operation. This value also sets the correct cushion
(the decrease in speed) points at the end of traverse.
Consult the truck data number on the data plate for the
applicable frame width. The minimum value is
1220 mm (48 in), and the maximum value is 2286 mm
(90 in). To put in the frame width:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct frame width is set.
ACCESS 1 goes to the F10.1 FRAME WIDTH
menu.
F10.2 STOP WIDTH = ___ (mm or in) - The stop width
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). This value is an electrical stop that is set
into traverse operation. The stop width ranges from
200 mm (8 in) to the full frame width (the F10.1 FRAME
WIDTH value). This stop only occurs when the auxiliary
mast and fork carriage moves in the same direction as
the forks. For example: with a frame width of 1524 mm
(60 in), the auxiliary mast and fork carriage moves
762 mm (30 in) to each side of the platform center.
With a stop width of 1270 mm (50 in), the auxiliary
mast and fork carriage moves 762 mm (30 in) from the
platform center when it moves away from the direction
of the forks. The auxiliary mast and fork carriage
moves 635 mm (25 in) from the platform center when it
moves in the same direction as the forks. The system
is set to cut 254 mm (10 in), but this only occurs when
the auxiliary mast and fork carriage moves in the same
direction as the forks (127 mm [5 in] to the left and the
same stop width to the right for a total stop width of
254 mm [10 in].) The minimum value is 200 mm (8 in),
and the maximum value is 2286 mm (90 in).To put in
the stop width:
Crown 2011 PF25326-139 Rev. 6/12

• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct stop width is set.
ACCESS 1 goes to the F10.2 STOP WIDTH menu.
F10.99 ESCAPE - goes to the F10 TRAVERSE
FRAME menu.
F11 FORK TYPE = ___ - There are six different types
of fork carriages. Consult the truck data number on the
data plate for the applicable fork types. The available
selections are:
• F11.1 TELESCOPIC
• F11.2 FIXED FORK
• F11.3 TILTING FORK
• F11.4 FORK POSITION
• F11.5 SHUTTLE FORKS
• F11.6 ROLL LADDER
• F11.99 ESCAPE.
F11._.1 FORK OFFSET = ___ (mm or in) - The fork
offset is in mm (the F2 MEASUREMENT menu is set to
METRIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). How the F11 FORK TYPE menu is set has
an effect on this menu number (for example: F11.1.1
for telescopic forks and F11.2.1 for fixed forks). If this
menu has (N/A), then the software default sets the fork
offset value. Fork offset is the distance from the edge
of the auxiliary mast and fork carriage cover to the fork
face. Consult the capacity plate for the applicable fork
offset. The minimum value is 76 mm (3 in), and the
maximum value is 305 mm (12 in). To put in the fork
offset:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct fork offset is set.
ACCESS 1 goes to the F11._.1 FORK OFFSET
menu.
F11._.2 FORK SPREAD = ___ (mm or in) - The fork
spread is in mm (the F2 MEASUREMENT menu is set
to METRIC) or in (the F2 MEASUREMENT menu is set
to ENGLISH). How the F11 FORK TYPE menu is set
has an effect on this menu number (for example:
F11.1.2 for telescopic forks and F11.2.2 for fixed forks).
If this menu has (N/A), then the software default sets
the fork spread value. The fork spread is the outer edge
of the two forks and is approximately equal to the width
of the fork carriage. The fork spread is manually adjust-
able (unless the truck has the optional fork positioner)
if you move the position of the forks on the fork car-
riage. The maximum fork spread value for the fork car-
Crown 2011 PF25326-140 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
riage is the value you must put in. Consult the
specification sheet for the applicable fork spread. The
minimum value is 762 mm (30 in), and the maximum
value is 1675 mm (66 in). To put in the fork spread:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct fork spread is set.
ACCESS 1 goes to the F11._.2 FORK SPREAD
menu.
F11._.99 ESCAPE - goes to the F11 FORK TYPE
menu.
F12 FORK LENGTH = ___ (mm or in) - The fork
length is in mm (the F2 MEASUREMENT menu is set
to METRIC) or in (the F2 MEASUREMENT menu is set
to ENGLISH). This menu sets the length of the forks.
Consult the data plate for the applicable fork length.
The minimum value is 762 mm (30 in), and the maxi-
mum value is 1524 mm (60 in). To put in the fork
length:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct fork length is set.
ACCESS 1 goes to the F12 FORK LENGTH menu.
F13 LOAD HNDLR LNGTH = ___ (mm or in) - The
load handler length is in mm (the F2 MEASUREMENT
menu is set to METRIC) or in (the F2 MEASUREMENT
menu is set to ENGLISH). The load handler length is
the distance from the front of the platform to the pivot
point of the auxiliary mast. Consult the truck data num-
ber on the data plate for the applicable load handler
length. The minimum value is 584 mm (23 in), and the
maximum value is 2515 mm (99 in). To put in the load
handler length:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct load handler length
is set. ACCESS 1 goes to the F13 LOAD HNDLR
LNGTH menu.
F14 PALLET WIDTH = ___ (mm or in) - The pallet
width is in mm (the F2 MEASUREMENT menu is set to
METRIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). This menu sets the widths of the pallets
that the truck moves. The minimum value is 762 mm
(30 in), and the maximum value is 2845 mm (112 in).
To put in the pallet width:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
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• Do the last step one digit at a time from the left side
to the right side until the correct pallet width is set.
ACCESS 1 goes to the F14 PALLET WIDTH menu.
F15 PALLET LENGTH = ___ (mm or in) - The pallet
length is in mm (the F2 MEASUREMENT menu is set
to METRIC) or in (the F2 MEASUREMENT menu is set
to ENGLISH). This menu sets the lengths of the pallets
that the truck moves. The minimum value is 762 mm
(30 in), and the maximum value is 2085 mm (82 in). To
put in the pallet length:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct pallet length is set.
ACCESS 1 goes to the F15 PALLET LENGTH
menu.
Note: If the forks are not 152 mm (6 in) off of the
ground, the green and amber indicators on the capacity
data monitor do not illuminate.
F17 CAPACITY DATA = ___ - This menu lets you set
up the capacity data monitor. When set up correctly, the
capacity data monitor tells you the maximum lift height
that you can safely lift a load. The green indicators
above the truck icon on ACCESS 1 are the height and
weight zones. The amber indicator shows the height
and weight zones of the forks. The available selections
are:
F17.1 DISABLE - Turns the capacity data monitor OFF
and goes out of the F17 CAPACITY DATA menu.
F17.2 ENABLE - Turns the capacity data monitor ON
and goes to the F17.3 ZONES menu.
F17.3 ZONES = ___ (0 - 4) - This menu is set from 1 to
4. Consult the capacity plate for the applicable number
of zones (zone 1 is at the top and zone 4 is at the bot-
tom of the capacity plate). To set the zones correctly:
• The height and weight are in zone 1 - set the F17.3
ZONES menu to 1.
• The height and weight are in zones 1 and 2 - set the
F17.3 ZONES menu to 2.
• The height and weight are in zones 1, 2, and 3 - set
the F17.3 ZONES menu to 3.
• The height and weight are in all four zones - set the
F17.3 ZONES menu to 4.
F17.4 HEIGHT 1 = ___ (mm or in) - The zone 1 height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 1 height, which is the height that you must put
in. The minimum value is 4600 mm (181 in), and the
maximum value is 17755 mm (699 in). To put in the
zone 1 height:
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• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 1 height is set.
ACCESS 1 goes to the F17.4 HEIGHT 1 menu.
F17.5 WEIGHT 1 = ___ (kg or lb) - The zone 1 weight
is in kg (the F2 MEASUREMENT menu is set to MET-
RIC) or lb (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 1 weight, which is the weight that you must put
in. The minimum value is 225 kg (500 lb), and the max-
imum value is 1585 kg (3500 lb). To put in the zone 1
weight:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 1 weight is
set. ACCESS 1 goes to the F17.5 WEIGHT 1
menu.
F17.6 HEIGHT 2 = ___ (mm or in) - The zone 2 height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 2 height, which is the height that you must put
in. The minimum value is 4600 mm (181 in), and the
maximum value is 17755 mm (699 in). To put in the
zone 2 height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 2 height is set.
ACCESS 1 goes to the F17.6 HEIGHT 2 menu.
F17.7 WEIGHT 2 = ___ (kg or lb) - The zone 2 weight
is in kg (the F2 MEASUREMENT menu is set to MET-
RIC) or lb (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 2 weight, which is the weight that you must put
in. The minimum value is 225 kg (500 lb), and the max-
imum value is 1585 kg (3500 lb). To put in the zone 2
weight:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 2 weight is
set. ACCESS 1 goes to the F17.7 WEIGHT 2
menu.
F17.8 HEIGHT 3 = ___ (mm or in) - The zone 3 height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 3 height, which is the height that you must put
Crown 2011 PF25326-141 Rev. 6/12

in. The minimum value is 4600 mm (181 in), and the
maximum value is 17755 mm (699 in). To put in the
zone 3 height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 3 height is set.
ACCESS 1 goes to the F17.8 HEIGHT 3 menu.
F17.9 WEIGHT 3 = ___ (kg or lb) - The zone 3 weight
is in kg (the F2 MEASUREMENT menu is set to MET-
RIC) or lb (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 3 weight, which is the weight that you must put
in. The minimum value is 225 kg (500 lb), and the max-
imum value is 1585 kg (3500 lb). To put in the zone 3
weight:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 3 weight is
set. ACCESS 1 goes to the F17.9 WEIGHT 3
menu.
F17.10 HEIGHT 4 = ___ (mm or in) - The zone 4
height is in mm (the F2 MEASUREMENT menu is set
to METRIC) or in (the F2 MEASUREMENT menu is set
to ENGLISH). Consult the capacity plate for the appli-
cable zone 4 height, which is the height that you must
put in. The minimum value is 4600 mm (181 in), and
the maximum value is 17755 mm (699 in). To put in the
zone 4 height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 4 height is set.
ACCESS 1 goes to the F17.10 HEIGHT 4 menu.
F17.11 WEIGHT 4 = ___ (kg or lb) - The zone 4 weight
is in kg (the F2 MEASUREMENT menu is set to MET-
RIC) or lb (the F2 MEASUREMENT menu is set to
ENGLISH). Consult the capacity plate for the applica-
ble zone 4 weight, which is the weight that you must put
in. The minimum value is 225 kg (500 lb), and the max-
imum value is 1585 kg (3500 lb). To put in the zone 4
weight:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct zone 4 weight is
set. ACCESS 1 goes to the F17.11 WEIGHT 4
menu.
F17.99 ESCAPE - goes to the F17 CAPACITY DATA
menu.
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ELECTRICAL SYSTEM
ACCESS 1 2 3®
Note: When the F18 WIRE GUIDANCE menu is set to
YES, the status alarm operates when the wire guid-
ance system senses the floor signal (the guidance sen-
sor bars are across the guide wire). If the wire guidance
system does not sense the floor signal, the status
alarm operates only during travel. When the truck stops
and you remove your hand from the right multi-task
control handle, the status alarm does not operate.
F18 WIRE GUIDANCE = ___ (no or yes) - Sets the
optional wire guidance system. Consult the truck data
number on the data plate for the applicable wire guid-
ance system. The available selections are:
• F18.1 NO
• F18.2 YES
• F18.99 ESCAPE.
F19 MANUAL WIRE = ___ - This menu shows as
(NOT AVAILABLE) if the F18 WIRE GUIDANCE menu
is set to NO. This menu sets how the truck operates
when it is in manual steer and the wire guidance sys-
tem senses the floor signal.
F19.1 STANDARD - Sets STANDARD and goes out of
the F19 MANUAL WIRE menu. During traction opera-
tion, ACCESS 1 shows the message SWITCH TO
AUTO and the status alarm operates when the wire
guidance system senses the floor signal. This does not
have an effect on the truck travel speed.
F19.2 SENSE & SLOW = ___ (m or ft) - This distance
is in m (the F2 MEASUREMENT menu is set to MET-
RIC) or ft (the F2 MEASUREMENT menu is set to
ENGLISH). During traction operation, ACCESS 1
shows the message SWITCH TO AUTO and the status
alarm operates when the wire guidance system senses
the floor signal. When the truck moves the set distance,
the travel speed decreases to 2.4 kph (1.5 mph) and
the status alarm operates until the guidance switch is
set to the automatic position. The minimum value is
two m (5 ft), and the maximum value is six m (20 ft).
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F19.3 SENSE & STOP = ___ (m or ft) - This distance F23.3 VIEW CODES - Shows the user codes one at a
is in m (the F2 MEASUREMENT menu is set to MET- time from #01 through #25. If there are user codes,
RIC) or ft (the F2 MEASUREMENT menu is set to ACCESS 1 shows:
ENGLISH). During traction operation, ACCESS 1 USER # ___ = ___
shows the message SWITCH TO AUTO and the status PERF LEVEL = ___
alarm operates when the wire guidance system senses  ESCAPE ↓ NEXT ↑ PREV
the floor signal. When the truck moves the set distance,
If there are no user codes, ACCESS 1 shows:
the truck applies the traction motor brake and the sta-
tus alarm operates until the guidance switch is set to USER # ___ = NO CODE
the automatic position. The minimum value is two m  ESCAPE ↓ NEXT ↑ PREV
(5 ft), and the maximum value is six m (20 ft). F23.4 ADD/MOD CODES - Lets you add or change the
F19.99 ESCAPE - goes to the F19 MANUAL WIRE user codes one at a time from #01 through #25. If there
menu. are user codes, ACCESS 1 shows:
F20 END AISLE = ___ - Sets the optional end aisle USER # ___ = ___
control, which senses the floor magnets at the end of PERF LEVEL = ___
the aisles. Consult the truck data number on the data  MODIFY ↓ NEXT ↑ PREV
plate for the applicable end aisle control. The available If there are no user codes, ACCESS 1 shows:
selections are: USER # ___ = NO CODE
• F20.1 NONE  ADD ↓ NEXT ↑ PREV
• F20.2 NORTH F23.5 DELETE CODES - Lets you remove the user
• F20.3 SOUTH codes one at a time from #01 through #25. If there are
user codes, ACCESS 1 shows:
• F20.99 ESCAPE.
USER # ___ = ___
• F21 TRAVEL ALARM = ___ - Sets the optional
PERF LEVEL = ___
travel alarm in the necessary travel direction. The
 DELETE ↓ NEXT ↑ PREV
available selections are:
If there are no user codes, ACCESS 1 shows:
• F21.1 NO ALARM
USER # ___ = NO CODE
• F21.2 FORWARD
 ESCAPE ↓ NEXT ↑ PREV
• F21.3 REVERSE
F23.6 TRUCK TIMEOUT = ___ (min) - Lets you set a
• F21.4 BOTH time limit for all 25 user codes. If you set a time limit and
• F21.99 ESCAPE. step away from the truck for more than the time limit,
F22 USER PERFORM = ___ (no or yes) - Sets the you must put in your user code to operate the truck.
performance levels in LEVEL 1. The available selec- F23.99 ESCAPE - goes to the F23 USER CODES
tions are: menu.
• F22.1 NO F24 COLD CONDITION = ___ - Sets the freezer con-
• F22.2 YES dition option. The available selections are:
• F22.99 ESCAPE. • F24.1 NO
F23 USER CODES = ___ - Lets you make a maximum • F24.2 YES
of 25 four digit user codes. Each user code applies to • F24.99 ESCAPE.
one of the three truck performance levels. F25 OPTIONS - Sets the optional traverse home posi-
F23.1 NO - Turns the user codes OFF and goes out of tion and pedestrian detection system.
the F23 USER CODES menu.
F23.2 YES - Turns the user codes ON and goes out of
the F23 USER CODES menu.

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F25.1 CNTR HOME TRVL = ___ - Sets the center trav-
erse home position. This menu is when the auxiliary
mast is at the center of the platform (the traverse reset
switch = SWITCH CLOSED). The traverse home posi-
tion is when the auxiliary mast is fully to the left side or
the right side of the platform. When you set this menu
to ENABLE, a different traverse home position and a
menu in the P1 SETUP P1, P2 SETUP P2, and P3
SETUP P3 menus are available. From there you can
adjust the truck travel speed when the auxiliary mast is
at the center of the platform. When you set this menu
to DISABLE, there is not a traverse home position at
the center of the platform, and the P1 SETUP P1, P2
SETUP P2, and P3 SETUP P3 menus are not availa-
ble. The truck travel speed is 2.4 kph (1.5 mph) when
the auxiliary mast is not in the fully left or right positions.
The available selections are:
• F25.1.1 DISABLE
• F25.1.2 ENABLE
• F25.1.99 ESCAPE.
F25.2 PDS = ___ - The optional pedestrian detection
system is only available on EU trucks.
F26 FRONT RAIL = ___ (full or narrow) - The stand-
ard front rail goes fully across the platform. This menu
sets an optional rail with the space to let you use the
reach forward function to put the material on a pallet.
When you set this menu to FULL or NARROW, the
truck does not have a gate on the left side of the plat-
form and ACCESS 1 shows the message IS TETHER
ATTACHED? The available selections are:
• F26.1 FULL
• F26.2 NARROW
• F26.99 ESCAPE.
F27 ZONE SELECT = ___ (no or yes) - Sets the op-
tional zone select switch. The available selections are:
• F27.1 NO
• F27.2 YES
• F27.99 ESCAPE.
F30 SCREEN SETUP = ___ - Sets what ACCESS 1
shows in LEVEL 1. The available selections are:
• F30.1 FORK HEIGHT = ON or OFF
• F30.2 LOAD WEIGHT = ON or OFF
• F30.3 TRUCK SPEED = ON or OFF
• F30.4 BATTERY = ON or OFF
• F30.5 OIL TEMP = ON or OFF. This menu is for
trucks with the optional temperature switch and
freezer condition with low temperature hydraulic oil.
Note: If the F30.6 SCROLL menu is set to OFF, a max-
imum of three messages are ON at the same time. If
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ELECTRICAL SYSTEM
ACCESS 1 2 3®
the F30.6 SCROLL menu is set to ON, one or all mes-
sages can be set to ON.
• F30.6 SCROLL = ON or OFF
• F30.99 ESCAPE.
Note: In the F99 SAVE? menu, ACCESS 1 shows the
message STOP TRUCK OPERATION TO CONTINUE
if the Access 1 2 3® system senses truck movement.
Stop all truck operations and step away from the truck.
After some time, ACCESS 1 goes to the F99 SAVE?
menu.
F99 SAVE? = ___ - Saves the FEATURES menu
changes and goes out of the FEATURES menu. The
available selections are:
• F99.1 NO SAVE - Does not save the FEATURES
menu changes and goes out of the FEATURES
menu.
Note: ACCESS 1 shows the message SAVING TO
MODULES PLEASE STANDBY when the
Access 1 2 3® system saves the FEATURES menu
changes. Make sure that ACCESS 1 goes to the FEA-
TURES menu before you turn the truck OFF or try to
operate the truck.
• F99.2 YES - Saves the FEATURES menu changes
and goes out of the FEATURES menu.
HOUR METERS
The HOUR METERS menu lets you look at and adjust
the hours of operation for the motors and control mod-
ules on the truck.
HOUR METERS Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2. To access LEVEL 3, hold the up
and down arrows and turn the truck ON.
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
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If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push the down arrow to go to the HOUR METERS
menu.
5. Push ENTER to go into the HOUR METERS
menu.
H1 TRUCK RUNTIME - in ACCESS 1. This is the total
hours of operation for the truck when the truck is ON
and the emergency disconnect contactor is closed. In
LEVEL 2, you can look at, but not adjust, the total hours
of operation. In LEVEL 3, you can look at and adjust
the total hours of operation. In LEVEL 3, you can only
set the five digit hour meter forward. You cannot set the
hour meter to 99999 and operate the truck for an hour
to go to 00000. The highest possible value is 65535.
Do not change the hour meter unless you replace
ACCESS 1.
H2 TRACTION MOTOR - in ACCESS 1. This is the to-
tal hours that the traction motor is in operation during
truck travel, or when the truck stops (during plugging,
coast, or regenerative braking). In LEVEL 2, you can
look at, but not adjust, the total hours of operation. In
LEVEL 3, you can look at and adjust the total hours of
operation. In LEVEL 3, you can set the five digit hour
meter from 65535 to 00000, which you must do if you
replace the traction motor.
H3 HYDRAULIC MOTOR - in ACCESS 1. This is the
total hours that the hydraulic motor is in operation dur-
ing all hydraulic functions (but not when you lower the
fork carriage). In LEVEL 2, you can look at, but not ad-
just, the total hours of operation. In LEVEL 3, you can
look at and adjust the total hours of operation. In
LEVEL 3, you can look at and adjust the total hours of
operation. In LEVEL 3, you can set the five digit hour
meter from 65535 to 00000, which you must do if you
replace the hydraulic motor.
H4 STEER MOTOR - in ACCESS 1. This is the total
hours that the steer motor is in operation during a steer
command. In LEVEL 2, you can look at, but not adjust,
the total hours of operation. In LEVEL 3, you can look
at and adjust the total hours of operation. In LEVEL 3,
you can look at and adjust the total hours of operation.
In LEVEL 3, you can set the five digit hour meter from
65535 to 00000, which you must do if you replace the
steer motor.
H5 ACCESS 1 - in ACCESS 1. This hour meter counts
up when the truck is ON and the emergency disconnect
contactor is closed.
H6 ACCESS 2 - in ACCESS 4. This hour meter counts
up when the truck is ON and the emergency disconnect
contactor is closed.
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H7 ACCESS 3 - in ACCESS 5. This hour meter counts
up when the truck is ON and the emergency disconnect
contactor is closed.
H8 ACCESS 4 - in ACCESS 4. This hour meter counts
up when the truck is ON and the emergency disconnect
contactor is closed.
H9 ACCESS 5 - in ACCESS 5. This hour meter counts
up when the truck is ON and the emergency disconnect
contactor is closed.
H10 ACCESS 6 - in ACCESS 6. This hour meter
counts up when the truck is ON and the emergency
disconnect contactor is closed.
H11 ACCESS 7 - in ACCESS 7. This hour meter
counts up when the truck is ON and the emergency
disconnect contactor is closed.
H12 ACCESS 8 - in ACCESS 8. This hour meter
counts up when the truck is ON and the emergency
disconnect contactor is closed.
H99 SAVE HOUR METERS - Push the up and down
arrows to go through these menus:
• H.99.1 NO SAVE
• H.99.2 YES, SAVE VALUES
Push ENTER to make a selection and go out of the
HOUR METERS menu.
EVENT CODES
A part of the software in the Access 1 2 3® system
monitors voltage and current levels on the input to and
the output from the control modules. When the voltage
and current levels are not in the correct parameters,
the software identifies the condition through a three
digit event code.
EVENT CODES Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2. To access LEVEL 3, hold the up
and down arrows and turn the truck ON.
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
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– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push the down arrow to go to the EVENT CODES
menu.
5. Push ENTER to go into the EVENT CODES menu.
L1 EVENT HISTORY - Shows the last 16 event codes.
EVENT CODE LOG EMPTY - Shows when there are
no event codes.
LAST = ___ @ ___ - Shows if there is a minimum of
one event code. ___ @ ___ = the three digit event code
and the five digit H1 TRUCK RUNTIME hour meter. If
there are other event codes, ACCESS 1 shows ↓
NEXT.
LAST-01 = ___ @ ___ - Shows the event code before
the event code in the LAST menu. ___ @ ___ = the
three digit event code and the five digit H1 TRUCK
RUNTIME hour meter. For example: 333 @ 14975. If
there are other event codes, ACCESS 1 shows ↓
NEXT.
LAST-02 = ___ @ ___ through LAST-15 = ___ @ ___
- Follow the same steps in the LAST-01 menu to show
the last 14 event codes.
L2 EVENT TOTALS - Shows the event codes and the
number of times they occur.
EVENT CODE LOG EMPTY - Shows when there are
no event codes.
EVENT CODE ___ = ___ - Shows the event codes and
the number of times they occur. For example:
• EVENT CODE 100 = 1
• EVENT CODE 217 = 3
• EVENT CODE 333 = 15.
L3 ERASE EVENT LOGS - Erases the event codes.
L3.1 ERASE HISTORY ONLY - Erases the event
codes in the L1 EVENT HISTORY menu, but not in the
L2 EVENT TOTALS menu.
• L3.1.1 YES, ERASE - Push ENTER to erase the
event codes and go to the L1 EVENT HISTORY
menu.
• L3.1.2 NO ERASE - Push ENTER to not erase the
event codes and go out of the L3.1 ERASE HIS-
TORY ONLY menu.
L3.2 ERASE TOTALS ONLY - Erases the event codes
in the L2 EVENT TOTALS menu, but not in the L1
EVENT HISTORY menu.
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ACCESS 1 2 3®
• L3.2.1 YES, ERASE - Push ENTER to erase the
event codes and go to the L1 EVENT HISTORY
menu.
• L3.2.2 NO ERASE - Push ENTER to not erase the
event codes and go out of the L3.2 ERASE TO-
TALS ONLY menu.
L3.3 ERASE ALL CODES - Erases all event codes.
• L3.3.1 YES, ERASE - Push ENTER to erase the
event codes and go to the L1 EVENT HISTORY
menu.
• L3.3.2 NO ERASE - Push ENTER to not erase the
event codes and go out of the L3.3 ERASE ALL
CODES menu.
L3.99 ESCAPE - goes out of the L3 ERASE EVENT
LOGS menu.
L99 ESCAPE - goes out of the EVENT CODES menu.
PERFORMANCE
The PERFORMANCE menu lets you adjust the perfor-
mance of the truck.
PERFORMANCE Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2 (you can only access the PER-
FORMANCE menu in LEVEL 2).
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
• Push the up arrow four times and then push EN-
TER.
• Push the up arrow three times and then push EN-
TER.
• Push the up arrow two times and then push EN-
TER.
• Push the up arrow one time and then push ENTER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push the down arrow to go to the PERFOR-
MANCE menu.
5. Push ENTER to go into the PERFORMANCE
menu.
Note: You must set the FEATURES menus before you
set or adjust the PERFORMANCE menus.
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P1 SETUP P1 - If the factory defaults are set, the pa-
rameters of the P1 performance level are the best pro-
ductivity levels for truck operation. You can use this
menu to adjust the parameters.
P2 SETUP P2 - If the factory defaults are set, the pa-
rameters of the P2 performance level are decreased
productivity levels (in relation to the P1 performance
level) for truck operation. You can use this menu to ad-
just the parameters.
P3 SETUP P3 - If the factory defaults are set, the pa-
rameters of the P3 performance level are the lowest
productivity levels (in relation to the P1 and P2 perfor-
mance levels) for truck operation. You can use this
menu to adjust the parameters.
P1.1, P2.1, and P3.1 TRAVEL ACCEL = ___ (1
through 9) - Adjusts the acceleration (the time for the
truck to go from stop to top speed). The range is 1 for
the longest acceleration time to 9 for the shortest accel-
eration time. The default value is set to 9 for the P1
performance level, 7 for the P2 performance level, and
5 for the P3 performance level.
P1.2, P2.2, and P3.2 GUIDE SPD CURVE = ___ (1
through 9) - Adjusts when the truck linear speed starts
to decrease as the platform raises during wire guid-
ance travel. The range is 1 (the truck starts to decrease
speed at a lower height) to 9 (the truck starts to de-
crease speed at a higher height). The default value is
set to 7 for the P1 and P2 performance levels, and 3 for
the P3 performance level.
P1.3, P2.3, and P3.3 MAX TRAV SPEEDS - Adjusts
the travel speed limits in a number of conditions.
P1.3.1, P2.3.1, and P3.3.1 FREE RANGING = ___
(kph or mph) - The speed is in kph (the F2 MEASURE-
MENT menu is set to METRIC) or mph (the F2 MEAS-
UREMENT menu is set to ENGLISH). This menu
adjusts the travel speed limit when you operate the
truck out of the range of a guide aisle. The minimum
value is 1.6 kph (1 mph), and the maximum value is
8.9 kph (5.5 mph). The default value is set to 8 9 kph
(5.5 mph) for the P1 and P2 performance levels, and
7.2 kph (4.5 mph) for the P3 performance level. To put
in the speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P1.3.1, P2.3.1, or
P3.3.1 FREE RANGING menu.
P1.3.2, P2.3.2, and P3.3.2 GUIDED SPEEDS - Ad-
justs the travel speed limit when you operate the truck
in a guide aisle.
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P1.3.2.1, P2.3.2.1, and P3.3.2.1 FORKS FIRST = ___
(kph or mph) - The speed is in kph (the F2 MEASURE-
MENT menu is set to METRIC) or mph (the F2 MEAS-
UREMENT menu is set to ENGLISH). This menu
adjusts the travel speed limit in a guide aisle in the forks
first direction. The minimum value is 1.6 kph (1 mph),
and the maximum value is 10.4 kph (6.5 mph). The de-
fault value is set to 10.4 kph (6.5 mph) for the P1 and
P2 performance levels, and 8 kph (5 mph) for the P3
performance level. To put in the speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P1.3.2.1, P2.3.2.1, or
P3.3.2.1 FORKS FIRST menu.
P1.3.2.2, P2.3.2.2, and P3.3.2.2 PUF SEATFWD =
___ (kph or mph) - The speed is in kph (the F2 MEAS-
UREMENT menu is set to METRIC) or mph (the F2
MEASUREMENT menu is set to ENGLISH). This
menu adjusts the travel speed limit in a guide aisle in
the power unit first direction with the operator seat for-
ward or at the 20 degree position. The minimum value
is 1.6 kph (1 mph), and the maximum value is 9.7 kph
(6 mph). The default value is set to 9.7 kph (6 mph) for
the P1 and P2 performance levels, and 7.2 kph
(4.5 mph) for the P3 performance level. To put in the
speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P1.3.2.2, P2.3.2.2, or
P3.3.2.2 PUF SEATFWD menu.
P1.3.2.3, P2.3.2.3, and P3.3.2.3 PUF SEATSID = ___
(kph or mph) - The speed is in kph (the F2 MEASURE-
MENT menu is set to METRIC) or mph (the F2 MEAS-
UREMENT menu is set to ENGLISH). This menu
adjusts the travel speed limit in a guide aisle in the
power unit first direction with the operator seat at the
270 or 315 degree position. The minimum value is
1.6 kph (1 mph), and the maximum value is 12 kph
(7.5 mph). The default value is set to 12 kph (7.5 mph)
for the P1 and P2 performance levels, and 9.7 kph
(6 mph) for the P3 performance level. To put in the
speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P1.3.2.3, P2.3.2.3, or
P3.3.2.3 PUF SEATSID menu.
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ACCESS 1 2 3®

P1.3.2.99, P2.3.2.99, and P3.3.2.99 ESCAPE - goes • Do the last step one digit at a time from the left side
to the P1.3.1, P2.3.2, or P3.3.2 GUIDED SPEEDS to the right side until the correct speed is set.
menu. ACCESS 1 goes out of the P1.3.3.2, P2.3.3.2, or
P1.3.3, P2.3.3, and P3.3.3 CENTER HOME - This P3.3.3.2 PUF CH TRVL menu.
menu shows as (NOT AVAILABLE) if the F25.1 CNTR P1.3.3.99, P2.3.3.99, and P3.3.3.99 ESCAPE - goes
HOME TRVL menu is set to DISABLE. This menu ad- to the P1.3.3, P2.3.3, or P3.3.3 CENTER HOME menu.
justs the travel speed limit when you operate the truck P1.4, P2.4, and P3.4 LOAD HANDLER - Adjusts the
with the auxiliary mast and fork carriage in the center of operation of the auxiliary mast and fork carriage func-
the platform. tions.
Note: How you set the F10.1 TRAVERSE FRAME P1.4.1, P2.4.1, and P3.4.1 RAISE SPEED = ___ (1
WIDTH and F14 PALLET WIDTH menus has an effect through 9) - Adjusts the speed of the fork carriage
on the travel speed limit for the P1.3.3.1, P2.3.3.1, and raise system. The range is 1 for the slowest speed to 9
P3.3.3.1 FF CH TRVL menus. Subtract the pallet width for the fastest speed. The default value is set to 9 for
from the frame width: the P1 performance level, 7 for the P2 performance
• If the result is equal to or more than 356 mm (14 in), level, and 5 for the P3 performance level.
you can set the P1.3.3.1, P2.3.3.1, and P3.3.3.1 FF P1.4.2, P2.4.2, and P3.4.2 LOWER SPEED = ___ (1
CH TRVL menus to a maximum of 8.8 kph through 9) - Adjusts the speed of the fork carriage
(5.5 mph). lower system. The range is 1 for the slowest speed to
o If the result is less than 356 mm (14 in), you can set 9 for the fastest speed. The default value is set to 9 for
the P1.3.3.1, P2.3.3.1, and P3.3.3.1 FF CH TRVL the P1 and P2 performance levels, and 5 for the P3
menus to a maximum of 4.8 kph (3 mph). performance level.
P1.3.3.1, P2.3.3.1, and P3.3.3.1 FF CH TRVL = ___ P1.4.3, P2.4.3, and P3.4.3 PIVOT SPEED = ___ (1
(kph or mph) - The speed is in kph (the F2 MEASURE- through 9) - Adjusts the pivot speed of the fork car-
MENT menu is set to METRIC) or mph (the F2 MEAS- riage. The range is 1 for the slowest speed to 9 for the
UREMENT menu is set to ENGLISH). This menu fastest speed. The default value is set to 7 for the P1
adjusts the travel speed limit in the forks first direction and P2 performance levels, and 3 for the P3 perfor-
when you operate the truck with the auxiliary mast and mance level.
fork carriage in the center of the platform. The mini-
mum value is 2.4 kph (1.5 mph), and the maximum
value is 8.9 kph (5.5 mph). The default value is set to
4.8 kph (3 mph) for the P1, P2, and P3 performance
levels. To put in the speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P1.3.3.1, P2.3.3.1, or
P3.3.3.1 FF CH TRVL menu.
P1.3.3.2, P2.3.3.2, and P3.3.3.2 PUF CH TRVL = ___
(kph or mph) - The speed is in kph (the F2 MEASURE-
MENT menu is set to METRIC) or mph (the F2 MEAS-
UREMENT menu is set to ENGLISH). This menu
adjusts the travel speed limit in the power unit first di-
rection when you operate the truck with the auxiliary
mast and fork carriage in the center of the platform.
The minimum value is 2.4 kph (1.5 mph), and the max-
imum value is 9.7 kph (6 mph). The default value is set
to 9.7 kph (6 mph) for the P1 and P2 performance lev-
els, and 8 kph (5 mph) for the P3 performance level. To
put in the speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.

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P1.4.4, P2.4.4, and P3.4.4 TRAVERSE SPEED = ___
(1 through 9) - Adjusts how quickly the fork carriage
moves from one traverse home position to the other.
The range is 1 for the slowest speed to 9 for the fastest
speed. The default value is set to 7 for the P1 and P2
performance levels, and 3 for the P3 performance
level.
P1.4.5, P2.4.5, and P3.4.5 FORK SPEED = ___ (1
through 9) - This menu shows as (NOT AVAILABLE) if
the F11 FORK TYPE menu is not set to TELESCOPIC.
This menu adjusts how quickly the optional telescopic
forks extend or retract. The range is 1 for the slowest
speed to 9 for the fastest speed. The default value is
set to 5 for the P1 and P2 performance levels, and 1 for
the P3 performance level.
P1.4.99, P2.4.99, and P3.4.99 ESCAPE - goes to the
P1.4, P2.4, or P3.4 LOAD HANDLER menu.
P1.5, P2.5, and P3.5 MAIN RAISE SPD = ___ (1
through 9) - Adjusts the mast raise speed. The range
is 1 for the slowest speed to 9 for the fastest speed.
The default value is set to 8 for the P1 performance
level, 5 for the P2 performance level, and 3 for the P3
performance level.
P1.5.99, P2.5.99, and P3.5.99 ESCAPE - goes to the
P1.5, P2.5, or P3.5 MAIN RAISE SPD menu.
P4 PLUG = ___ (1 through 9) - Adjusts the plugging
force. Plugging is when the truck moves and you move
the multi-task control handle through the neutral posi-
tion to the opposite direction of travel. ACCESS 3
changes the direction of current flow through the trac-
tion motor and the rotor turns decrease. This does not
cause damage to your truck traction system and can
save wear on the drive tire and traction motor brake.
The range is 1 for the minimum plugging force (the
truck comes to a stop in the longest distance) to 9 for
the most plugging force (the truck comes to a stop in
the shortest distance). The default value is set to 7. The
plugging distance is in relation to the position of the
multi-task control handle. For example: the longest
plugging distance occurs when this menu is set to 1
and the multi-task control handle moves from one di-
rection of travel through neutral (but only to a position
not very far from neutral). The shortest plugging dis-
tance occurs when this menu is set to 9 and the multi-
task control handle moves from one direction of travel
through neutral (and fully to the opposite travel direc-
tion).
P5 COAST = ___ (1 through 9) - Adjusts the regener-
ative current of the traction motor when the right multi-
task control handle moves to the neutral position during
truck movement. The range is 1 (the highest quantity of
regenerative energy applies to the traction motor,
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which causes a shorter distance) to 9 (the lowest quan-
tity of regenerative energy applies to the traction motor,
which causes a longer distance). The default value is
set to 9.
P6 BRAKING - Adjusts the brake force of the truck.
The traction motor brake and the regenerative current
of the traction motor work together to stop the truck.
P6.1 BRAKING FF = ___ (1 through 9) - Adjusts the
brake force of the truck when the truck moves in the
forks first direction. The range is 1 for the most brake
force to 9 for the minimum brake force. The default
value is set to 7.
P6.2 BRAKING PUF = ___ (1 through 9) - Adjusts the
brake force of the truck when the truck moves in the
power unit first direction. The range is 1 for the most
brake force to 9 for the minimum brake force. The de-
fault value is set to 7.
P6.99 ESCAPE - goes to the P6 BRAKING menu.
P7 FREE RANGE SPEEDS - Sets a height where the
travel speed decreases or stops when you operate the
truck in manual steer and out of the range of a guide
aisle. The adjustments in this menu are of no relation
to the adjustments in the P1.3, P2.3, and P3.3 MAX
TRAV SPEEDS menus. The height limits in this menu
are from the platform height (the height sense encoder
input), not the height of the fork carriage.
P7.1 SPD LIM HT 1MPH = ___ (mm or in) - The height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). When the platform is at the raise height set
in this menu, the truck travel speed decreases to
1.6 kph (1 mph). For example: if this menu is set to
3810 mm (150 in), and the platform is below that
height, the travel speed limit does not decrease. When
the platform is at or more than 3810 mm (150 in), the
travel speed decreases to 1.6 kph (1 mph). The mini-
mum value is 0 mm (0 in), and the maximum value is
17755 mm (699 in). The default value is set to
17755 mm (699 in). To put in the height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct height is set.
ACCESS 1 goes out of the P7.1 SPD LIM HT
1MPH menu.
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P7.2 SPD LIM HT 0MPH = ___ (mm or in) - The height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). When the platform is at the raise height set
in this menu, the truck travel speed decreases to 0 kph
(0 mph). For example: if this menu is set to 5080 mm
(200 in), and the platform is below that height, the
travel speed limit does not decrease. When the plat-
form is at or more than 5080 mm (200 in), the travel
speed decreases to 0 kph (0 mph). The minimum
value is 0 mm (0 in), and the maximum value is
17755 mm (699 in). The default value is set to
17755 mm (699 in). To put in the height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct height is set.
ACCESS 1 goes out of the P7.2 SPD LIM HT
0MPH menu.
P7.99 ESCAPE - goes to the P7 FREE RANGE
SPEEDS menu.
P8 GUIDED SPEEDS - Sets a height where the travel
speed decreases or stops when you operate a wire
guidance truck in a guide aisle. This menu also sets the
travel speed limit during the time that the wire guidance
system senses the floor signal. The adjustments in this
menu are of no relation to the adjustments in the P1.2,
P2.2, and P3.2 GUIDE SPD CURVE and P1.3.2,
P2.3.2, and P3.3.2 GUIDED SPEEDS menus. The
height limits in this menu are from the platform height
(the height sense encoder input), not the height of the
fork carriage.
P8.1 SPD LIM HT 1MPH = ___ (mm or in) - The height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). When the platform is at the raise height set
in this menu, the truck travel speed decreases to
1.6 kph (1 mph). For example: if this menu is set to
3810 mm (150 in), and the platform is below that
height, the travel speed limit does not decrease. When
the platform is at or more than 3810 mm (150 in), the
travel speed decreases to 1.6 kph (1 mph). The mini-
mum value is 0 mm (0 in), and the maximum value is
17755 mm (699 in). The default value is set to
17755 mm (699 in). To put in the height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct height is set.
ACCESS 1 goes out of the P8.1 SPD LIM HT
1MPH menu.
Crown 2011 PF25326-150 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
P8.2 SPD LIM HT 0MPH = ___ (mm or in) - The height
is in mm (the F2 MEASUREMENT menu is set to MET-
RIC) or in (the F2 MEASUREMENT menu is set to
ENGLISH). When the platform is at the raise height set
in this menu, the truck travel speed decreases to 0 kph
(0 mph). For example: if this menu is set to 5080 mm
(200 in), and the platform is below that height, the
travel speed limit does not decrease. When the plat-
form is at or more than 5080 mm (200 in), the travel
speed decreases to 0 kph (0 mph). The minimum
value is 0 mm (0 in), and the maximum value is
17755 mm (699 in). The default value is set to
17755 mm (699 in). To put in the height:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct height is set.
ACCESS 1 goes out of the P8.2 SPD LIM HT
0MPH menu.
P8.3 ACQUIRE SPEED = ___ (kph or mph) - The
speed is in kph (the F2 MEASUREMENT menu is set
to METRIC) or mph (the F2 MEASUREMENT menu is
set to ENGLISH). The minimum value is 2.4 kph
(1.5 mph), and the maximum value is 4 kph (2.5 mph).
The default value is set to 4 kph (2.5 mph). To put in the
speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P8.3 ACQUIRE SPEED
menu.
P8.99 ESCAPE - goes to the P8 GUIDED SPEEDS
menu.
P9 BDI = ___ (1 through 9) - Adjusts the condition of
battery charge. The adjustment of this value has an ef-
fect on when the lift lockout function occurs. The lift
lockout function does not let the platform raise when
the battery voltage drops to a specified level. When this
menu is set to the factory default value, lift lockout oc-
curs when the condition of battery charge is approxi-
mately 20% (the battery is 80% empty). The range is 1
to 9. The default value is set to 5. If you set this value
to less than 5, the battery must be more than 80%
empty before the lift lockout function occurs. If you set
this value to more than 5, lift lockout occurs before the
battery is at the 80% empty level.
P10 EAC SETUP - This menu shows as (NOT AVAIL-
ABLE) if the F20 END AISLE menu is set to NONE.
This menu sets up the optional end aisle control.
ACCESS 6 controls and monitors end aisle control.
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ELECTRICAL SYSTEM
ACCESS 1 2 3®
P10.1 EAC MODE = ___ - Sets the traction system
feedback when the end aisle control senses that the
truck moves across the floor magnets. The available
selections are:
• P10.1.1 SLOWDOWN (the traction system is at a
set speed).
• P10.1.2 SLOWDN AUTO-RESUME (the traction
system is at a set speed for a set distance, then
goes to the usual speed).
• P10.1.3 SLOWDN AUTO-STOP (the traction sys-
tem is at a set speed for a set distance, then the
truck stops).
• P10.1.4 STOP USING MOTOR (plugging stops the
truck).
• P10.1.5 STOP USING BRAKE (plugging and the
traction motor brake stop the truck).
• P10.1.99 ESCAPE - goes to the P10.1 EAC MODE
menu.
P10.2 FF DIRECTION - Sets the traction system con-
trol when the end aisle control senses that the truck
moves across the floor magnets in the forks first direc-
tion.
P10.2.1 EAC ZONE SPD = ___ (kph or mph) - The
speed is in kph (the F2 MEASUREMENT menu is set
to METRIC) or mph (the F2 MEASUREMENT menu is
set to ENGLISH). ACCESS 6 knows that the truck is in
a zone when the end aisle control senses the floor
magnets. This menu sets a speed limit for the zone.
The minimum value is 1.6 kph (1 mph), and the maxi-
mum value is 9.7 kph (6 mph). The default value is set
to 3.2 kph (2 mph). To put in the speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set.
ACCESS 1 goes out of the P10.2.1 EAC ZONE
SPD menu.
P10.2.2 DECEL RATE = ___ (1 through 9) - This
menu shows as (NOT AVAILABLE) if the P10.1 EAC
MODE menu is set to STOP USING BRAKE. This
menu sets how quickly the traction system decreases
the truck speed (by plugging) to the speed limit set in
the P10.2.1 EAC ZONE SPD menu. The range is 1 for
the slowest truck speed decrease to 9 for the fastest
truck speed decrease. The default value is set to 3.
P10.2.3 RESUME DIST = ___ (m or ft) - The distance
is in m (the F2 MEASUREMENT menu is set to MET-
RIC) or ft (the F2 MEASUREMENT menu is set to
ENGLISH). This menu shows as (NOT AVAILABLE) if
the P10.1 EAC MODE menu is not set to SLOWDN
AUTO-RESUME. This menu sets the truck travel dis-
M4.3-1970-151 TSP 7000 SERIES
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tance (after the end aisle control senses the floor mag-
nets) before the traction system goes to the usual
speed. The minimum value is 3 m (10 ft), and the max-
imum value is 18.3 m (60 ft). The default value is set to
13.7 m (45 ft). To put in the distance:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct distance is set.
ACCESS 1 goes out of the P10.2.3 RESUME DIST
menu.
P10.2.4 STOP DIST = ___ (m or ft) - The distance is in
m (the F2 MEASUREMENT menu is set to METRIC) or
ft (the F2 MEASUREMENT menu is set to ENGLISH).
This menu shows as (NOT AVAILABLE) if the P10.1
EAC MODE menu is not set to SLOWDN AUTO-STOP.
This menu is sets the truck travel distance (after the
end aisle control senses the floor magnets) before it
stops. The minimum value is 0 m (0 ft), and the maxi-
mum value is 12.2 m (40 ft). The default value is set to
6.1 m (20 ft). To put in the distance:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct distance is set.
ACCESS 1 goes out of the P10.2.4 STOP DIST
menu.
P10.2.99 ESCAPE - goes to the P10.2 FF DIRECTION
menu.
P10.3 PUF DIRECTION - Sets the traction system con-
trol when the end aisle control senses that the truck
moves across the floor magnets in the power unit first
direction.
P10.3.1 EAC ZONE SPD = ___ (kph or mph) - The
speed is in kph (the F2 MEASUREMENT menu is set
to METRIC) or mph (the F2 MEASUREMENT menu is
set to ENGLISH). ACCESS 6 knows that the truck is in
a zone when the end aisle control senses the floor
magnets. This menu sets a speed limit for the zone.
The minimum value is 1.6 kph (1 mph), and the maxi-
mum value is 9.7 kph (6 mph). The default value is set
to 3.2 kph (2 mph). To put in the speed:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct speed is set. AC-
CESS 1 goes out of the P10.3.1 EAC ZONE SPD
menu.
P10.3.2 DECEL RATE = ___ (1 through 9) - This
menu shows as (NOT AVAILABLE) if the P10.1 EAC
MODE menu is set to STOP USING BRAKE. This
Crown 2011 PF25326-151 Rev. 6/12

menu sets how quickly the traction system decreases
the truck speed (by plugging) to the speed limit set in
the P10.3.1 EAC ZONE SPD menu. The range is 1 for
the slowest truck speed decrease to 9 for the fastest
truck speed decrease. The default value is set to 5.
P10.3.3 RESUME DIST = ___ (m or ft) - The distance
is in m (the F2 MEASUREMENT menu is set to MET-
RIC) or ft (the F2 MEASUREMENT menu is set to
ENGLISH). This menu shows as (NOT AVAILABLE) if
the P10.1 EAC MODE menu is not set to SLOWDN
AUTO-RESUME. This menu sets the truck travel dis-
tance (after the end aisle control senses the floor mag-
nets) before the traction system goes to the usual
speed. The minimum value is 3 m (10 ft), and the max-
imum value is 18.3 m (60 ft). The default value is set to
13.7 m (45 ft). To put in the distance:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct distance is set.
ACCESS 1 goes out of the P10.3.3 RESUME DIST
menu.
P10.3.4 STOP DIST = ___ (m or ft) - The distance is in
m (the F2 MEASUREMENT menu is set to METRIC) or
ft (the F2 MEASUREMENT menu is set to ENGLISH).
This menu shows as (NOT AVAILABLE) if the P10.1
EAC MODE menu is not set to SLOWDN AUTO-STOP.
This menu is sets the truck travel distance (after the
end aisle control senses the floor magnets) before it
stops. The minimum value is 0 m (0 ft), and the maxi-
mum value is 12.2 m (40 ft). The default value is set to
6.1 m (20 ft). To put in the distance:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct distance is set.
ACCESS 1 goes out of the P10.3.4 STOP DIST
menu.
P10.3.99 ESCAPE - goes to the P10.3 PUF DIREC-
TION menu.
P10.4 SLOWDOWN DIR = ___ - This menu shows as
(NOT AVAILABLE) if the P10.1 EAC MODE menu is
set to SLOWDN AUTO-RESUME. This menu tells
ACCESS 6 when to decrease the truck speed.
• P10.4.1 OUT OF AISLE ONLY - The truck speed
decreases only when the truck moves across the
floor magnets and out of a guide aisle.
• P10.4.2 IN & OUT OF AISLE - The truck speed de-
creases when the truck moves across the floor
magnets and into or out of a guide aisle.
Crown 2011 PF25326-152 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
P10.4.99 ESCAPE - goes to the P10.4 SLOWDOWN
DIR menu.
P10.5 MAGNET SPREAD = ___ (m or ft) - The dis-
tance is in m (the F2 MEASUREMENT menu is set to
METRIC) or ft (the F2 MEASUREMENT menu is set to
ENGLISH). This menu shows as (NOT AVAILABLE) if
the P10.1 EAC MODE menu is not set to SLOWDN
AUTO- RESUME. This menu sets how far apart the two
sets of floor magnets are. The minimum value is 6 m
(20 ft), and the maximum value is 45.7 m (150 ft). To
put in the distance:
• Push the up and down arrows to go through the dig-
its and then push ENTER.
• Do the last step one digit at a time from the left side
to the right side until the correct distance is set. AC-
CESS 1 goes out of the P10.5 MAGNET SPREAD
menu.
P10.99 ESCAPE - goes to the P10 EAC SETUP menu.
P11 MAIN HOIST R/L - Sets the performance for the
platform and mast raise and lower system.
P11.1 MAIN RAISE - Sets the performance for the plat-
form and mast raise system.
P11.1.1 MAX SPEED = ___ - This menu shows as
(NOT AVAILABLE). Adjust the mast raise speed in the
P1.5, P2.5, and P3.5 MAIN RAISE SPD menus.
P11.1.2 MAIN R ACCEL = ___ (1 through 9) - Adjusts
the platform and mast raise system acceleration rate.
This is the rate that the platform and mast move from
no or slow raise to full speed raise. The range is 1 for
the slowest acceleration rate to 9 for the fastest accel-
eration rate. The default value is set to 6.
P11.1.3 MAIN R DECEL = ___ (1 through 9) - Adjusts
the platform and mast raise system deceleration rate.
This is the rate that the platform and mast stop or move
to slow raise when the multi-task control handle moves
to neutral. The range is 1 for the slowest deceleration
time to 9 for the fastest deceleration time. The default
value is set to 7.
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ELECTRICAL SYSTEM
ACCESS 1 2 3®
P11.1.4 MAIN R STAGE = ___ (1 through 9) - This
menu shows as (NOT AVAILABLE) if the F7 MAST
TYPE menu is set to TN. This menu adjusts how
quickly the platform and mast raise system operates
during staging on TF or TT masts. The range is 1 for
the most cushion during staging to 9 for minimum cush-
ion during staging. With the most cushion, the platform
and mast raise slowly before and during the staging
point, then raise quickly after the staging point. With
minimum cushion, the platform and mast raise quickly
during staging. The default value is set to 5.
P11.1.99 ESCAPE - goes to the P11.1 MAIN RAISE
menu.
P11.2 MAIN LOWER - Sets the performance for the
platform and mast lower system.
P11.2.1 MAX SPEED = ___ - Adjusts the platform and
mast lower system speed. The range is 1 for the slow-
est speed to 9 for the fastest speed. The default value
is set to 9.
P11.2.2 MAIN L ACCEL = ___ (1 through 9) - Adjusts
the platform and mast lower system acceleration rate.
This is the rate that the platform and mast move from
no or slow lower to full speed lower. The range is 1 for
the slowest acceleration rate to 9 for the fastest accel-
eration rate. The default value is set to 4.
P11.2.3 MAIN L DECEL = ___ (1 through 9) - Adjusts
the platform and mast lower system deceleration rate.
This is the rate that the platform and mast stop or move
to slow lower when the multi-task control handle moves
to neutral. The range is 1 for the slowest deceleration
time to 9 for the fastest deceleration time. The default
value is set to 7.
P11.2.4 MAIN L STAGE = ___ (1 through 9) - This
menu shows as (NOT AVAILABLE) if the F7 MAST
TYPE menu is set to TN. This menu adjusts how
quickly the platform and mast lower system operates
during staging on TF or TT masts. The range is 1 for
the most cushion during staging to 9 for minimum cush-
ion during staging. With the most cushion, the platform
and mast lower slowly before and during the staging
point, then lower quickly after the staging point. With
minimum cushion, the platform and mast lower quickly
during staging. The default value is set to 5.
P11.2.99 ESCAPE - goes to the P11.2 MAIN LOWER
menu.
P11.99 ESCAPE - goes to the P11 MAIN HOIST R/L
menu.
P12 AUX HOIST R/L - Sets the performance for the
fork carriage raise and lower system.
P12.1 AUX RAISE - Sets the performance for the fork
carriage raise system.
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P12.1.1 AUX ACCEL = ___ (1 through 9) - Adjusts the
fork carriage raise system acceleration rate. This is the
rate that the fork carriage moves from no or slow raise
to full speed raise. The range is 1 for the slowest accel-
eration rate to 9 for the fastest acceleration rate. The
default value is set to 6.
P12.1.2 AUX DECEL = ___ (1 through 9) - Adjusts the
fork carriage raise system deceleration rate. This is the
rate that the fork carriage stops or moves to slow raise
when the thumbwheel moves to neutral. The range is 1
for the slowest deceleration time to 9 for the fastest de-
celeration time. The default value is set to 7.
P12.1.99 ESCAPE - goes to the P12.1 AUX RAISE
menu.
P12.2 AUX LOWER - Sets the performance for the fork
carriage lower system.
P12.2.1 AUX L ACCEL = ___ (1 through 9) - Adjusts
the fork carriage lower system acceleration rate. This is
the rate that the fork carriage moves from no or slow
lower to full speed lower. The range is 1 for the slowest
acceleration rate to 9 for the fastest acceleration rate.
The default value is set to 6.
P12.2.2 AUX L DECEL = ___ (1 through 9) - Adjusts
the fork carriage lower system deceleration rate. This
is the rate that the fork carriage stops or moves to slow
lower when the thumbwheel moves to neutral. The
range is 1 for the slowest deceleration time to 9 for the
fastest deceleration time. The default value is set to 7.
P12.2.99 ESCAPE - goes to the P12.2 AUX LOWER
menu.
P12.99 ESCAPE - goes to the P12 AUX HOIST R/L
menu.
P13 PDS SETUP - The optional pedestrian detection
system is only available on EU trucks.
Note: In the P99 SAVE? menu, ACCESS 1 shows the
message STOP TRUCK OPERATION TO CONTINUE
if the Access 1 2 3® system senses truck movement.
Stop all truck operations and step away from the truck.
After some time, ACCESS 1 goes to the P99 SAVE?
menu.
P99 SAVE? - Saves the PERFORMANCE menu
changes and goes out of the PERFORMANCE menu.
The available selections are:
• P99.1 NO SAVE - Does not save the PERFOR-
MANCE menu changes and goes out of the PER-
FORMANCE menu.
Note: ACCESS 1 shows the message SAVING TO
MODULES PLEASE STANDBY when the
Access 1 2 3® system saves the PERFORMANCE
menu changes. Make sure that ACCESS 1 goes to the
Crown 2011 PF25326-153 Rev. 6/12

PERFORMANCE menu before you turn the truck OFF
or try to operate the truck.
• P99.2 YES - Saves the PERFORMANCE menu
changes and goes out of the PERFORMANCE
menu.
• P99.3 LOAD ALL DEFAULTS - Sets the PERFOR-
MANCE menus to the factory default values.
UTILITIES
The UTILITIES menu contains software part numbers
and truck modes.
UTILITIES Menu Access
1. Turn the truck OFF.
Note: Make sure that you hold the arrows through the
truck start up and self-test sequences.
2. Hold down the up arrow and turn the truck ON to
access LEVEL 2. To access LEVEL 3, hold the up
and down arrows and turn the truck ON.
3. When the truck start up and self-test sequences
are complete, you must put in your user code. Put
in the user code, one digit at a time, from the left
side to the right side with the up arrow and ENTER.
For example, with a user code of 4321:
– Push the up arrow four times and then push EN-
TER.
– Push the up arrow three times and then push EN-
TER.
– Push the up arrow two times and then push EN-
TER.
– Push the up arrow one time and then push EN-
TER.
If you push the up arrow too many times, use the down
arrow to make the necessary corrections before you
push ENTER.
4. Push the down arrow to go to the UTILITIES menu.
5. Push ENTER to go into the UTILITIES menu.
U1 PART NUMBERS - This menu contains the part
number for the software in the control modules. This
menu also contains the vehicle part number. The soft-
ware part number identifies the software for the truck.
The software part number contains 11 digits. The first
six digits are the primary part number. This part number
does not change unless there is an important software
revision. The next three digits are changes to the soft-
ware. The changes are usually in relation to truck per-
formance. The last two digits are small changes to the
software code (software version). An example of a typ-
ical software part number is:
150801-001-03
Crown 2011 PF25326-154 Rev. 6/12 TSP 7000 SERIES
ELECTRICAL SYSTEM
ACCESS 1 2 3®
The 03 at the end identifies this file as version 3 soft-
ware.
U1.1 ACCESS 1 - Shows the ACCESS 1 software.
U1.2 ACCESS 2 - Shows the ACCESS 2 software.
U1.3 ACCESS 3 - Shows the ACCESS 3 software.
U1.4 ACCESS 4 - Shows the ACCESS 4 software.
U1.5 ACCESS 5 - Shows the ACCESS 5 software.
U1.6 ACCESS 6 - Shows the ACCESS 6 software.
U1.7 ACCESS 7 - Shows the ACCESS 7 software.
U1.8 ACCESS 8 - Shows the ACCESS 8 software.
U1.9 VEHICLE - The software files are in a vehicle
code folder, which has an 11 digit part number. The last
two digits are the software version.
Note: The U2 ACTIVATE TOW MODE menu shows in
LEVEL 3, but none of the truck functions operate and
the traction motor brake does not release.
U2 ACTIVATE TOW MODE - In LEVEL 2, this menu
releases the traction motor brake to push or pull the
truck.
U2.1 TOW MODE
TOW MODE ACTIVATED
KEY DOWN TO REMOVE - When ACCESS 1 shows
this message, tow mode is ON, and truck travel is not
available. The up and down arrows do not operate until
you turn the truck OFF and ON. When tow mode is ON,
follow these procedures:
• You must be on the operator seat.
• You must operate a minimum of two of the three
foot presence switch pedals.
• A hand must be on the right multi-task control han-
dle before the traction motor brake releases.
Note: You can set the U3 SHIPPING MODE menu in
LEVEL 2 and LEVEL 3.
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ELECTRICAL SYSTEM
ACCESS 1 2 3®

U3 SHIPPING MODE - When you turn the truck ON,

the Access 1 2 3® system does a self-test. During the
self-test, the eight control modules speak with each
other through a controller area network (CAN). If one or
more of the control modules do not speak with the oth-
ers, event codes occur and some truck functions are
not available. The control modules also look for feed-
back from the components that they control. If there is
no feedback, event codes occur and some truck func-
tions are not available. This menu lets you safely move
the power unit and mast and platform assembly to an
area where the remaining components are installed.
1 ENABLE SHIP MODE
 SELECT ↓ NEXT ↑ PREV
KEY DOWN TO ENABLE - Turn the truck OFF, then
turn the truck ON in LEVEL 1. ACCESS 1 shows the
message SHIPPING MODE ACTIVE.
Note: To set the 2 DISABLE SHIP MODE menu, turn
the truck ON in LEVEL 2 or LEVEL 3.
2 DISABLE SHIP MODE
 SELECT ↓ NEXT ↑ PREV
KEY DOWN TO DISABLE - Turn the truck OFF and
ON.
U3.99 ESCAPE - goes out of the U3 SHIPPING MODE
menu.
Note: You can set the U4 TRUCK LOCKOUT menu in
LEVEL 2 and LEVEL 3.
U4 TRUCK LOCKOUT - Electrically locks out all truck
functions.
1 ENABLE LOCKOUT
 SELECT ↓ NEXT ↑ PREV
KEY DOWN TO ENABLE - Turn the truck OFF, then
turn the truck ON in LEVEL 1. ACCESS 1 shows the
message:
TRUCK LOCKOUT
ACTIVATED
CONTACT SUPERVISOR
Note: To set the 2 DISABLE LOCKOUT menu, turn the
truck ON in LEVEL 2 or LEVEL 3.
2 DISABLE LOCKOUT
 SELECT ↓ NEXT ↑ PREV
KEY DOWN TO DISABLE - Turn the truck OFF and
ON.
U4.99 ESCAPE - goes out of the U4 TRUCK LOCK-
OUT menu.
U99 ESCAPE - goes out of the UTILITIES menu.

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 ELECTRICAL SYSTEM
GUIDANCE SYSTEM

Guidance System
Operation of the Wire Guidance
System
General Operation
The wire guidance system steers the truck in an aisle
without guide rails. A guide wire is installed in the floor
in the center of each aisle. A line driver supplies a sig-
nal at a constant frequency of 5.2 kHz, 6.25 kHz,
7.0 kHz, or 10 kHz. The wire transmits the signal. Refer
to Figure 27164.

Figure 27164
1 Line Driver
2 Storage Racks
3 Wire in Floor
4 Transmitted Signal
5 Floor
6 Epoxy

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345
ELECTRICAL SYSTEM
GUIDANCE SYSTEM
The sensor bars are installed at the center of each end
of the truck near the floor. Each sensor bar contains
four coils. Each of the coils operates as an antenna.
The coils receive the signal transmission from the wire
in the floor. The nearer a coil is to the wire, the higher
the intensity of the signal it receives. The ACCESS 5
(steer control module) compares the intensity of the
signals to sense the location of the truck as compared
to the wire. When the wire guidance switch (GUS) is
set to ON, ACCESS 5 uses the data from the coils to
supply the correct voltage to the steer motor (M3) to
keep the truck in the center of the aisle. Feedback from
the steering feedback encoder (ECR6) makes sure
that the drive tire (drive wheel) turns in the applicable
direction. Refer to Figure 12991-02.
Figure 27165
1 Drive Wheel Sensor Bar
2 Load Wheel Sensor Bar
3 Maximum angle at which the truck comes to the guide wire
is 30 degrees
When the truck is on the wire guidance system, some
conditions can cause the truck to automatically de-
crease the speed:
• The truck receives a low signal intensity from the
wire.
• The truck goes a small distance from the wire.
• The End of Aisle Control (EAC) (Optional) is on.
When the truck is on the wire guidance system, some
conditions can cause the truck to automatically stop:
• The signal intensity from the wire is missing or is too
low.
M4.3-1970-501 TSP 7000 SERIES
346
• The angle at which the truck comes to the wire is
more than 30 degrees.
• The truck goes too far from the wire.
• The End of Aisle Control (EAC) (Optional) is on.
Align the truck to the wire guidance system.
Refer to Figure 27165.
To align a truck to the wire guidance signal, set the wire
guidance switch (GUS) to the automatic position.
• The angle at which the truck comes to the guide
wire cannot be more than 30 degrees.
• The traction speed must be less than 2.4 km/h
(1.5 mph).
• If the angle at which the truck comes to the guide
wire is more than 30 degrees, the truck automati-
cally applies the brakes to stop the truck.
• If the speed is more than 2.4 km/h (1.5 mph), the
truck decreases the speed to 2.4 km/h (1.5 mph)
until the truck aligns with the wire. After the truck
aligns with the wire, the system removes the
2.4 km/h (1.5 mph) speed limit and applies the ap-
plicable speed limit for the speed to height.
Steer Modes
The wire guidance switch (GUS) is on the RH armrest.
This switch lets the operator set the steering of the
truck to the manual or automatic mode.
Manual
When you set GUS to the manual position, the operator
controls the steering of the truck. The manual mode in-
dicator light is ON.
Automatic
When you set GUS to the automatic position, the oper-
ator continues to control the truck steering until the
truck receives the signal from the wire guidance sys-
tem. The truck decreases the speed to 2.4 km/h
(1.5 mph). The manual mode indicator and the auto-
matic mode indicator stay ON.
When a sensor bar receives the transmission signal
from the guide wire, the display changes to AUTO AC-
QUISITION mode and the alarm will operate for one
second.
– If the angle at which the truck comes to the guide
wire is more than 30 degrees, the truck automat-
ically applies the brakes to stop the truck. To re-
lease the brakes, set GUS to the manual position.
– If the angle of the truck to the wire is in the correct
position, the manual mode indicator goes OFF.
The wire guidance system controls the truck
Crown 2012 PF25702-2
 ELECTRICAL SYSTEM
GUIDANCE SYSTEM

steering, but the speed limit stays at 2.4 km/h (1.5 • The angle of the truck to the wire guidance signal is
mph). 1 - 1.8 degrees.
When the truck moves in either direction, the wire guid- • The drive tire (drive wheel) angle is 6 - 12 degrees
ance system aligns the truck when all of the parame- from the center.
ters that follow are correct: – When the truck goes into AUTO TRACK DEVIA-
• The truck is less than 19 mm from the wire. TION, the alarm pulsates and truck speed limit is
• The truck angle is less than one degree. 2.4 km/h.
• The drive tire (drive wheel) is less than 6 degrees – When the truck goes back to the correct condi-
from center. tions, the alarm stops pulsating and it operates
for two seconds to tell that the automatic mode is
When the truck is correctly aligned, the alarm operates
on. The speed limit goes back to the applicable
for two seconds. The automatic mode is on and the
speed to height curve.
truck is automatically steered by the wire guidance sys-
tem. The system removes the 2.4 km/h (1.5 mph)
speed limit and applies the applicable speed limit for
the speed to height.
If the wire guidance signal decreases near the mini-
mum intensity that is necessary to steer the truck, the
items that follow occur:
• The signal intensity indicator on the display comes
ON (Signal).
• The truck speed decreases to 2.4 km/h (1.5 mph)
maximum.
If the wire guidance signal is missing or is below the
minimum intensity that is necessary to steer the truck,
the items that follow occur:
• The alarm operates.
• The system applies the brake to stop the truck.
• The system changes to manual mode.
• The automatic indicator goes OFF and the manual
indicator comes ON.
• To release the brake, move GUS to the manual po-
sition.
AUTO FIELD STRENGTH - This condition occurs
when the sensor bars receive a wire guidance signal
that is near the minimum that is necessary to continue
automatic mode.
– When the truck goes into AUTO FIELD
STRENGTH, the alarm pulsates, the field
strength indicator comes ON, and the truck
speed limit is 2.4 km/h.
– When the wire guidance signal goes above the
minimum levels, the alarm stops pulsating, the
field strength indicator goes OFF, and the speed
limit goes back to applicable speed to height
curve.
AUTO TRACK DEVIATION - This condition occurs
when one of the conditions that follow occurs:
• The center of the truck moves from the guidance
signal by 19 - 38 mm.

Crown 2012 PF25702-3 TSP 7000 SERIES M4.3-1970-502

347
ELECTRICAL SYSTEM
GUIDANCE SYSTEM

AUTO WIRE LOST - This condition occurs if one or

more of the situations that follow occur:
• The wire guidance signal is missing.
• The center of the truck moves from the guidance
signal by more than 38 mm.
• The angle of the truck to the wire guidance signal is
more than 1.8 degrees.
• The drive tire (drive wheel) angle is more than 12
degrees from the center. The system lets the truck
degree change more than 12 degrees immediately
after a change of direction.
– When the truck goes into AUTO WIRE LOST, the
alarm operates continuously and the system ap-
plies the brake to stop the truck. You must set the Figure 27166
GUS to the manual position to release the 1 Sensor bar
brakes.
2 Center of the truck
3 82–86 mm (3.25–3.38 in)
Sensors
4 Floor
Refer to Figure 27166.
5 Guide wire
The sensor bars are attached to adjustable brackets
6 Adjustable brackets
which let you adjust the distance between the sensor
bars and the floor. Line Driver Output
• When the output of the line driver is set to 220 mA,
Before you align the truck, make sure that the signal
the sensor bar must be 82 - 86 mm from the floor.
intensity of the line driver is correct. Use the Crown
The sensor bar must be level.
field strength meter (112953) to set up or to do a test of
• The voltage must be 5 V, between terminals 5 (pos- the intensity of the guide wire signal. Crown recom-
itive) and 3 (negative). mends the calibration of the field strength meter annu-
ally. Speak to Crown for instructions on the calibration
of the field strength meter.

Figure 27167

M4.3-1970-503 TSP 7000 SERIES Crown 2012 PF25702-4

348
 ELECTRICAL SYSTEM
GUIDANCE SYSTEM

The field strength meter shows the peak to peak volt- 1 Line Driver
age of the signal from the guide wire in the floor. This
2 Storage Racks
value is the same that the sensors receive when they
are set at the recommended height from the floor. Re- 3 Wire in Floor
fer to the Field Strength Cross-Reference chart for the 4 Transmitted Signal
best field strength values. 5 Floor
6 Epoxy
Field Strength Cross-Reference Chart

Frequency Field Strength Value

6.25 kHz 168-190
5.2 kHz 100-118
7.0 kHz 168-190
10.0 kHz 100-120

Figure 27164

Crown 2012 PF25702-5 TSP 7000 SERIES M4.3-1970-504

349
ELECTRICAL SYSTEM
GUIDANCE SYSTEM
The Crown line driver has a current meter which accu-
rately shows the current in the guidance wire. But, the
meter on the line driver, may not be the correct field
strength of the signal because the floor conditions that
follow:
• Wire depth
• Metal reinforcement material in the area
• Electrical conduit.
Adjust the line driver output to increase the field
strength to correctly steer the truck. Refer to the Instal-
lation of Wire Guidance Line Driver Instructions,
PF6669.
Calibration
At installation, it is important to calibrate the truck at the
highest field strength value. If you calibrate the truck on
a wire at the lowest field strength value, the truck can
weave more on a wire with a higher field strength. The
components that follow can have an effect on the wire
guidance calibration:
• The front and rear sensor bars
• ACCESS 6 (guidance control module)
• ACCESS 5 (steer control module)
• The steer angle feedback encoder (ECR6).
CAUTION
When you change or adjust one or more of these com-
ponents, you must calibrate the wire guidance system.
The wire guidance calibration has four steps:
1. The peak sensor coil search finds the maximum
coil value of each coil when is goes above a guide
wire. The system compares the maximum values
and makes an electronic correction for weak coils.
When you do the peak sensor coil search, the two
sensor bars must move fully across the guide wire.
2. The drive tire (drive wheel) position finds the center
position of the drive tire (drive wheel) to supply
straight line travel.
3. The truck angle calibration finds the angular devia-
tion of the truck which causes the truck to move at
an angle.
4. The X-offset position calibration puts the mechani-
cal center of the truck above the guidance signal.
To complete the procedures for wire guidance calibra-
tion, do the instructions on ACCESS 1 Calibration
Menu. You can only access the wire guidance calibra-
tion in the "one-button" mode.
M4.3-1970-505 TSP 7000 SERIES
350
Troubleshooting
The software on the truck does tests on the compo-
nents of the wire guidance system. Refer to the In-
foPoint® Quick Reference Guide - Event Codes 631
thru 639 for all troubleshooting and diagnostics.
Two conditions could cause the unsatisfactory perfor-
mance of the wire guidance system.
1. Incorrect feedback data from the steering feedback
encoder (ECR6) encoder can occur in two situa-
tions:
– The drive tire (drive wheel) moves but it does not
turn the encoder input shaft.
– The steering feedback encoder (ECR6) is not
aligned correctly.
2. The sensor bar coils are saturated.
Sensor Bar Saturation
To do a check of the sensor bar coils complete the
steps that follow:
1. Move the truck to put the center of the truck is
above the guidance wire in the floor.
2. Use the ACCESS 1 ANALYZER MENU to see the
scaled values. Go to A2.4.5.2 GS1 SCALED. The
display shows the scaled values for the coils in the
drive tire (drive wheel) sensor bar. Use A2.4.6.2
GS2 SCALED to see the scaled values for the coils
in the load wheel sensor bar.
– The outboard sensor scaled values will be lower
than the inboard sensor scaled values, because
the outboard sensors are farther from the guide
wire than the inboard sensors.
3. Move the truck above the guide wire at an angle
less than five degrees.
4. Record the maximum scaled value of each coil as
it is directly above the guide wire.
– If the coils are saturated (i.e. values of 99%), then
calibrate the wire guidance system.
– If the maximum scaled values for the four coils
have more than 10% difference, then calibrate
the wire guidance system.
– When you do the peak sensor coil search, the
two sensor bars must move fully across the guide
wire.
– Make sure that the sensor bar height and line in-
tensity is correct, as measured with a field
strength meter (112953). Refer to Electrical >
Line Driver Output.
Crown 2012 PF25702-6

End Aisle Control (EAC)
EAC Operation
The End Aisle Control (EAC) system tells the operator
that the end or intersection of an aisle is near. This sys-
tem uses magnets in the floor at the ends and intersec-
tions of the aisles. When the magnetic sensors on the
truck sense the magnets in the floor, the sensors send
a signal to Access 1 2 3®. The Access 1 2 3® system
decreases the speed or stops the truck.
ACCESS 1 shows a message when the truck is in an
EAC zone:
• Zone 1 - Out of Aisle or Entering Aisle
• Zone 2 - Center of Magnets
• Zone 3 - Out of Aisle or Exiting Aisle
End Aisle Control has three modes of operation:
• The Manual Guide mode operates when the truck is
not in rail or wire guidance mode. Manual steer and
traction commands control the traction speed.
Fig. 203 (21241-01)
1 Manual Override Switch (ORS1)
2 End Aisle Sensors Reverse Direction (Power Unit First)
3 Front Bumper
4 End Aisle Sensors Forward Direction (Forks First)
Crown 2012 PF25716-1
ELECTRICAL SYSTEM
END AISLE CONTROL (EAC)
• The Auto Guide mode operates when the truck is in
rail or wire guidance mode. The system applies the
applicable speed limit for the speed to height.
• The End of Aisle, Auto Guide mode operates when
the truck is in rail or wire guidance mode and the
system senses the magnets near the end of an
aisle.
Use FEATURES MENU > F20 END AISLE to set EAC.
Use PERFORMANCE MENU > P10 EAC SETUP to
set the EAC features (speed, stop distance, auto-re-
sume, etc). Refer to ELECTRICAL > Access 1 2 3® for
more information.
EAC in Wire Guidance Calibration
Use CALIBRATION MENU > C5 WIRE GUIDE to cali-
brate the truck. Refer to ELECTRICAL >
Access 1 2 3® for more information.
• When you do a calibration for which GUS is in the
manual position, EAC is OFF. The speed limit is set
to maximum or 2.4 km/h.
• When you do a calibration for which GUS is in the
automatic position, EAC is ON. The EAC system
controls the speed limit.
TSP 7000 SERIES M4.3-1970-600
351
ELECTRICAL SYSTEM
END AISLE CONTROL (EAC)

EAC Components
Refer to Figure 203.
The EAC system includes the components that follow:
• A bumper with four sensors (A1, A2, B1, and B2)
• The EAC distribution board
• ACCESS 5
• ACCESS 6
• An override switch (ORS1) in the LH armrest.

Sensors
Different sensors are necessary in relation to the loca-
tion of the truck. Use red sensors, which are standard,
for trucks in the northern hemisphere. Use blue sen-
Fig. 204 (21242-01)
sors, for trucks in the southern hemisphere. Use FEA-
1 CA610 goes to B2
TURES MENU > F20 END AISLE to set the EAC for
the correct truck location. 2 CA609 goes to A2
3 CA608 goes to ACCESS 6, CA602 pins 1-2
Sensors A1 and B1 operate in the forward (forks lead-
ing) direction. Sensors A2 and B2 operate in the re- 4 CA607 goes to ACCESS 6, CA602 pins 3-4
verse (forks trailing) direction. 5 CA606 goes to A1
6 CA605 goes to B1
Sensor Installation
Four sensors are in the front bumper on the mainframe.
For standard operation, install the A1 and A2 sensors
200 mm from the centerline of the truck. Install the B1
and B2 sensors 305 mm from the centerline of the
truck.
In special operations you can install the A1 and A2 sen-
sors more than 200 mm from the centerline of the
truck. But, the B1 and B2 sensors must be a minimum
of 100 mm from the A sensors.
In all situations, the height from the floor to the sensors
must be 18 to 25 mm.

EAC Distribution Board

Refer to Figure 204.
The EAC distribution board is in the center of the front
bumper on the mainframe. The EAC distribution board
connects the EAC components. The signals from the
sensors and EAC distribution board go to CA602, pins
1 through 14 on wire guidance module.

M4.3-1970-601 TSP 7000 SERIES Crown 2012 PF25716-2

352
 ELECTRICAL SYSTEM
END AISLE CONTROL (EAC)

Troubleshooting
ACCESS 6 (Wire Guidance Module) - CA602 Make sure that the sensor installation is correct. Refer
Pins 1 - 14 to Electrical > End Aisle Control (EAC) > EAC Compo-
nents > Sensors > Sensor Installation.
CA602-1 +12 V EAC Sensor Power
The Access 1 2 3 system monitors the EAC compo-
CA602-2 EAC Sensor Battery Negative nents. An event code usually occurs if there is an issue
CA602-3 EAC A1 Test Approximately 7 V In Test with the EAC system. Refer to Electrical > Event Codes
Mode for more information.
Use the Analyzer Menu - A2.4.7 EAC to see the status
CA602-4 EAC A1 Analog 0 - 5 V When Over Magnet
of each sensor. Refer to Electrical > Access 1 2 3 ® for
CA602-5 EAC A1 Digital 0 V When Sensing Magnet more information.
5 V When Not Sensing Magnet
CA602-6 EAC A2 Test Approximately 7 V In Test
Mode
CA602-7 EAC A2 Analog 0 - 5 V When Over Magnet
CA602-8 EAC A2 Digital 0 V When Sensing Magnet
5 V When Not Sensing Magnet
CA602-9 EAC A2 Analog 0 - 5 V When Over Magnet
CA602-10 EAC B1 Analog 0 - 5 V When Over Magnet
CA602-11 EAC B1 Digital 0 V When Sensing Magnet
5 V When Not Sensing Magnet
CA602-12 EAC B2 Test Approximately 7 V In Test
Mode
CA602-13 EAC B2 Analog 0 - 5 V When Over Magnet
CA602-14 EAC B2 Digital 0 V When Sensing Magnet
5 V When Not Sensing Magnet
EAC Pin 1 0 V When Sensing Magnet
Sensor 5 V When Not Sensing Magnet
EAC Pin 2 Battery Negative
Sensor
EAC Pin 3 0 V When Not In Selftest
Sensor Approximately 7 V For Several
Milliseconds In Self-Test
EAC Pin 4 0 - 5 V When Over Magnet
Sensor
EAC Pin 5 +12 V
Sensor

Crown 2012 PF25716-3 TSP 7000 SERIES M4.3-1970-602

353
ELECTRICAL SYSTEM
CONTACTORS

Contactors
Emergency Disconnect Contactor
(ED1)
Inspection
Use the information below to help when you do main-
tenance on the truck and to provide checks to help you
keep the truck operating satisfactorily.

Contacts
• Replace the contacts before the silver surface on
the contact fully erodes through to the backing ma-
terial.
• Contacts must always be replaced in mating pairs.

Fig. 205 (21243)

Coil
• Remove all electrical connections.
Note: The truck must be at room temperature before
you measure the coil resistance. The heat from the op-
eration of the coil can change the resistance measure-
ment on the coil.
• The resistance measurement of the coil must be 54
Ω ± 15%.
• If the measurement does not fall in the acceptable
range, replace the coil.
• Coil voltage is 36 or 48 V.
• A coil suppression diode is installed across the con-
tactor coil to decrease the noise in the coil.

M4.4-1970-001 TSP 7000 SERIES Crown 2012 PF25719-1

354
 ELECTRICAL SYSTEM
CONTACTORS

Contact Replacement 4. Put the chocks against the tires to prevent the
movement of the truck.
Refer to Figure 206
5. Disconnect the battery.
6. Wait two minutes after you disconnect the battery
2 for the capacitors to release.
(a) 7. Lockout/tagout the truck. Refer to SAFETY > Con-
0

trol of Hazardous Energy > Lockout/Tagout.

1
3 Remove the contactor
8. Open the top cover on the power unit.
1
9. Remove the rear door on the power unit.
10. Disconnect all electrical connections to the contac-
tor.
4
11. Remove the two screws that hold the contactor
bracket on the base plate. Save the screws.
12. Remove the contactor and bracket from the truck.
(a)
Replace the contacts
0

1 7 13. Remove the two screws (2) and washers (3) from
the cover (4).
14. Remove the cover (4) and attached fixed contacts
8
(1) from the contactor.
15. Put the spring (7), retainer (8), washer (9), and
5
spacer (10) to the side.
6 16. Discard the used moving contact (6).
17. Remove the two fixed contacts (1) from the cover
(4). Save the hardware and discard the used con-
9
tacts.
10 18. Install two new fixed contacts in the cap and use
the hardware that you saved in step 14. Torque to
13.4–14.6 Nm.
19. Install the washer (9) and spacer (10) on the new
moving contact (6).
11
20. Install the moving contact (6), washer (9), and
spacer (10) on the coil (11).
21. Install the spring (7) and retainer (8) on the moving
contact (6).
22. Install the cover (4) and attached fixed contacts (1)
12 on the moving contact assembly (5).
23. Install the two screws (2) and washers (3) and
Fig. 206 (21245-01) tighten the screws.
(a) Torque to 13.4–14.6 Nm (9.9–10.8 ft lb)
Install the contactor
Prepare the truck 24. Install the contactor and bracket on the base plate.
1. Move the truck to a maintenance area with a level 25. Install the two screws that you removed in step 11
floor. to hold the bracket on the base plate.
2. Fully lower the platform and forks. 26. Attach the electrical connections to the contacts (1)
3. Turn the truck OFF. and the coil (11).

Crown 2012 PF25719-2 TSP 7000 SERIES M4.4-1970-002

355
ELECTRICAL SYSTEM
CONTACTORS

Prepare the truck for operation 21. Install the cover (4) and attached fixed contacts (1)
27. Install the rear door on the power unit. on the moving contact assembly (5).
28. Close the top cover on the power unit. 22. Install the two screws (2) and washers (3) and
tighten the screws.
29. Connect the battery.
30. Remove the chocks. Install the contactor
31. Turn the truck ON. 23. Install the contactor and bracket on the base plate.
32. Make sure that the truck operates correctly. 24. Install the two screws that you removed in step 11
to hold the bracket on the base plate.
Coil Replacement 25. Attach the electrical connections to the contacts (1)
Refer to Figure 206 and the coil (11).

Prepare the truck Prepare the truck for operation

1. Move the truck to a maintenance area with a level 26. Install the rear door on the power unit.
floor. 27. Close the top cover on the power unit.
2. Fully lower the platform and forks. 28. Connect the battery.
3. Turn the truck OFF. 29. Remove the chocks.
4. Put the chocks against the tires to prevent the 30. Turn the truck ON.
movement of the truck. 31. Make sure that the truck operates correctly.
5. Disconnect the battery.
6. Wait two minutes after you disconnect the battery
Logic Power Contactors (K2 & K3)
for the capacitors to release. K2 and K3 supply power to the control modules. The
7. Lockout/tagout the truck. Refer to SAFETY > Con- coil voltage is 48 V DC. The coil resistance is 325 Ω ±
trol of Hazardous Energy > Lockout/Tagout. 15%. There is a coil suppression diode across the con-
tactor coil to decrease noise in the coil. This contactor
Remove the contactor
is non-repairable. Replace the contactor if it does not
8. Open the top cover on the power unit. operate correctly.
9. Remove the rear door on the power unit.
10. Disconnect all electrical connections to the contac-
tor.
11. Remove the two screws that hold the contactor
bracket to the base plate. Save the screws.
12. Remove the contactor and bracket from the truck.
Replace the coil
13. Remove the two screws (2) and washers (3) from
the cover (4).
14. Remove the cover (4) and attached fixed contacts
(1) from the contactor.
15. Remove the moving contact assembly (5) from the
coil (11).
16. Remove the two screws that hold the coil on the
bracket.
17. Discard the used coil.
18. Install the new coil on the bracket.
19. Install the two screws that hold the coil on the
bracket.
20. Install the moving contact assembly (5) on the coil
(11).

M4.4-1970-003 TSP 7000 SERIES Crown 2012 PF25719-3

356
 ELECTRICAL SYSTEM
BATTERY

Battery

WARNING
The battery gases can be explosive.
An injury or death could occur.
 Do not smoke, use an open flame, or make an arc
or sparks around the battery. 1
 Make sure that the airflow is good in an area when
you charge the battery.

CAUTION
The battery contains sulfuric acid.
Sulfuric acid could cause burns.
 Do not let the sulfuric acid touch the eyes, skin, or
clothing.
 If the sulfuric acid touches you, flush the area im-
mediately and fully with clean water and get medi-
cal aid.
The battery for your Turret Stockpicker is in the power
unit between the mast and drive unit. To get access to
the top of the battery, lift the top tray (1) on the power
unit. To remove the battery, you must remove the bat-
tery cover (2) and retainer (3) from the left side of truck.
Refer to Figure 207.
2 3
Fig. 207 (21262-01)
The maintenance of the battery is important for satis-
factory truck operation and maximum battery life.
The leakage voltage from the battery terminals to the
battery could cause some incorrect symptoms with the
truck electrical system. The leakage voltage does not
have an effect on truck operation unless a short circuit
occurs, or there is bad circuit wire insulation to the truck
frame. This is because the components of the truck
electrical system are isolated from the truck frame.
A voltage check from the battery connector terminal to
the battery must be less than 50% +BV. If the voltage
check for leakage voltage is more than 50% +BV, the
leakage voltage drains the battery. As the battery be-
comes dirty, the battery charge decreases because of
the leakage voltage drain. A clean battery has more of
a battery charge for truck operation and does not have
an effect on the operation of electronic devices.

Crown 2005 PF15108-1 Rev. 6/12 TSP 7000 SERIES M4.6-1960-001

02 Rev. 6/12
357
ELECTRICAL SYSTEM
BATTERY
CAUTION
Only approved personnel must do maintenance
and repair on batteries.
• The truck, tools, and mechanisms could be dam-
aged.
• Do not do maintenance on the truck if you do not
know it.
Safety Procedures
• Wear protective items when you clean or repair the
batteries.
• Do not let the battery acid touch the eyes, skin,
clothing, or floor. If the battery acid touches the
eyes, you must flush them immediately with distilled
water and get medical aid immediately.
• If the battery acid touches the skin, you must clean
it immediately with distilled water and soap.
• If you spill the battery acid on the floor or on a dif-
ferent surface, use a Battery Spill Kit (300035) to
make the battery acid neutral and clean it up. Fol-
low the manufacturer directions to use the kit.
• Keep the vent plugs tightly in position at all times,
but not when you add distilled water or use a hy-
drometer.
• Do not let flames or sparks near the battery. Gas
made while the battery charges is very explosive.
This gas stays in the cells after you charge the bat-
tery.
• Do not put metal or conductive objects on the bat-
tery because they can cause a short circuit.
• Do not let contamination, solution, or other un-
wanted material into the cells. The contamination
makes the battery acid neutral and lowers the avail-
able battery charge.
• If you must repair the battery, follow the battery
manufacturer instructions for the applicable repair
procedures.
Battery Inspection
• Monitor the level of battery acid before you charge
the battery.
• Keep the level of battery acid at 13 mm above the
element protector. If the level of battery acid is low,
add some distilled water or an approved local sup-
ply (consult the battery manufacturer) at after you
fully charge the battery. Do not add too much water.
• For maximum battery life, monitor and record the
specific gravity daily on a cell.
M4.6-1960-002 TSP 7000 SERIES
02 Rev. 6/12
358
• Monitor a different cell monthly and record the spe-
cific gravity on all cells one or two times a year. Do
not record the specific gravity immediately after you
add the distilled water.
• Charge the battery to fully mix the distilled water
and battery acid before you record the specific
gravity. The specific gravity (at full charge) must be
between 1.280 and 1.320.
Battery Charging
Before you charge the battery, follow these proce-
dures:
• Charge the battery only in areas for that use.
• Make sure that the battery charger you use agrees
with the voltage and amperage of the truck battery.
This voltage is on the truck data plate.
• Before you connect or disconnect a battery to a bat-
tery charger, make sure that the battery charger is
OFF. If you do this and the battery charger is ON,
an injury could occur to you, the battery, and the
battery charger.
• Before you charge the battery, make sure that the
cells contain the correct quantity of distilled water. A
low level of water could do damage to the cells.
When you examine the water levels, do not use ex-
plosive materials (for example, a lighter). The bat-
tery fumes are explosive.
• Before you connect the battery cable to the connec-
tor, turn the truck OFF, apply the brake, and make
sure that all controls are in the OFF position. You
must fully connect the battery cable before you op-
erate the truck. If the connection is not tight, heat
welds the two parts of the battery connector to-
gether, which makes it hard to remove and neces-
sary to replace.
• You must examine and clean the corrosion from the
battery terminals regularly. A good battery terminal
connection is necessary not only for operation, but
also to charge the battery. Clean the battery termi-
nals with the Battery Terminal Cleaner (363124).
Seal the battery terminals with the Battery Terminal
Protector (363125).
• You must keep the battery cover closed, but not
when you charge the battery.
• How you use the truck changes the battery charge
requirements. You must give the battery an equaliz-
ing charge weekly (if applicable, set the battery
charger to the equalizing charge mode).
Crown 2005 PF15108-2 Rev. 6/12
 ELECTRICAL SYSTEM
BATTERY

• Make sure that the battery you use agrees with the
weight, dimension, amperage, and voltage specifi-
cations of the truck (refer to the data plate). Do not
operate a truck without the correct battery.
• Refer to the battery charger manual for more data
on procedures, operation, and maintenance.
4. Make daily battery checks and add distilled water
when it is necessary.
5. Connect the battery to the battery connector and
make sure that the connections are tight.
6. Install the retainer and battery cover on the left side
of truck.

CAUTION
Make sure that the battery charger is connected to
the battery and not the truck.
The wire guidance system could be damaged.
• Connect the battery to the battery charger.

How to Charge the Battery

1. Move the truck to a maintenance area with a bat-
tery charger and a level floor.
2. Lower the platform and forks fully.
3. Turn the truck OFF.
4. Disconnect the battery.
5. Put the chocks against the wheels to prevent the
movement of the truck.
6. Lockout/Tagout the truck. Refer to the SAFETY >
Control of Hazardous Energy > Lockout/Tagout
section.
7. Remove the battery cover and retainer from the left
side of truck.
8. Turn the battery charger control to the OFF posi-
tion.
9. Connect the battery to the battery charger and
make sure that the connections are tight.
10. Set the timer for a specified time.
11. Make sure that the ammeter shows a charge. A
fully charged battery must read between 2.1 and
2.3 V for each cell. If all the cells are less than
2.1 V, the battery could be defective. There cannot
be a difference of more than ± 0.03 V in the cell
voltages. If the difference is more than 0.03 V, the
cell could be defective.

How to Remove the Battery from the Bat-

tery Charger
1. Make sure that the battery charger is OFF.
2. Disconnect the connector.
3. Stow the battery charger cable to prevent damage
(broken connectors could cause defective connec-
tors and connections).

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ELECTRICAL SYSTEM
BATTERY

Battery Removal 8. Put the battery roller stand adjacent to the truck.
Make sure that the battery roller stand aligns with
the battery.
CAUTION 9. Make sure that the battery roller stand is the same
height as the battery, and is the same length as the
Do not let an object made of metal touch the top of
battery. Move the battery onto the battery roller
the battery cells.
stand.
This could cause a short circuit when you remove or
10. Lift or move the battery to the applicable area.
move the battery.
11. Examine the battery rollers and replace the worn or
 Use an insulator (such as plywood) as a cover on
damaged battery rollers.
the top of the battery before and during removal and
installation. 12. Install the retainer and battery cover on the left side
of truck.

Battery Installation
CAUTION
CAUTION
Do not move the battery from the truck without a
battery roller stand in position. Make sure that you install the same battery or a
An injury could occur. battery of equal weight in the truck.
If you install a smaller battery, the truck will not be sta-
 Make sure that the battery roller stand is in position
ble.
before you move the battery.
 Refer to the data plate for the minimum battery
weight.

1. Make sure that the key switch is in the OFF posi-

tion.
2. Put the chocks against the wheels to prevent the
movement of the truck.
3. Remove the battery cover and retainer from the left
side of truck.
4. Put the battery roller stand adjacent to the truck.
Make sure that the battery roller stand aligns with
the battery compartment.
5. Make sure that the battery roller stand is the same
height as the battery, and is the same length as the
battery. Move the battery from the battery roller
Fig. 208 (8251) stand and into the battery compartment.
6. Connect the battery.
1. Move the truck to a maintenance area with a level
floor. 7. Install the retainer and battery cover on the left side
of truck.
2. Lower the platform and forks fully.
3. Turn the truck OFF.
4. Disconnect the battery.
5. Put the chocks against the wheels to prevent the
movement of the truck.
6. Lockout/Tagout the truck. Refer to the SAFETY >
Control of Hazardous Energy > Lockout/Tagout
section.
7. Remove the battery cover and retainer from the left
side of truck.

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 ELECTRICAL SYSTEM
BATTERY

Battery Load Test

Although the battery charges fully, and the battery acid
and specific gravity levels are good, you must repair or
replace a battery at some point. The battery has ap-
proximately 300 charge cycles for each year (you can
charge and use the battery almost 2000 times). The
best procedure to see if you must repair or replace a
battery is to do a battery load test. To do a battery load
test:
1. Connect a fully charged battery to the truck.
2. Connect a digital volt-ohm multimeter (DVOM)
across the positive and negative terminals of the
battery.
3. Turn the truck ON.
4. Fully raise the forks. Momentarily raise the forks
again.
5. Read the voltage on the DVOM. The battery must
not decrease more than 0.5 V a cell. A 48 V battery has
24 cells. If the voltage drops more than 12 V, you must
repair or replace the battery.
If the battery is in the permitted voltage range, do a test
of the voltage of each cell. Make sure that each cell is
equal. The voltage must not decrease more than 0.5 V
a cell. All cells must read almost the same voltage
when you do a cell load test. If the cell voltage is lower
than the others, there could be a problem with the cell.

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ELECTRICAL SYSTEM
MOTORS

Motors The steer motor is a DC motor that contains four

brushes. Refer to section M6.0 for brush inspection
The TSP 7000 has a traction motor, a hydraulic pump and recommended replacement lengths.
motor, and a steer motor.
The traction motor has an internal encoder (ECR7) to
monitor the speed and position along with an internal
temperature sensor (TS1) to monitor the motor temper-
ature. A feedback splitter (FSB) is external on the trac-
tion motor.
The hydraulic pump motor has an internal encoder
(ECR8) to monitor the pump position and an internal
temperature sensor (TS2) to monitor the motor temper-
ature.

Fig. 209 (26886)

Motor Information Chart

Motor Type Traction Motor Hydraulic Motor Steer Motor

Part Number 149315 149316 149317
Motor Type AC Induction AC Induction DC Permanent Magnet
Voltage 45 V AC 45 V AC 80 V DC
Rated Output
7.3 21.2 0.56
Kw
Direction of Rotation Bi-Directional Bi-Directional Bi-Directional
Motor Diameter
264 264 122
mm
No. of Brushes N/A N/A 4
Internal Sensors ECR7/TS1 ECR8/TS2 N/A

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 ELECTRICAL SYSTEM
EVENT CODE INTRODUCTION

Event Code Introduction Software

CAUTION
If you connect the control connectors when the
truck is ON, the truck could be damaged.
The truck electrical system could be damaged.
 Do not turn the truck ON with the control connectors
disconnected.
 Do not remove or connect the control connectors
while the truck is ON.
CAUTION
When you replace a control module and do an up-
date to the module software, make sure that the ad-
justments are correct.
The truck will not operate correctly.
 Calibrate the truck. Refer to the ELECTRICAL >
Access 1 2 3® > CALIBRATION section.
Troubleshooting Steps
Most malfunctions occur in or at output devices (relays,
contactors, and motors). The next components to ex-
amine are connectors, wires, and input devices
(switches, potentiometers, and encoders). The last
components to examine are the control modules. You
must do a test of the output devices, then the input de-
vices, and then the control module to which these de-
vices attach. When you measure the voltage and
resistance of these components, use a digital volt-ohm
multimeter (DVOM). Make sure that you connect all
components after you complete the event code steps.
To make sure that your truck has the newest
Access 1 2 3® software, do these steps:
1. Turn the truck ON.
2. Use ACCESS 1 go into LEVEL 2: FIELD SERVICE
MODE.
3. Push the up or down arrows to go to the UTILITIES
menu. From there you can see the control module
and software part numbers that are applicable to
your truck.
No Event Code
If the truck malfunctions and no event code shows, the
malfunction is usually not electrical. If you turn the truck
ON, but an event code does not show, the malfunction
is usually mechanical or hydraulic, but not electrical.
The mechanical and hydraulic data is in the applicable
section in this manual.
Component Locations
The component and wire location maps are at locations
on the truck to help you quickly find the location of the
components. All components are clearly identified at
the connection points. Refer to the COMPONENTRY
section for more data on each component.

Malfunctions
When a malfunction occurs, use ACCESS 1 to go into
LEVEL 2: FIELD SERVICE MODE
Note: Your monitor system has three user levels:
LEVEL 1: OPERATOR MODE
LEVEL 2: FIELD SERVICE MODE (Full Truck Opera-
tion)
LEVEL 3: ANALYZER/TEST MODE (No Truck Opera-
tion)
This section includes LEVEL 2 and LEVEL 3 data. For
LEVEL 1 data, refer to the Operator Manual and the
ELECTRICAL > Access 1 2 3® section. For menu data,
refer to the ELECTRICAL > Access 1 2 3® section.

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ELECTRICAL SYSTEM
EVENT CODE INTRODUCTION

Test Points
The test points in the event code descriptions are on
the distribution panel. For an example, refer to
Figure 210. The distribution panel and test point loca-
tions could be different than in Figure 210.

Fig. 210 (24633)

Power Cable Connections

WARNING
A charged capacitor could be dangerous.
Because of capacitance voltage in some control mod-
ules, an injury or damage to the truck could occur.
 When you do the truck maintenance around the bus
bars and related power cables, discharge the ca-
pacitors.
 Refer to the SAFETY > Control of Hazardous En-
ergy > Capacitance section for procedures to dis-
charge the capacitors

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Event Codes
ACCESS Module Listing:
ACCESS 1: Display Control Module (DCM)
ACCESS 2: Hydraulic Control Module (HCM)
ACCESS 3: Traction Control Module (TCM)
ACCESS 4: Vehicle Control Module (VCM)
ACCESS 5: Steering Control Module (SCM)
ACCESS 6: Guidance Control Module (GCM)
ACCESS 7: Accessory Control Module (ACM)
ACCESS 8: Operator Control Module (OCM)
CAUTION
After you change a module or install software make
sure the truck parameters are correct and calibrated as
is necessary.
Locating malfunctions
Malfunctions occur in or at the output components such
as contactors, solenoid valves, and motors. The next
components to examine are the connectors, wires, wire
harnesses, and input devices such as switches, poten-
tiometers or encoders. The last component to think is
the motor control system. Do the troubleshooting pro-
cedure on the output device, continue to the input de-
vices, then, and only then, move on to the ACCESS
module to which these devices attach. Be sure to con-
nect all components disconnected after you complete
the Event Code steps.
CAUTION
The truck’s electrical system could be damaged.
 Do not turn the truck ON with the control connectors
disconnected.
 Do not disconnect or connect the control connec-
tors while the truck is ON.
When a Malfunction Occurs
• Go to the ACCESS 1 and access the Level 2: Ser-
vice Mode as follows.
Note: The trucks event code system can be monitored
at three levels of authorization:
Level 1: Operator Mode
Level 2: Service Mode (Full Truck Operation)
Level 3: Analyzer or Test Mode (No Truck Operation)
Crown 2012 PF25715-1 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODES
This section will supply instruction on the Level 2 and
Level 3 modes. For instruction on the Level 1 mode
refer to the Operators Manual. Refer to the
ACCESS 1 2 3 ® section for more service mode in-
structions.
No Event Code?
When the truck malfunctions and no event code is
shown it usually is an indication that the malfunction is
not electrical.
If the truck turns ON and an event code is not shown, it
is an indication that the malfunction is a mechanical or
hydraulic problem not an electrical problem. Informa-
tion about the mechanical and hydraulic troubleshoot-
ing is in these sections of the Service and Parts
manual.
Locate Malfunctioning Components
Component and wire location maps are installed at
special locations on the truck to help you quickly find
the location of the components.
All components are clearly identified at the connection
points.
Test Points
Test points used in the event code descriptions are
found on the power unit or platform distribution panels.
Power Cable Connections
CAUTION
Risk of injury because of the capacitance voltage
on the motor control panel, when you do mainte-
nance in which you touch the bus bars and related
power cables.
 You must de-energize the capacitor on the traction
control panel.
 Put a minimum of a 100 Ω, 2 W resistor
(062033-030) between the positive (+) and nega-
tive (-) of the capacitor for 15 or more seconds or
disconnect the battery and turn the key to the
START position for 30 seconds. The voltage must
be lowered to less than 1 V. Turn the truck OFF.
M4.8-1970-001
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ELECTRICAL SYSTEM
EVENT CODES

10
3 11
2
1 12

13 14

15

6
8
5 4 16

Fig. 211 (13919-02)

1 DCM - ACCESS 1 Display Control Module 9 ACCESS 1 Display Module (DCM)
2 HCM - ACCESS 2 Hydraulic Control Module 10 Power ON Indicator
3 CM - ACCESS 3 Traction Control Module 11 Display Screen
4 VCM - ACCESS 4 Vehicle Control Module 12 Service Required Indicator
5 SCM - ACCESS 5 Steering Control Module 13 Capacity Data Monitor
6 GCM - ACCESS 6 Guidance Control Module 14 Battery Discharge Indicator
7 ACM - ACCESS 7 Accessory Control Module 15 Enter or Return Key, used to navigate in and out of menus and
to accept inputs
8 OCM - ACCESS 8 Operator Control Module 16 Navigation Keys
• Up Arrow
• Down Arrow
Used to scroll through menus

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 100

Event Code Group 100 • If: The resistance >120 Ω.

– Then replace ACCESS 5.
Event Code 101 • If: The resistance = 60 Ω.
– Then measure the resistance of RES3 in the wire
ACCESS 1 module CAN event.
harness between CA703-1 and CA703-12.
All truck functions do not operate.
• If: RES3 = bad.
Note: No -BV to the modules on the CAN bus will put
– Then replace RES3 or the wire harness.
a load on the bus and decrease the CAN transmis-
sions. Step 5: Measure for a CAN line short circuit to -BV,
+BV, and the truck frame. Disconnect the battery and
Step 1: Turn the truck OFF and examine ACCESS 1
measure the resistance at the power unit from CAN_L
CAN_H wire CA304-4 to CA106-8 and CAN_L wire
to the -BV bus bar. CAN_L to TP8 and TP9 on the
CA304-5 to CA106-2.
power unit distribution panel, and CAN_L to the truck
• If: No wire or connector problems are found and the frame. The resistance must > 10 K Ω.
event code continues.
• If: The resistance ≠ 10 K Ω.
– Then continue to Step 2.
– Then repair or replace the wires.
• If: Wire or a connector problem is found.
– Then repair or replace the wire or connector.
Step 2: Turn the truck ON and measure the voltage to ACCESS1
ACCESS 1 CA304-3 to CA104-3 and CA304-2 to DCM ALM1
CA104-6. CA304
• If: No wire or connector problems are found and the 512 2 BATT NEG
event code continues. 207 3 +BV
027 4 CAN_H
– Then continue to Step 3. 022 5 CAN_L
• If: Wire or a connector problem is found.
– Then repair or replace the wire or connector.
Platform Distribution Panel
Step 3: Measure for -BV to the other modules on the
CA106
CAN bus and that the module indicator lights are ON.
022 2
• If: The module is without power. 027 8
– Then measure for +B and -BV. If one or more are CA104
missing then examine the related wires, connec- 207 3
tor, and fuse. 512 6
Step 4: CAN transmission line test. Turn the truck OFF.
Fig. 212 (27250)
• If: The resistance = 0 Ω.
– Then a short circuit between the CAN_H and
CAN_L. Examine the wires, connectors, and ACCESS 7
fuses. Repair or replace the wires, connectors or ACM
fuses. CA703 (BLK)
RES3
• If: The resistance > 120 Ω. 059 1 CAN_H
058 12 CAN_L
– Then a CAN bus resistor could be open. Discon-
nect CA402 from ACCESS 5 and measure the
resistance between CA402-4 and CA402-5 of Fig. 213 (27251)
ACCESS 5.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 100

Event Code 104 • If: The resistance =120 Ω.

– Then measure the resistance of RES3 in the wire
ACCESS 1 and ACCESS 4 module CAN event. harness between CA703-1 and CA703-12.
All truck functions do not operate. • If: RES3 = bad.
Note: ACCESS 1 CAN bus transmission with – Then replace RES3 or the wire harness.
ACCESS 4 has not occurred in a specified time.
Step 3: Turn the truck OFF and disconnect the battery.
Step 1: Turn the truck ON and look at the status of the Measure the resistance at the power unit from CAN_L
ACCESS 4 LED’s. to the -BV bus bar, CAN_L to TP8, TP9 on the power
• If: The ACCESS 4 LED’s = ON and the event code unit distribution panel, and CAN_L to the truck frame.
continues. The resistance must be > 10 K Ω.
– Then continue to Step 2. • If: The resistance < 10 K Ω.
• If: The ACCESS 4 LED’s = OFF. – Then repair or replace the wires.
– Then measure for +BV between CA314-1 and
CA314-2.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000).
– Then replace ACCESS 4. CA107 FU19 CA101 ACCESS4
3 1 VCM
• If: The voltage = 0 V.
CA103 CA314 (BRN)
– Then examine the wire between CA314-1 and TP9
13 2950 1 +BV IN
CA103-13 and the wire between CA314-2 and 518 2 BATT COMM IN
CA101-1. Examine FU19 on the platform distri-
bution panel and FU7 on the power unit distribu-
tion panel. Repair or replace as is necessary. Fig. 214 (27254)
Step 2: CAN transmission line test. Turn the truck OFF.
Measure the resistance between CAN_H and CAN_L ACCESS 7
the resistance must = 60 Ω. ACM
• If: The resistance = 0 Ω. RES3 CA703 (BLK)
– Then a short circuit between the CAN_H and 059 1 CAN_H
058 12 CAN_L
CAN_L. Examine the wires, connectors, and
fuses. Repair or replace the wires, connectors or
fuses. Fig. 215 (27251)
• If: The resistance > 120 Ω.
– Then a CAN bus resistor could be open. Discon-
nect CA402 from ACCESS 5 and measure the
resistance between CA402-4 and CA402-5 of
ACCESS 5.
• If: The resistance > 120 Ω.
– Then replace ACCESS 5.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 100

Event Code 105 • If: The resistance < 10 K Ω.

– Then repair or replace the wires as is necessary.
ACCESS 1 and ACCESS 5 module CAN event.
All truck functions do not operate. Event Code 106
Note: ACCESS 1 CAN bus transmission with
ACCESS 1 and ACCESS 6 module CAN event.
ACCESS 5 has not occurred in a specified time.
All truck functions are do not operate.
Step 1: Turn the truck ON and look at the status of
ACCESS 5 LED’s. Note: ACCESS 1 CAN bus transmission with
ACCESS 6 has not occurred in a specified time.
• If: The ACCESS 5 LED’s = ON and the event code
continues. Step 1: Turn the truck ON and look at the status of
ACCESS 6 LED’s.
– Then continue to Step 2.
• If: The ACCESS 6 LED’s = ON and the event code
• If: The ACCESS 5 LED’s = OFF.
continues.
– Then measure for +BV between CA403-3 and
– Then continue to Step 2.
CA403-10.
• If: The ACCESS 6 LED’s = OFF.
• If: The voltage = 48 V (TSP 6500) or 72/80 V (TSP
7000). – Then measure for +BV between CA601-1 and
CA601-2.
– Then replace ACCESS 5.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
• If: The voltage = 0 V.
(TSP 7000).
– Then examine the wire between CA403-1 to
– Then replace ACCESS 6.
CA406, the wire between CA403-10 to CA206-9,
and FU8 on the power unit distribution panel. • If: The voltage = 0 V.
Step 2: CAN transmission line test. Turn the truck OFF. – Then examine the wire between CA601-2 and
CA406, the wire between CA601-1 and
Measure the resistance between CAN_H and CAN_L
CA206-11, and FU8 on the power unit distribu-
the resistance must = 60 Ω.
tion panel.
• If: The resistance = 0 Ω.
Step 2: CAN transmission line test. Turn the truck OFF.
– Then a short circuit between CAN_H and
Measure the resistance between CAN_H and CAN_L
CAN_L. Examine the related wires, connections
resistance must = 60 Ω.
and fuses. Repair or replace the wires, connec-
tors or fuses as is necessary. • If: The resistance = 0 Ω.
• If: The resistance > 60 Ω. – Then a short circuit between the CAN_H and
CAN_L. Examine all related wires, connections
– Then a CAN bus resistor could be open. Discon-
and fuses. Repair or replace as is necessary.
nect CA402 from ACCESS 5, measure the resist-
ance between CA402-4 and CA402-5 of • If: The resistance > 60 Ω.
ACCESS 5. – Then a CAN bus resistor could be open. Discon-
• If: The resistance > 120 Ω. nect CA402 from ACCESS 5 and measure the
resistance between CA402-4 and CA402-5 of the
– Then replace ACCESS 5.
ACCESS 5. module
• If: The resistance = 120 Ω.
• If: The resistance > 120 Ω.
– Then measure RES3 in the wire harness be-
– Then replace ACCESS 5.
tween CA703-1 and CA703-12.
• If: The resistance = 120 Ω.
• If: RES3 = bad.
– Then measure RES3 in the wire harness be-
– Then replace RES3 or the wire harness.
tween CA703-1 and CA703-12.
Step 3: Measure for a CAN line short circuit to -BV,
• If: RES3 = bad.
+BV or the truck frame.
– Then replace RES3 or the wire harness.
Turn the truck OFF and disconnect the battery. Meas-
ure the resistance at the power unit from CAN_L to the
-BV bus bar, CAN_L to TP8, and TP9 on the power unit
distribution panel and CAN_L to truck frame. The re-
sistance > 10 K Ω.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 100

Step 3: Measure for a CAN line short circuit to -BV, Event Code 107
+BV or the truck frame.
Turn the truck OFF and disconnect the battery. Meas- ACCESS 1 and ACCESS 7 module CAN event.
ure the resistance at the power unit from CAN_L to the All truck functions do not operate.
-BV bus bar, CAN_L to TP8 and TP9 on the power unit Note: ACCESS 1 CAN bus transmission with
distribution panel and CAN_L to the truck frame. Re- ACCESS 7 has not occurred in a specified time.
sistance must be > 10 K Ω.
Step 1: Turn the truck ON and look at the status of the
• If: The resistance < 10 K Ω. ACCESS 7 LED’s.
– Then repair or replace the wires. • If: The ACCESS 7 LED’s = ON and the event code
continues.
– Then continue to Step 2.
ACCESS6 • If: The ACCESS 7 LED’s = OFF.
GCM
CA601 – Then measure for +BV between CA703-7 and
2905 1 +BVAK CA703-8.
507 2 BATT COMM • If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000).
Power Unit Distribution Panel – Then replace ACCESS 7.
CA206 FU8 • If: The voltage = 0 V.
2905 11
– Then examine the wire between CA703-8 and
TP17 CA701-1, the wire between CA703-7 and
CA204 4 CA701-2, FU17 on the platform distribution
panel, and FU8 on the power unit distribution
CA406 panel.
NEG BUS Step 2: CAN transmission line test. Turn the truck OFF.
507 Measure the resistance between CAN_H and CAN_L
the resistance must = 60 Ω.
Fig. 216 (27252) • If: The resistance = 0 Ω.
– Then a short circuit between the CAN_H and
CAN_L. Examine related wires, connections and
ACCESS 7 fuses. Repair or replace as is necessary.
ACM
• If: The resistance > 60 Ω.
RES3 CA703 (BLK)
059 1 CAN_H – Then a CAN bus resistor could be open. Discon-
058 12 CAN_L nect CA402 from the ACCESS 5 module. Meas-
ure the resistance between CA402-4 and
Fig. 217 (27251)
CA402-5 of the ACCESS 5 module.
• If: The resistance > 120 Ω.
– Then replace ACCESS 5.
• If: The resistance = 120 Ω.
– Then measure the resistance of RES3 in the wire
harness between CA703-1 and CA703-12.
• If: RES3 = bad.
– Then replace RES3 or the wire harness.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 100

Step 3: Measure for a CAN line short circuit to -BV, Event Code 108
+BV or the truck frame.
Turn the truck OFF and disconnect the battery. Meas- ACCESS 1 and ACCESS 8 module CAN error.
ure the resistance at the power unit from CAN_L to the All truck functions do not operate.
-BV bus bar, CAN_L to TP8 and TP9 on the power unit Note: ACCESS 1 CAN bus transmission with
distribution panel and CAN_L to the truck frame. The ACCESS 8 has not occurred in a specified time.
resistance must be > 10 K Ω.
Step 1: Turn the truck ON and look at the status of the
• If: The resistance < 10 K Ω. ACCESS 8 LED’s.
– Then repair or replace the wires. • If: The ACCESS 8 LED’s = ON and the event code
continues.
– Then continue to Step 2.
Platform
• If: The ACCESS 8 LED’s = OFF.
Distribution ACCESS7
Panel ACM – Then measure for +BV between CA504-1 and
FU17 CA105 CA703 (BLK)
CA504-2.
1 BLK
2 059 1 CAN_H • If: The voltage = 48 V (TSP 6500) or 72/80 V (TSP
TP10
1 2974 7 +BV INPUT 7000).
CA106 WHT 2 569 8 BATT NEG IN
6 BRN 7 046 058 12 CAN_L – Then replace ACCESS 8.
1
CA107
7 YEL 8 047 • If: The voltage = 0 V.
CA701
– Then examine the wire between CA504-2 and
CA505-1, the wire between CA504-1 and
RES3
CA318-6, FU18 on the platform distribution
panel, and FU7 on the power unit distribution
Fig. 218 (27255) panel.
Step 2: CAN transmission line test. Turn the truck OFF.
Measure the resistance between CAN_H and CAN_L.
The resistance must = 60 Ω.
• If: The resistance = 0 Ω.
– Then a short circuit between CAN_H and
CAN_L. Examine related wires, connections, and
fuses. Repair or replace as necessary.
– Then a CAN bus resistor could be open. Discon-
nect CA402 from the ACCESS 5 module. Meas-
ure the resistance between CA402-4 and
CA402-5 of ACCESS 5.
• If: The resistance > 120 Ω.
– Then replace ACCESS 5.
• If: The resistance = 120 Ω.
– Then measure RES3 in the wire harness be-
tween CA703-1 and CA703-12.
• If: RES3 = bad.
– Then replace RES3 or the wire harness.
Step 3: Measure for a CAN line short circuit to -BV,
+BV or the truck frame.
Turn the truck OFF and disconnect the battery. Meas-
ure the resistance at the power unit from CAN_L to the
-BV bus bar, CAN_L to TP8 and TP9 on the power unit
distribution panel, and CAN_L to the truck frame. The
resistance must be > 10 K Ω.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 100

• If: The resistance < 10 K Ω. Event Code 116

– Then repair or replace the wires.
ACCESS 6 module software not compatible with
the other modules.
ACCESS8 All functions do not operate.
OCM Step 1: Install a new ACCESS 6 with compatible soft-
CA318 CA504 (BRN) ware or load ACCESS 6 with compatible software.
6 2995 1 +BV IN
1 520 2 BATT COMM IN Event Code 117
CA505
ACCESS 7 module software not compatible with
Fig. 219 (27256) the other modules.
All functions do not operate.
Step 1: Install a new ACCESS 7 with compatible soft-
ACCESS 7 ware or load ACCESS 7 with compatible software.
ACM
RES3 CA703 (BLK) Event Code 118
059 1 CAN_H
058 12 CAN_L ACCESS 8 module software not compatible with
the other modules.
Fig. 220 (27251) All functions do not operate.
Event Code 112 Step 1: Install a new ACCESS 8 with compatible soft-
ware or load ACCESS 8 with compatible software.
ACCESS 2 module software not compatible with
the other modules. Event Code 119
All functions do not operate. Truck software not compatible with the truck.
Step 1: Install a new ACCESS 2 with compatible soft- All functions do not operate.
ware or load ACCESS 2 with compatible software.
Step 1: Examine truck software in the Utilities menu to
Event Code 113 see if it is a standard or a standard freezer truck or a
low temperature freezer truck.
ACCESS 3 module software not compatible with • If: The truck is a low temperature freezer truck.
the other modules.
– Then install the low temperature freezer truck
All functions do not operate. software.
Step 1: Install a new ACCESS 3 with compatible soft- • If: The software is correct.
ware or load ACCESS 3 with compatible software.
– Then examine the hydraulic oil temperature sen-
sor and wires.
Event Code 114
ACCESS 4 module software not compatible with Event Code 122
the other modules.
ACCESS 2 incorrect voltage.
All functions do not operate.
All functions do not operate.
Step 1: Install a new ACCESS 4 with compatible soft-
Step 1: Look at the truck voltage setting in the Features
ware or load ACCESS 4 with compatible software.
menu.
Event Code 115 • If: The value set does not agree with the battery
voltage.
ACCESS 5 module software not compatible with – Then correct the value to agree with the battery
the other modules. voltage.
All functions do not operate. Step 2: Examine the ACCESS 2 part number.
Step 1: Install a new ACCESS 5 with compatible soft- • If: The incorrect ACCESS 2 part number was in-
ware or load ACCESS 5 with compatible software. stalled.

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– Then install the correct ACCESS 2 module.
Step 3: Examine the ACCESS 2 software part number.
• If: The incorrect software was installed in
ACCESS 2.
– Then install the correct software in ACCESS 2.
Event Code 123
ACCESS 3 incorrect voltage.
All functions do not operate.
Step 1: Look at the truck voltage setting in the Features
menu.
• If: The value set does not agree with the battery
voltage.
– Then correct the value to agree with the battery
voltage.
Step 2: Examine the ACCESS 3 part number.
• If: The incorrect ACCESS 3 part number was in-
stalled.
– Then install the correct ACCESS 3 module.
Step 3: Examine the ACCESS 3 software part number.
• If: The incorrect software was installed in
ACCESS 3.
– Then install the correct software in ACCESS 3.
Event Code 125
ACCESS 5 incorrect voltage.
All functions do not operate.
Step 1: Look at the truck voltage setting in the Features
menu.
• If: The value set does not agree with the battery
voltage.
– Then correct the value to agree with the battery
voltage.
Step 2: Examine the ACCESS 5 part number.
• If: The incorrect ACCESS 5 part number was in-
stalled.
– Then install the correct ACCESS 5 module.
Step 3: Examine the ACCESS 5 software part number.
• If: The incorrect software was installed in
ACCESS 5.
– Then install the correct software in ACCESS 5.
Event Code 150
(Event Codes 191, 194, 195, 196, 197, 198 will be
shown with this Event Code)
Crown 2012 PF25715-9 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODE GROUP 100
ACCESS 1 has received an incorrect event code or
message.
All functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event ode does not continue then operate
the truck and monitor the event code.
Event Code 191
ACCESS 1 has reported invalid event code.
All truck functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event code does not continue then operate
the truck and monitor the event code.
Event Code 194
ACCESS 4 has reported invalid Event Code.
All functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event code does not continue then operate
the truck and monitor the event code.
Event Code 195
ACCESS 5 has reported an invalid event code.
All functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event code does not continue then operate
the truck and monitor the event code.
Event Code 196
ACCESS 7 has reported an invalid event code.
All functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event code does not continue then operate
the truck and monitor the event code.
M4.8-1970-010
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ELECTRICAL SYSTEM
EVENT CODE GROUP 100

Event Code 197

ACCESS 7 has reported invalid event code.
All functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event code does not continue then operate
the truck and monitor the event code.

Event Code 198

ACCESS 8 has reported an invalid event code.
All functions do not operate.
Step 1: Note if other event codes are shown.
Step 2: Report the event code to Crown service.
Step 3: Turn the truck OFF, then ON.
Step 4: The event code does not continue then operate
the truck and monitor the event code.

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Event Code Group 200
Event Code 212
ACCESS 2 module current is out of range.
The primary raise, lower, auxiliary raise, traverse, pivot,
fork extend or retract do not operate.
Note: The event code is recorded when a high current
is sensed at ACCESS 2, terminals U, V, or W. Possible
cause is a short circuit in the power cables or motor
coil.
Step 1: Turn the truck OFF. Measure the resistance of
the power cables U, V, W for short circuits to the truck
frame.
• If: A short circuit in the power cables is found.
– Then repair or replace the power cables.
• If: The power cables do not have a short circuit in
them.
– Then continue to Step 2.
Step 2: Measure the resistance of the hydraulic pump
motor coil for a short circuit to the truck frame.
• If: The motor coil has a short circuit to the truck
frame.
– Then replace the pump motor.
• If: The motor coil does not have a short circuit and
the Event Code continues.
– Then replace ACCESS 2.
Note: If the event code continues after you replace
ACCESS 2 there could be a phase to phase motor
short circuit. A motor replacement is necessary to do a
function test for this condition.
Event Code 213
ACCESS 2 module current sensor event.
The primary raise, lower, auxiliary raise, traverse, pivot,
fork extend or retract do not operate.
Note: The event code is recorded if an incorrect cur-
rent offset is sensed by the ACCESS 2 current sen-
sors.
Step 1: Turn the truck OFF. Measure resistance of the
hydraulic pump motor coil for a short circuit to the truck
frame.
• If: The motor coil has a short circuit.
– Then replace the motor.
• If: The motor coil does not have a short circuit and
the Event Code continues.
– Then replace ACCESS 2.
Crown 2012 PF25715-11 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODE GROUP 200
Note: If the event code continues after you replace
ACCESS 2 there could be a phase to phase motor
short circuit. A motor replacement is necessary to do a
function test for this condition.
Event Code 214
ACCESS 2 module precharge event.
The primary raise, lower, auxiliary raise, traverse, pivot,
fork extend or retract do not operate.
Step 1: Load the default parameters and set the values
as required.
Event Code 215
ACCESS 2 module internal temperature is to low.
The primary raise, lower, auxiliary raise, traverse, pivot,
fork extend or retract do not operate.
Step 1: The event code is recorded if the internal
ACCESS 2 temperature is less than -40 °C (-40 °F).
This could occur if you park the truck with the truck OFF
in -40 °C (-40 °F) for an extended period of time. Move
the truck to a warm area, when ACCESS 2 tempera-
ture has increased, turn the truck ON.
• If: ACCESS 2 is warm and the event code contin-
ues.
– Then replace ACCESS 2.
Event Code 216
ACCESS 2 module internal temperature is too
high.
Primary raise, lower auxiliary raise, traverse, pivot, fork
extend or retract do not operate.
Step 1: The event code is recorded if the internal
ACCESS 2 temperature is more than 95 °C (203 °F).
As the temperature increases Event Code 222 will be
recorded when ACCESS 2 temperature is more than
85 °C (185 °F). When Event Code 222 is recorded
ACCESS 2 performance will decrease until the tem-
perature lowers. Let the truck cool and examine the
bolts that mount ACCESS 2.
• If: After the module is cool and the hydraulic system
operates at usual performance levels.
– Then the truck can be put in operation.
• If: After the module is cool and Event Codes 216,
222 continue.
– Then replace ACCESS 2.
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ELECTRICAL SYSTEM
EVENT CODE GROUP 200
Event Code 217
ACCESS 2 module battery voltage is out of range.
Primary raise, lower, auxiliary raise, traverse, pivot,
fork extend or retract do not operate.
Step 1: Examine for the correct battery.
• If: The correct battery is installed.
– Then continue to Step 2.
Step 2: Measure the battery voltage.
• If: The battery = 48–52 V (TSP 6500), 72–84 V
(TSP 7000).
– Then the battery = 48–52 V or 72–84 V, continue
to Step 3.
• If: The battery voltage is below or above the voltage
range.
– Then charge or replace the battery.
Step 3: Make sure of the operation of ED1.
• If: The ED1 contactor engages.
– Then measure for +BV between ACCESS 2 +B
and -BV terminals.
• If: The voltage = +BV and the event code continues.
– Then replace ACCESS 2.
• If: The +BV voltage is out of range.
– Then examine FU12.
• If: FU12 = bad.
– Then replace FU12.
• If: FU12 = good.
– Then examine the ACCESS 2 power cable con-
nections.
Event Code 218
ACCESS 2 module battery voltage is out of range.
Primary raise, lower, auxiliary raise, traverse, pivot,
fork extend or retract do not operate.
Step 1: Examine for the correct battery.
• If: The correct battery is installed.
– Then continue to Step 2.
Step 2: Measure the battery voltage.
• If: The battery = 48–52 V (TSP 6500) or 72–84 V
(TSP 7000).
– Then the battery = 48–52 V or 72–84 V, continue
to Step 3.
• If: The battery voltage is below or above the voltage
range.
– Then charge or replace the battery.
M4.8-1970-013 TSP 7000 SERIES
376
Step 3: Examine the power cable connections.
ACCESS 2 -BV and +B and the hydraulic pump motor
U, V, W.
• If: Loose connections are found.
– Then tighten the connections.
• If: Connections are tight and the event code contin-
ues.
– Then replace ACCESS 2.
Event Code 222
ACCESS 2 module temperature is high module
performance is decreased.
The primary raise and lower do not operate.
Step 1: The event code is recorded if the ACCESS 2
bottom plate temperature is more than 85 °C (185 °F).
Possible cause is high external temperature or the load
on the hydraulic system or an incorrect install of the
ACCESS 2 module. Let the hydraulic system cool,
then turn the truck ON.
• If: The hydraulic system operates at the set perfor-
mance point.
– Then put the truck into operation.
• If: The ACCESS 2 is cool and the event code con-
tinues.
– Then replace ACCESS 2.
Event Code 223
ACCESS 2 module has a low voltage input module
performance is decreased.
The hydraulic function is decreased (in limp mode).
Note: Event Code 223 could be recorded as the result
of other events. Look for other event codes and repair
them before you repair Event Code 223.
Step 1: The event code is recorded when the voltage
at ACCESS 2 +B terminal is low. Examine for the cor-
rect battery.
• If: The correct battery is installed.
– Then continue to Step 2.
Step 2: Turn the truck OFF and disconnect the battery.
Measure the +BV at the battery connector.
• If: The battery = 48–52 V (TSP 6500) or 72–84 V
(TSP 7000).
– Then continue to Step 3.
• If: The +BV is below the voltage range.
– Then charge or replace the battery.
Step 3: Make sure of the operation of ED1.
• If: The ED1 contactor engages.
Crown 2012 PF25715-12
 ELECTRICAL SYSTEM
EVENT CODE GROUP 200

– Then measure the battery voltage between Step 1: Turn the truck ON. Measure for 5 V between
ACCESS 2 +B and -BV terminals. CA411-26 and -BV.
• If: The battery = 48–52 V (TSP 6500) or 72–84 V • If: The voltage ≠ 4.5–5.5 V.
(TSP 7000) and the event code continues. – Then disconnect the wire from CA411-26. Meas-
– Then replace ACCESS 2. ure the voltage between CA411-26 and-BV.
• If: The battery ≠ 48–52 V (TSP 6500) or 72–84 V • If: The voltage = 4.5–5.5 V.
(TSP 7000). – Then a short circuit in the wires to ECR8 or ECR8
– Then examine FU12, the power cable connec- has a short circuit. Examine the wire between
tions between the battery, ED1, ACCESS 2. CA411-26 to CA415-1, the wire between
CA415-1 and ECR8, the wire between CA411-31
Event Code 224 to CA415-3, the wire between CA415-3 and
ECR8, the wire CA411-32 to CA415-4, and the
ACCESS 2 module input voltage is high module wire CA415-4 to ECR8.
performance is decreased.
• If: The wires = bad.
The primary lower does not operate, all other hydrau-
lics performance is decreased (limp mode). – Then repair or replace the wires.
Note: Event Code 224 could be recorded as the result • If: The wires and connections are good.
of other event codes. Look for other event codes and – Then replace ECR8.
repair them before you repair Event Code 224. • If: The event code continues.
The event code is recorded if the voltage at – Then replace ACCESS 2.
ACCESS 2, +B terminal is too high. This could occur if
the regenerative brake operation current is high and
will increase the battery voltage during a regen brake
operation. ACCESS 2
Step 1: Examine for the correct battery. CA411 HCM
• If: The correct battery is installed in the truck. 526 7 I/O BATT NEG OUTPUT
102 8 HYDRAULIC MTR TEMP SENSE INPUT
– Then continue to Step 2. 708 26 +5V OUT
Step 2: Disconnect the battery and measure for +BV at 025 31 HYD MTR SPEED ENCODER CH A
026 32 HYD MTR SPEED ENCODER CH B
the connector.
• If: The voltage = 48–52 V (TSP 6500) or 72–84 V B+ B-
(TSP 7000).
ECR8
– Then continue to Step 3. CA415
1 RED +5V
• If: The +BV is above the voltage range. 593 2 BLK BATT NEG
– Then replace the battery. 3 WHT CH A
4 BLU CH B
Step 3: Examine the power cable on ACCESS 2, +B 594 5 BLK
and -BV terminals. Examine the U, V, and W connec- 6 WHT
tions on ACCESS 2 and the hydraulic pump motor. TS2
• If: The connections are loose.
Fig. 221 (27257)
– Then tighten the connections.
• If: Connections are tight and the event code contin- Event Code 228
ues. ACCESS 2 module has sensed a hydraulic pump
– Then replace ACCESS 2. motor (M2) high temperature, performance is de-
creased.
Event Code 225 The primary raise and lower do not operate.
ACCESS 2 module 5 V supply is out of range. Note: The temperature is monitored through TS2 in
The primary raise, lower, auxiliary raise performance is M2.
decreased (limp mode). Step 1: The event code is recorded when the motor
temperature is more than a set limit. The temperature

Crown 2012 PF25715-13 TSP 7000 SERIES M4.8-1970-014

377
ELECTRICAL SYSTEM
EVENT CODE GROUP 200

is monitored through TS2 in M2. Turn the truck OFF

and let the system cool then turn the truck ON.
• If: The hydraulic system operates at set perfor- ACCESS 2
mance point. HCM
CA411
– Then put the truck in operation. 526 7 I/O BATT NEG OUTPUT
• If: M2 is cool and the event code continues. 102 8 HYDRAULIC MTR TEMP SENSE INPUT
708 26 +5V OUT
– Then replace M2. 025 31 HYD MTR SPEED ENCODER CH A
• If: The event code continues. 026 32 HYD MTR SPEED ENCODER CH B
– Then replace ACCESS 2. B+ B-

Event Code 229 CA415 ECR8

ACCESS 2 hydraulic pump motor M2 temperature 1 RED +5V

sensor TS2 event.
Primary raise, lower do not operate, auxiliary raise per-
formance is decreased (limp mode).
Step 1: The event code is recorded when the motor
temperature is more than a set limit. The temperature
is monitored by sensor TS2 in M2. Turn the truck OFF
and let the system cool then turn the truck ON.
• If: The hydraulic system operates at a set perfor-
mance point.
– Then put the truck in operation.
• If: The event code continues.
– Then turn the truck OFF and examine the wire
between CA411-8 to CA415-6. The wire between
CA415-6 to TS2 and the wire between CA411-7
to CA415-5. The wire between CA415-5 to TS2.
• If: The wires = bad.
– Then repair or replace the wires.
• If: The wires are good and the event code contin-
ues.
– Then replace M2.
593 2 BLK BATT NEG
3 WHT CH A
4 BLU CH B
594 5 BLK
6 WHT
TS2
Fig. 222 (27257)
Event Code 231
ACCESS 2 module high performance hydraulics
fan driver has a short circuit or an open circuit.
Note: The Event Code is recorded with these condi-
tion(s).
• An open FAN3 or wires to prevent current flow
when FAN3 driver is requested.
• Short circuit between +B and CA411-6. Could be
FAN3 or the wires.
• Short circuit between -BV and CA411-6. Could be
internal or external to ACCESS 2, will record at
truck ON.
Step 1: Go to F15 in the Features menu. Make sure
that the standard performance is set for standard
trucks or high performance is set for high performance
trucks.
• If: F15 feature has the incorrect performance set.
– Then correct the F15 performance selection.
• If: F15 is correct and the event code continues.
– Then continue to Step 2.
Turn the truck ON while you push the up and down ar-
row buttons.
• If: FAN3 is on then a short circuit to -BV problem.
– Then go to the short circuit -BV test.
Step 2: Turn the truck ON while you push the up and
down buttons. Go to FAN3 A4.4.13 in the ANALYZER
menu. Push and hold the ENTER button (turns ON the
driver).

M4.8-1970-015 TSP 7000 SERIES Crown 2012 PF25715-14

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 200

• If: The +BV voltage is measured across FAN3 ter-

minals and the FAN3 does not operate.
– Then replace FAN3.
• If: The voltage = 0 V across FAN3 terminals.
– Then a positive or negative is missing. Continue
to Step 3.
Step 3: Turn the truck OFF and measure the wire from
CA411-13 to FAN3 for continuity or for an open circuit.
Turn the truck ON while you push the up and down ar-
row buttons. Go to FAN3 A4.4.13 in the ANALYZER
menu. Press and hold the ENTER button (turns ON the
driver).
• If: The voltage is +BV between CA411-6 and the
negative terminal of FAN3.
– Then an open circuit between FAN3 and
ACCESS 2. Measure the voltage on the wire be-
tween CA411-6 and SB41.
• If: The voltage = 0 V.
– Then replace ACCESS 2.
Short circuit to -BV test:
Make sure that the problem continues, turn the truck
ON while you push the up and down arrow buttons.
• If: FAN3 operates continuously.
– Then turn the truck OFF and remove the wire
from CA411-6. Turn the truck ON, while you push
the up and down buttons. Measure the voltage
across FAN3.
• If: The voltage = 0 V.
– Then replace ACCESS 2.
• If: The voltage > 1 V.
– Then the wire between CA411-6 and SB41 is
bad. Replace the wire.
Step 4: Examine the wires for cuts in the insulation or
a short circuit to the truck frame. Examine the wire from
FAN3 to CA411-13, the wire from CA411-6 to SB41,
and SB41 wires.
• If: The problem continues.
– Then replace FAN3.
ACCESS 2
HCM
CA411
5997 6 H/P HYD FAN DRIVER
13 +BV/SUPPRESSION FOR HCM DRIVERS
B+ B-
FAN3
SB41
29121
Fig. 223 (27258)
Event Code 232
ACCESS 2 module horn (HN) driver has a short cir-
cuit or an open circuit.
The travel is decreased (in limp mode) to 1.6 km/h
(1.0 mph or less).
Note: Event is recorded because of the these condi-
tion(s):
• An open circuit in the HN or wires to prevent current
flow when the HN driver is requested.
• A short circuit between +BV and CA411-13. Event
could be because of a bad HN or a short circuit in
the wires between the HN and ACCESS 2.
• A short circuit between -BV and CA411- 19. The HN
is energized at key ON. Event could be a short cir-
cuit external or internal to ACCESS 2.
Step 1: Turn the truck ON.
• If: The wrench light illuminates and Event Code 232
is recorded.
– Then a short circuit to - BV or an open circuit
problem. Refer to Steps 2 and 3.
• If: The wrench light does not illuminate and Event
Code 232 is not recorded.
– Then push the HN button for a minimum of three
seconds.
• If: The wrench light illuminates and Event Code 232
is recorded when the HN button is pushed and
when the HN button is released the wrench light
goes out.
– Then a short circuit to +BV problem. Refer to the
short circuit to +BV test.
• If: The HN sounds continuously when the truck is
ON.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 200

– Then a short circuit to -BV problem. Refer to the – Then replace ACCESS 2.
short circuit to -BV test. Short circuit to -BV test:
Turn the truck ON to make sure the problem continues.
• If: The HN sounds continuously.
ACCESS 2 – Then turn the truck OFF and remove the wire
CA411
59107 2 SVMR DRIVER from CA411-19.
5904 3 SVA DRIVER • If: Turn the truck ON and measure the voltage
5906 4 PVML DRIVER across the HN terminals > 1 V.
5976 5 SVML DRIVER
4913 13 +BV/SUPPRESSION FOR – Then replace the wire between CA411-19 and
ACCESS 2 DRIVERS the negative terminal on the HN.
5928 19 HORN LOW
B+ B- • If: The voltage across the HN terminals = 0 V.
FAN3 – Then replace ACCESS 2.
CA406 Short circuit to +BV test:
4914
+ Turn the truck ON and push the HN button for a mini-
2914 HN
5928 mum of three seconds to make sure the problem con-
tinues.
• If: The wrench light illuminates but goes out when
CA414 (GRN) the HN button is released.
4914 1 4926 – Then turn the truck OFF and disconnect the wire
5906 2 5911 PVML
5904 3 5910 SVA 4929 from the negative terminal on the HN. Turn the
5976 4 5990 4930 truck ON.
59107 5 SVML • If: The wrench light illuminates continuously and
59108 4931 Event Code 232 is recorded.
SVMR – Then replace the HN.
• If: The wrench light does not illuminate unless the
Fig. 224 (27259) HN button is pushed for a minimum of three sec-
Step 2: Turn the Truck ON while you push the up and onds and does not illuminate when the button is re-
down buttons. Go to HN A4.4.7 in the ANALYZER leased and Event Code 232 is recorded.
menu. Push and hold the ENTER button (turns ON the – Then a short circuit in the truck wires or
HN driver). ACCESS 2. Examine the wire between
• If: The voltage +BV is measured across the HN and CA411-13 and the +BV terminal on the HN. Ex-
the HN does not operate. amine the wire between CA411-19 and the -BV
terminal on the HN module.
– Then replace the HN.
• If: No short circuits are found and the event code
• If: The voltage = 0 V.
continues.
– Then continue to Step 3.
– Then replace ACCESS 2.
Step3: Turn the Truck OFF. Measure the resistance of
the wire from CA411-13 to the +BV terminal on the HN Event Code 233
for an open circuit. Measure the resistance of the wire
from CA411-19 to the -BV terminal on the HN for an ACCESS 2 module PVML driver has a short circuit
open circuit. Turn the truck ON while you push the up or an open circuit.
and down buttons. Go to HN A4.4.7 in the ANALYZER The primary raise and lower do not operate and auxil-
menu. Press and hold ENTER (turns ON the HN iary raise function is decreased (in limp mode).
driver). Note: Event code is recorded with these condition(s).
• If: The voltage +BV is measured across the HN. • Open in the PVML coil or wires. Prevents current
– Then an open circuit between the HN and flow when the PVML driver is requested.
ACCESS 2. Examine the wire between • A short circuit to +B. Possible cause, a short circuit
CA411-19 and -BV terminal on the HN. in the PVML coil or a short circuit in the wires be-
• If: The voltage = 0 V. tween the PVML and ACCESS 2.

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• A short circuit to -BV. Supplies voltage to PVML
when truck is ON. Possible cause, a short circuit in
the wires to ACCESS 2.
Step 1: Turn the truck ON.
• If: The wrench light illuminates and Event Code 233
is recorded.
– Then a short circuit to -BV or a short circuit to the
truck frame problem, follow Steps 2, 3, 4.
• If: The wrench light does not illuminate and Event
Code 233 is not recorded.
– Then raise the primary mast 305 mm (12.0 in)
and try to lower. Look for event code.
• If: When you do a primary lower the wrench light
illuminates and records Event Code 233. When the
primary lower is stopped the wrench light goes off.
– Then a short circuit to +B is the problem. Turn the
truck OFF and remove the wire from CA414-2 to
PVML. Turn the truck ON.
• If: The wrench light illuminates and stays ON and
Event Code 233 is recorded.
– Then replace the PVML.
• If: The wrench light does not illuminate but Event
Code 233 is recorded when you try a primary lower.
– Then a short circuit in the truck wires or
ACCESS 2. Turn the truck OFF and measure the
resistance of the wires between PVML and
ACCESS 2. If no problems are found in the wires
then replace ACCESS 2.
Step 2: Turn the truck OFF and disconnect all the wires
from the PVML. Measure the resistance of the PVML
coil.
• If: The resistance ≠ 20 - 40 Ω.
– Then replace the PVML.
Crown 2012 PF25715-17 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODE GROUP 200
• If: The resistance = 20 - 40 Ω.
– Then continue with Step 3.
Step 3: Connect the wires to the PVML. Turn the truck
ON and measure the voltage across the PVML termi-
nals.
• If: The voltage > 1 V.
– Then a short circuit to -BV. Turn the truck OFF
and remove the wire from CA411-4 and turn the
truck ON.
• If: The voltage = 0 V.
– Then ACCESS 2 has a short circuit, replace
ACCESS 2.
• If: The voltage > 1 V.
– Then a short circuit in the wires, examine the
wires.
• If: The wires are good and the event code contin-
ues.
– Then continue to Step 4.
Step 4: Measure the voltage between -BV and the pos-
itive terminal on PVML with the GRN/WHT wire and
keep the wires connected. Go to PVML A4.4.4 in the
ANALYZER menu. Press and hold the ENTER button
(drives the PVML).
• If: The voltage = 0 V.
– Then a positive voltage is missing. Examine the
wire from CA414-1 to PVML and the wire from
CA414-1 to CA406 (+). The wire from CA411-13
to CA406 (+).
• If: The voltage = +BV.
– Then the negative voltage is missing. Measure
the negative output between the PVML terminal
with the GRN/WHT wire and CA411-2. Turn the
truck ON while you push the up and down but-
tons. Go to PVML A4.4.4 in the ANALYZER
menu. Press and hold the ENTER button (drives
SVML).
• If: The voltage = +BV.
– Then an open circuit between ACCESS 2 and
PVML. Examine the wire connections.
• If: The voltage = 0 V.
– Then replace ACCESS 2.
• If: The voltage = 24 V for three seconds and then
falls to 0 V.
– Then this is a correct function indication. The
problem could be an intermittent connection. Ex-
amine the wires and connections.
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Step 2: Turn the truck OFF and connect the wires to

SVA. Turn the truck ON. Measure the voltage from -BV
ACCESS 2 and to SVA terminal with the RED/WHT wire.
CA411 • If: Battery voltage is not measured.
59107 2 SVMR DRIVER
5904 3 SVA DRIVER – Then an open circuit between the RED/WHT wire
5906 4 PVML DRIVER from SVA to ACCESS 2 CA411-13. Repair or re-
5976 5 SVML DRIVER place the wire.
4913 13 +BV/SUPPRESSION FOR
ACCESS 2 DRIVERS • If: The voltage = +BV.
5928 19 HORN LOW
B+ B- – Then continue to Step 3.
FAN3 Step 3: Measure the voltage across the SVA terminals.
Turn the truck OFF, then ON while you push the up and
CA406
4914 down buttons. Go to SVA A4.4.3 in the ANALYZER
+
menu. Push and hold the ENTER button (drives SVA).
2914 HN
5928 • If: The voltage = 0 V.
– Then the negative is missing. Measure the nega-
tive output between the SVA terminal with the
CA414 (GRN)
GRN/WHT wire and CA411-3. Turn the truck
4914 1 4926
5906 2 5911 PVML OFF then ON while you push the up and down
5904 3 5910 SVA 4929 buttons. Go to SP1 A4.4.3 in the ANALYZER
5976 4 5990 4930 menu. Push and hold the ENTER button (drives
59107 5 SVML SP1).
59108 4931 • If: The voltage = 24 V for three seconds and then
SVMR falls to 0 V.
– Then this is a correct function indication. Problem
Fig. 225 (27259) could be an intermittent connection. Examine the
wires.
Event Code 234 • If: The voltage = +BV.
ACCESS 2 module SVA driver has a short circuit or – Then a short circuit to -BV problem. Measure the
an open circuit. voltage across the SVA coil terminals.
The primary raise, lower, and auxiliary raise function is • If: The voltage > 1 V.
decreased (in limp mode). – Then a short circuit problem. Turn the truck OFF
Note: Event Code is recorded with these condition(s). and remove the wire from CA411-3 and turn the
• An open coil or wires prevents current flow when truck ON.
the SVA driver is requested. • If: The voltage > 1 V.
• A short circuit to +B. Possible cause, short circuit in – Then a short circuit in the wires between SVA
the SVA coil or short circuit in wires between SVA and ACCESS 2 examine the wires.
and ACCESS 2. • If: The voltage = 0 V.
• A short circuit to -BV. Supplies voltage to SVA. Pos- – Then replace ACCESS 2.
sible cause a short circuit in the wires or
ACCESS 2.
Step 1: Turn the truck OFF and remove the wires from
SVA. Measure the resistance of the SVA coil.
• If: The resistance ≠ 20–40 Ω.
– Then replace SVA.
• If: The resistance = 20–740 Ω.
– Then continue with Step 2.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 200

– Then raise the primary mast 305 mm (12.0 in)

and check for event code.
• If: As you do the primary raise the wrench light illu-
ACCESS 2
CA411 minates and records Event Code 235 but when
59107 2 SVMR DRIVER raise control is stopped the wrench light goes off.
5904 3 SVA DRIVER – Then a short circuit to +B problem. Turn the truck
5906 4 PVML DRIVER
5976 5 SVML DRIVER OFF and remove the wire from the SVMR termi-
4913 13 +BV/SUPPRESSION FOR nal that goes to CA414-5. Turn the truck ON.
ACCESS 2 DRIVERS
• If: The wrench light illuminates and Event Code 235
5928 19 HORN LOW
B+ B- is recorded.
FAN3 – Then replace SVMR.
CA406
4914 • If: The wrench light does not illuminate but Event
+ Code 235 is recorded when you try a primary raise.
2914 HN
5928 – Then a short circuit problem in the truck wires or
ACCESS 2. Examine the wires between SVMR
and ACCESS 2.
CA414 (GRN) • If: No problems found with the wires.
4914 1 4926 – Then replace ACCESS 2.
5906 2 5911 PVML
5904 3 5910 SVA 4929 Step 2: Turn the truck OFF and disconnect the two
5976 4 5990 4930 wires from SVMR. Measure the resistance of the
59107 5 SVML SVMR coil.
59108 4931 • If: The resistance ≠ 20–40 Ω.
SVMR – Then replace SVMR.
• If: The resistance = 20–40 Ω.
Fig. 226 (27259) – Then continue to Step 3.
Event Code 235 Step 3: Connect the two wires to SVMR. Turn the truck
ON and measure the voltage across the SVMR termi-
ACCESS 2 module SVMR driver has a short circuit nals.
or an open circuit. • If: The voltage > 1 V.
The primary raise and auxiliary raise do not operate. – Then a short circuit to -BV problem. Turn the
Primary lower function decreased (limp mode). truck OFF and remove the wire from CA411-2
Note: Event Code is recorded with these condition(s). and turn the truck ON.
• An open SVMR coil or wires to prevent current flow • If: The voltage > 1 V.
when SVMR driver is requested. – Then a short circuit problem. Examine the wires.
• Short circuit to +B. Possible cause, defective SVMR • If: No problem found in the wires.
or a short circuit in the wires to SVMR or
ACCESS 2. – Then replace ACCESS 2.
• Short circuit to -BV. Supplies voltage to SVMR coil Step 4: Measure the voltage between -BV and the pos-
when the truck ON. Possible cause, a short circuit itive terminal on SVMR. Go to A4.4.2 in the ANALYZER
in the wires or ACCESS 2. menu, press and hold the ENTER button (drives the
component).
Step 1: Turn the truck ON.
• If: The voltage = 0 V.
• If: The wrench light illuminates and Event Code 235
is recorded. – Then the positive voltage is missing. Examine the
wire from SVMR to SVML and the wire from
– Then a short circuit to -BV or an open circuit. Fol- SVML to SVA. The wire from SVA to PVML and
low Steps 2–4. the wire from PVML to CA414-1. The wire from
• If: The truck is ON and the wrench light does not CA414-1 to CA406 (HN+) and the wire from
illuminate and Event Code 235 is not recorded. CA411-13 (HN+) to CA411-19 (ACCESS 2).
• If: The voltage = +BV.

Crown 2012 PF25715-19 TSP 7000 SERIES M4.8-1970-024

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ELECTRICAL SYSTEM
EVENT CODE GROUP 200

– Then the negative voltage is missing examine the • If: Event code continues.
wires. – Then replace ACCESS 2.
• If: The voltage = 24 V for three seconds and then
falls to 0 V.
– Then this is a correct function indication. Problem ACCESS 2
could be an intermittent or loose connection. Ex- HCM
CA411
amine the wires and connections.
526 7 I/O BATT NEG OUTPUT
102 8 HYDRAULIC MTR TEMP SENSE INPUT
708 26 +5V OUT
ACCESS 2 025 31 HYD MTR SPEED ENCODER CH A
CA411 026 32 HYD MTR SPEED ENCODER CH B
59107 2 SVMR DRIVER
5904 3 SVA DRIVER B+ B-
5906 4 PVML DRIVER
5976 5 SVML DRIVER ECR8
4913 13 +BV/SUPPRESSION FOR CA415
ACCESS 2 DRIVERS 1 RED +5V
5928 19 HORN LOW 593 2 BLK BATT NEG
B+ B- 3 WHT CH A
FAN3 4 BLU CH B
594 5 BLK
CA406 6 WHT
4914
+ TS2
2914 HN
5928
Fig. 228 (27257)

Event Code 237

CA414 (GRN)
4914 1 4926 Pump motor open (M2).
5906 2 5911 PVML
SVA The primary raise and lower, auxiliary raise, traverse,
5904 3 5910 4929
5976 4 5990 pivot, fork extend or retract are do not operate.
4930
59107 5 SVML Note: The event code recorded if (M2) is open.
59108 4931 Step 1: Turn the truck OFF. Measure the continuity of
SVMR the M2 phase cables from the ACCESS 2 terminals to
the related M2 terminals.
Fig. 227 (27259) • If: A cable connection has an open circuit.
Event Code 236 – Then repair or replace the cable or connections.
• If: No problems are found with all three connec-
ACCESS 2 module hydraulic pump motor feedback tions.
encoder (ECR8) count is out of tolerance.
– Then measure for continuity at the M2 terminals
The primary raise and lower do not operate, all auxil- U to V, V to W, and W to U.
iary functions are decreased (in limp mode).
• If: One or more terminals read an open circuit.
Note: Event Code 236 could be the result of other
– Then replace M2.
events. If other event codes have been recorded. Re-
pair them before you continue with Event Code 236. • If: No problems found at the M2 terminals.
Step 1: Turn the truck OFF. Examine the wires for a – Then replace ACCESS 2.
short circuit or an open circuit between CA415 and
ECR8. The wire between CA411-26 to CA415-1. The Event Code 238
wires between CA411-7 to CA415-2 and CA415-5. The ACCESS 2 module SVML driver problem.
wire between CA411-31 to CA415-3 and the wire be-
The primary raise and lower do not operate. All load
tween CA411-32 to CA415-4.
handler functions do not operate.
• If: No problem found in the wires and the event
Step 1: Turn the truck OFF and ON.
code continues.
• If: The event code does not continue.
– Then replace ECR8.

M4.8-1970-025 TSP 7000 SERIES Crown 2012 PF25715-20

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– Then monitor the event code
• If: The event code continues.
– Then replace ACCESS 2.
Event Code 246
ACCESS 2 module incorrect software is installed.
All hydraulic functions are do not operate.
Step 1: Install the correct software into ACCESS 2.
• If: The event code continues.
– Then replace ACCESS 2.
Event Code 247
ACCESS 2 module internal problem.
All hydraulic functions do not operate except for auxil-
iary lower.
Step 1: ACCESS 2 could have the incorrect software
installed, install the software.
• If: Event code continues after software install.
– Then replace ACCESS 2.
Event Code 249
ACCESS 2 module parameter change event.
All hydraulic functions are do not operate.
Step 1: Turn the truck OFF then ON.
• If: The event code continues.
– Then replace ACCESS 2.
Event Code 251
ACCESS 2 module general event.
All hydraulic functions do not operate.
Step 1: The ACCESS 2 module could have the incor-
rect software installed, install the correct software.
• If: Event code continues after software install.
– Then replace ACCESS 2.
Event Code 253
Hydraulic oil overtemp (Freezer special only).
Full speed primary raise does not operate.
Note: This event code is recorded if the oil temperature
is > 60 °C (150 °F).
Step 1: Examine the oil temperature in the Analyzer
menu A2.4.21.
• If: The oil temperature > 60 °C (150 °F).
– Then let the hydraulic oil cool.
Crown 2012 PF25715-21 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODE GROUP 200
Step 2: Measure the temperature in the area where the
truck is in operation. Low temperature freezer trucks
are to be operated in freezer applications of -40 °C to
-12 °C (-40 °F to -10 °F)
• If: The truck is operated in an environment > -12 °C
(10 °F).
– Then this event code could be recorded.
Event Code 254
Hydraulic oil temperature sensor problem (Freezer
special only).
Full speed primary raise does not operate.
Step 1: Turn the truck OFF and measure the oil tem-
perature sensor wires for an open circuit or a short cir-
cuit.
• If: An open circuit or short circuit is found.
– Then repair or replace the bad wire as is neces-
sary.
• If: No bad wires are found.
– Then continue with Step 2.
Step 2: Measure the resistance of the oil sensor. The
resistance must = 30,000 Ω at a temperature of 25 °C
(77 °F).
• If: The resistance ≠ 30,000 Ω at a temperature of
25 °C (77 °F).
– The replace the oil sensor.
Event Code 255
ACCESS 2 Primary Chain Slack.
The primary or auxiliary lower, traction, pivot, traverse,
and fork extend or retract do not operate.
Step 1: Turn the truck ON and do the primary raise
function.
• If: The wrench light is OFF all functions operate.
– Then the chain slack condition has been cor-
rected.
• If: The chain slack condition continues.
– Then turn the truck ON while you push the up but-
ton. Go to A2.2.15 in the ANALYZER menu to
see CHS5, CHS6 switch condition.
• If: The CHS5 or CHS6 chain slack switch(es) are
open.
– Then examine the chain and switch adjustments
and adjust as is necessary.
M4.8-1970-027
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ELECTRICAL SYSTEM
EVENT CODE GROUP 200

– Then measure the voltage between -BV and

CA415-1.
ACCESS 2 Power Unit • If: The voltage = 5 V (± 0.5 V) and Event Code 269
HCM Distribution Panel is recorded.
CA411 CA206 – Then replace ECR8.
10 22 16 15 • If: The voltage = 0 V.
– Then an open circuit between ACCESS 2 and
CA416 CA801 CHS5 ECR8. Examine the wires between CA415 and
1 BLACK 1 SLACK ECR8 and the wire from CA411-26 to CA415-1.
2 WHITE 2 CHS6 The wire from CA411-7 to CA415-2 and
3 3 CA415-5. The wire from CA411-31 to CA415-3
4 4 CHS7 and the wire from CA411-32 to CA415-4.
BREAK
5 RED • If: The voltage < 5 V.
6 GREEN CHS8
– Then remove the wire from CA415-1 and meas-
ure the voltage between the wire disconnected
Fig. 229 (27260)
from CA415-1 and -BV.
Event Code 256 • If: The voltage = 5 V.
ACCESS 2 Primary Chain Break. – Then replace ECR8.
The primary, auxiliary raise, lower, traction, pivot, trav- • If: The voltage ≠ 5 V.
erse, and fork extend, retract do not operate. – Then replace ACCESS 2.
Step1: Examine the condition of the mast chains.
• If: The mast chain condition is good.
– Then continue to Step 2. ACCESS 2
CA411 HCM
Step 2:Turn the truck ON while push the up button. Go
to the ANALYZER menu to A2.2.16 to see CHS7, 526 7 I/O BATT NEG OUTPUT
CHS8 switch condition. 102 8 HYDRAULIC MTR TEMP SENSE INPUT
708 26 +5V OUT
• If: CHS7 or CHS8 chain break switches are open. 025 31 HYD MTR SPEED ENCODER CH A
026 32 HYD MTR SPEED ENCODER CH B
– Then examine the chain routing, mast and plat-
form hardware. B+ B-

Event Code 268 CA415 ECR8

ACCESS 2 module internal problem. 1 RED +5V

593 2 BLK BATT NEG
The primary raise, auxiliary raise, traverse, pivot and 3 WHT CH A
fork extend do not operate. 4 BLU CH B
594 5 BLK
The primary lower operation is decreased (limp mode). 6 WHT
Step 1: Replace ACCESS 2. TS2

Event Code 269 Fig. 230 (27257)

ACCESS 2 module 5 V power supply is out of Event Code 272

range.
ACCESS 2 module CAN timeout.
The primary raise and lower do not operate, auxiliary
All hydraulic functions do not operate, auxiliary lower
raise operation is decreased (in limp mode).
does operate.
Step 1: Turn the truck ON and measure the voltage
Step 1: The event code is shown and flashed.
between -BV and CA411-26.
• If: Event Code 407 is shown on ACCESS 1 and
• If: The voltage = 5 V (± 0.5 V) and Event Code 269
Event Code 272 is flashed on ACCESS 2.
is recorded.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 200

– Then turn the truck OFF and examine the CAN
wires between ACCESS 2 CA411-23 and
CA411-35 and the power unit distribution panel
CA201-4 and CA201-10. Make sure the CAN_H
and CAN_L wires are on the correct terminal.
Measure the resistance between CAN_H and
CAN_L lines. The resistance must be approxi-
mately 60 Ω. Examine for short circuits or the
CAN resistors. The CAN bus has two resistors.
One in the ACCESS 5 module and one in the
wire harness between CA703-12 and CA701-8.
• If: Event Codes 504, 701, 803 are shown on
ACCESS 1 and Event Code 272 is flashed on
ACCESS 2.
– Then examine the two CAN wires between
ACCESS 4 CA314-3 and CA314-4 and the plat-
form distribution panel CA106-1 and CA106-9.
ACCESS 7
ACM
RES3 CA703 (BLK)
059 1 CAN_H
058 12 CAN_L
Fig. 231 (27251)
Event Code 273
ACCESS 2 module ECR8 hydraulic pump motor
(M2) encoder count out of range.
Primary raise and lower do not operate, all auxiliary hy-
draulic functions are decreased (in limp mode).
Note: Event Code 273 could be the result of other
event codes. If other event codes have been recorded
repair them before you continue with Event Code 273.
Step 1: Examine the wires for a short circuit or an open
circuit. Examine the wires between CA415 and ECR8.
The wire from CA411-26 to CA415-1 and the wire from
CA411-7 to CA415-2 and CA415-5. The wire from
CA411-31 to CA415-3 and the wire from CA411-32 to
CA415-4.
• If: The wires are good and the event code contin-
ues.
– Then replace ECR8.
ACCESS 2
CA411 HCM
526 7 I/O BATT NEG OUTPUT
102 8 HYDRAULIC MTR TEMP SENSE INPUT
708 26 +5V OUT
025 31 HYD MTR SPEED ENCODER CH A
026 32 HYD MTR SPEED ENCODER CH B

Power Unit B+ B-
Distribution ACCESS 2
Panel HCM ECR8
CA415
CA201 CA411
1 RED +5V
4 024 35 CAN L 593 2 BLK BATT NEG
CA206 10 023 23 CAN H 3 WHT CH A
10 1 +BV (KYS) INPUT 4 BLU CH B
594 5 BLK
2904 6 WHT
B- B+ TS2

Fig. 232 (27261)

Fig. 234 (27257)

Event Code 278

Platform ACCESS 4
Distribution ACCESS 2 module internal problem.
VCM
Panel All hydraulic functions do not operate, auxiliary lower
CA106 CA314 (BRN) does operate.
1 028 4 CAN_L
9 029 3 CAN_H Step 1: Replace ACCESS 2.

Event Codes 289, 291

Fig. 233 (27262)
Event Code 289 Hydraulic motor type problem
Event Code 291 ACCESS 2 software not correct
All hydraulic functions do not operate, auxiliary lower
will operate.

Crown 2012 PF25715-23 TSP 7000 SERIES M4.8-1970-030

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ELECTRICAL SYSTEM
EVENT CODE GROUP 200

Note: The event code could be the result of incorrect

software installed in ACCESS 2.
Step 1: Turn the truck OFF and then ON.
• If: The event code does not continue.
– Then monitor the event code.
• If: The event code continues.
– Then go to Step 2.
Step 2: Install the current software in the truck.
• If: The event code continues.
– Then go to Step 3.
Step 3: Replace ACCESS 2 and install the current soft-
ware in the truck.

Event Code 293

ACCESS 2 encoder LOS (Limited Operating Strat-
egy)
Full speed primary raise does not operate.
Note: This event code could occur after Event Code
236 or 273 is recorded. Use Event Codes 236, 237 as
a guide to repair this event code.
Step 1: Turn the truck OFF and then ON.
• If: The event code continues.
– Then replace ACCESS 2 and install the current
software.

Event Code 298

ACCESS 2 incorrect model value.
All hydraulic functions do not operate, auxiliary lower
will operate.
Note: The event code could be the result of incorrect
software installed in ACCESS 2.
Step 1: Turn the truck OFF and then ON.
• If: The event code does not continue.
– Then monitor the event code
• If: The event code continues.
– Then go to Step 2.
Step 2: Install the current software in the truck.
• If: The event code continues.
– Then go to Step 3.
Step 3: Replace ACCESS 2 and install the current soft-
ware in the truck.

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Event Code Group 300
Event Code 300
ACCESS 3 module pre-charge timeout or problem
to follow ACCESS 5 module ED1 command.
The traction is does not operate.
Step 1: Find the current status of Event Codes 546,
547, 548.
• If: The above event codes have been recorded.
– Then follow the procedure for Event Code 546.
• If: None of the above event codes have been re-
corded.
– Then follow procedure for Event Code 503 to look
for CAN bus problems.
• If: The event code continues.
– Then replace ACCESS 3.
Event Code 312
ACCESS 3 module high current condition.
The traction does not operate.
Step 1: Turn the truck OFF and disconnect the traction
motor (M1) power cables from ACCESS 3. Measure
the cables for a cable to cable short circuit and for a
cable to the frame for a short circuit.
• If: A short circuit between the U, V, W cables or the
frame.
– Then remove the power cables and measure for
short circuits directly on M1.
• If: A short circuit in M1.
– Then replace M1.
• If: No short circuits are found in M1.
– Then measure for a short circuit in the power ca-
bles.
• If: No short circuits are found in the power cables
and the event code continues.
– Then replace ACCESS 3.
Event Code 313
ACCESS 3 module traction motor (M1) current sen-
sor problem.
Traction is does not operate.
Step 1: Turn the truck OFF and measure the M1 power
cables for short circuits to M1 or to the truck frame.
• If: A short circuit problem is found between the U, V,
W cables and the truck or the M1 frame.
Crown 2012 PF25715-25 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODE GROUP 300
– Then remove the power cables and measure M1
for a short circuit to the M1 or to the truck frame.
• If: The M1 has a short circuit.
– Then replace M1.
• If: No M1 short circuit problems.
– Then a problem is in the power cables and the
frame, repair as is necessary.
• If: No short circuits are found and the event code
continues.
– Then replace ACCESS 3.
Event Code 315
ACCESS 3 module heatsink temperature < -40 °C
(-40 °F).
Traction is does not operate.
Step 1: Measure the temperature of the trucks environ-
ment.
• If: The temperature of the trucks environment
< -40 °C (-40 °F) and the truck has not been used
for an extended time.
– Then you must warm the ACCESS 3 heatsink for
the truck to operate.
• If: The temperature of the trucks environment
< -40 °C (-40 °F) the and event code continues.
– Then replace ACCESS 3.
Event Codes 317, 318
ACCESS 3 module +BV is below or above range.
The traction is does not operate.
Note: If Event Code 541 occurs for an ED system prob-
lem. Then repair Event Code 541 first.
Step 1: Make sure the Feature menu is set for the cor-
rect battery voltage (48 V TSP 6500 or 72/80 V
TSP 7000).
• If: The incorrect battery voltage is set.
– Then set the correct battery voltage.
• If: The battery voltage selection is correct.
– Then make sure the battery voltage and charge
level are correct.
• If: The battery voltage is not correct or the battery
charge is low.
– Then charge or change the battery.
• If: The battery voltage and charge level is correct.
– Then continue to Step 2.
Step 2: Measure for +BV between CA401-1 and -BV.
M4.8-1970-003
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ELECTRICAL SYSTEM
EVENT CODE GROUP 300

• If: The voltage = 48 V (TSP 6500) or 72/80 V

(TSP 7000).
– Then continue to Step 3. ACCESS 3
• If: The voltage > 0 V < 48 V (TSP 6500) 72/80 V TCM
CA401
(TSP 7000). 1 +BV(KYS) INPUT
– Then measure for +BV between CA206-8 and
-BV. 2902 B+ B-
• If: The voltage = 48 V (TSP 6500) or 72/80 V
Power Unit Distribution Panel
(TSP 7000).
CA206 FU8
– Then examine the wire between CA206-8 and 8
CA401-1.
• If: The voltage > 0 V < 48 V (TSP 6500) or 72/80 V TP17
CA204 4
(TSP 7000).
– Then examine FU8. CA406
• If: FU8 = good.
– Then examine the wire between K2 and NEG BUS
2986
CA204-4.
Step 3: Measure for +BV between ACCESS 3 +BV ter- 503
503
minal and -BV terminal.
• If: The voltage = 0 V K2
– Then examine FU11.
• If: The voltage < 48 V (TSP 6500) or 72/80 V FU11
(TSP 7000). ED1
– Then examine the ACCESS 3 +B and -BV cable
connections.
• If: The +B and -BV cable connections are good. BATT
– Then examine the cable connections between
ED1, FU11, and the -BV bus and ACCESS 3 -BV
terminal. Fig. 235 (27263)
• If: The voltage = 48 V (TSP 6500) or 72/80 V Event Code 322
(TSP 7000) and event code continues.
– Then replace ACCESS 3. ACCESS 3 has an internal temperature of more
than 85 °C (185 °F).
Full traction does not operate.
Step 1: Make sure ACCESS 3 is installed correctly.
• If: The ACCESS 3 is not installed tightly to the truck.
– Then correctly install the ACCESS 3 to the truck
(refer to service manual for screw torque).
• If: ACCESS 3 is installed correctly.
– Then examine M1 for correct operation.
Note: Heavy current use by M1 will increase the
ACCESS 3 operation temperature.
• If: M1 is good and the event code continues.
– Then replace ACCESS 3.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 300

Event Codes 323, 324 • If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
(TSP 7000).
ACCESS 3 module +BV cutback. – Then examine the ACCESS 3 +B and -BV cable
The procedures below apply to Event Codes 323, 324. connections.
Note: If Event Code 541 occurs for an ED system prob- • If: The +B and - BV cable connections are good.
lem. Then repair Event Code 541 first. – Then examine the cable connections between
Full traction does not operate. ED1, FU11, and the -BV bus and ACCESS 3,
Step 1: Make sure the Feature menu is set for the cor- -BV terminal.
rect battery voltage (48 V TSP 6500 or 72/80 V • If: The voltage = 48 V (TSP 6500) or 72/80 V
TSP 7000). (TSP 7000) and event code continues.
• If: The incorrect battery voltage is set. – Then replace ACCESS 3.
– Then set the correct battery voltage.
• If: The battery voltage selection is correct.
– Then make sure the battery voltage and charge ACCESS 3
TCM
level are correct. CA401
• If: The battery voltage is not correct or the battery 1 +BV(KYS) INPUT
charge is low.
2902 B+ B-
– Then charge or change the battery.
• If: The battery voltage and charge level is correct. Power Unit Distribution Panel
– Then continue to Step 2. CA206 FU8
8
Step 2: Measure for +BV between CA401-1 and -BV.
• If: The voltage = 48 V (TSP 6500) or 72/80 V TP17
(TSP 7000). CA204 4
– Then continue to Step 3.
CA406
• If: The voltage > 0 V < 48 V (TSP 6500) 72/80 V
(TSP 7000).
– Then measure for +BV between CA206-8 and 2986 NEG BUS
-BV. 503
503
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000). K2
– Then examine the wire between CA206-8 and
CA401-1.
• If: The voltage > 0 V < 48 V (TSP 6500) or 72/80 V FU11
ED1
(TSP 7000).
– Then examine FU8.
• If: FU8 = good. BATT
– Then examine the wire between K2 and
CA204-4.
Step 3: Measure for +BV between ACCESS 3 +BV ter- Fig. 236 (27263)
minal and - BV terminal.
• If: The voltage = 0 V Event Code 325
– Then examine FU11. ACCESS 3 module 5 V for ECR7 is out of range.
The traction does not operate.
Step 1: Turn the truck ON and measure for 5 V be-
tween CA401-26 and -BV.
• If: The voltage = 5 V (± 0.1 V) and the event code
continues.

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– Then replace ACCESS 3. Event Code 326

• If: The voltage ≠ 5 V.
– Then turn the truck OFF an remove the wire from
CA401-26. Turn the truck ON and measure for
5 V between CA401-26 and -BV.
• If: The voltage = 5 V.
– Then turn the truck OFF and connect the wire to
CA401-26 and continue to Step 2.
• If: The voltage ≠ 5 V.
– Then replace ACCESS 3.
Step 2: Turn the truck OFF and disconnect CA409
from the traction feedback module (FSB). Turn the
truck ON and measure for 5 V between CA401-26 and
-BV.
• If: The voltage = 5 V.
– Then replace ECR7.
• If: The voltage ≠ 5 V.
– Turn the truck OFF and disconnect CA408 from
FSB. Turn the truck ON and measure for 5 V be-
tween CA401-26 and -BV.
• If: The voltage = 5 V.
– Then replace FSB.
• If: The voltage ≠ 5 V.
– Then examine the wires between CA401-26 and
FSB.
ACCESS 3 module pedestrian detection system
(PDS) Platform Down driver CA401-19 over current.
Full traction does not operate (limp mode).
Note: The event code is recorded with these condi-
tion(s).
• The driver is pulling too much current.
• Damaged PDS (EU Option).
Step 1: Turn the truck OFF. Measure the resistance of
the wire from the PDS to CA612-1 and the wire from
CA612-1 to CA401-19. If the wires have a short circuit
to +B, the PDS or ACCESS 3 could be damaged.
• If: The wires = good.
– Then look for damage to the PDS.
• If: The PDS = good.
– Then replace ACCESS 3.
Note: Go to the ANALYZER Menu.
• To see the output driver turn the truck ON while you
push the up button and select PDS A3.4.14.
• To examine the output driver measure the voltage
between CA612-1 and -BV. Turn the truck ON while
you push the up and down buttons, select the PDS
A4.4.14 in the ANALYZER menu. Press and hold
the ENTER button (turns ON the driver) 5 V = OFF
and 0 V = ON.

Event Code 327

ACCESS 3
ACCESS 3 module pedestrian detection system
CA401 TCM (PDS) quit button driver CA401-20 is over current.
7 I/O BATTERY NEGATIVE
26 +5V OUT Full traction does not operate.
31 SPEED ENCODER CH B Note: The event code is recorded with these condi-
32 SPEED ENCODER CH A
tion(s).
B+ B- • The driver is pulling too much current.
• Damaged PDS (EU Option).
FSB
CA408 Step 1: Turn the truck OFF. Measure the resistance of
702 1 the wire from the PDS to CA612-2 and the wire from
511 2 CA612-2 to CA401-20. If wires have a short circuit to
001 3 ECR7 +B, PDS or ACCESS 3 could be damaged.
002 4 CA409
706 5 1 RED +5V • If: The wires = good.
514 6 2 BLK BATT NEG
– Then look for damage to the PDS.
009 7 3 BLU CH B
010 8 4 WHT CH A • If: The PDS = good.
103 9 5 BLK
WHT – Then replace ACCESS 3.
6
TS1 Note: Go to the ANALYZER Menu.
• To see the output driver turn the truck ON while you
Fig. 237 (27264) push the up button to select PDS A3.4.15 in the AN-
ALYZER menu.

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• To examine the output driver measure the voltage – Then replace TS1.
between CA612-1 and -BV. Turn the truck ON while • If: TS1 is good and the event code continues.
you push the up and down buttons, select the PDS
– Then replace ACCESS 3.
A4.4.15 in the ANALYZER menu. Press and hold
the ENTER button (turns ON the driver) 5 V = OFF
and 0 V = ON.
ACCESS 3
CA401 TCM
ACCESS 3 7 I/O BATTERY NEGATIVE
TCM 8 TRACTION MOTOR TEMP SENSE INPUT
CA611 CA401 B+ B-
7 5999 3
8 59101 6 FSB
CA612 59103 19 CA408
59104 20 514 6 CA409
1 B+ B-
2 103 9 5 BLK
6 WHT
PDS TS1
TRK GUIDANCE DETECT LOW=ACTIVE
TRK EAC DETECT LOW=IN TRK EAC Fig. 239 (27266)
901 TRK DETECTS PLATFORM LOWERED
109 PDS CABIN QUIT BUTTON INPUT Event Code 331
ACCESS 3 module pedestrian detection system
Fig. 238 (27265) (PDS) End of Aisle driver CA401-6 has a short cir-
Event Code 328 cuit or an open.
Full traction does not operate.
ACCESS 3 module traction motor (M1) temperature
Note: The event code is recorded with these condi-
above the permitted range.
tion(s).
Traction does not operate.
• A short circuit between ACCESS 3, PDS, wires,
Step 1: Check M1 for correct operation. and +B.
• If: Conditions such as vibration or high pitch sound. • An open circuit internal to the PDS system or wires.
– Then repair or replace M1. • A damaged PDS.
• If: M1 is good and the event code continues. Step 1: Turn the truck OFF and measure for short cir-
– Then replace ACCESS 3. cuits. The PDS wire to CA611-8 and the wire from
CA611-8 to CA401-6.
Event Code 329 • If: No short circuits are found.
ACCESS 3 module traction motor (M1) temperature – Then measure the wires for an open circuit.
sensor (TS1) out of range. • If: The wires are good and the event code contin-
Traction does not operate. ues.
Step 1: Turn the truck OFF. Measure the M1 sensor – Then replace the PDS.
wires for an open circuit or a short circuit. Measure the • If: The PDS = good.
wire between CA401-8 and CA408-9 and the wire be-
– Then replace ACCESS 3.
tween CA401-7 to CA408-6. The wire between
CA409-5 to TS1, the wire between CA409-6 to TS1 Note: Go to the ANALYZER Menu.
and CA408-6 to CA409-6. • To see the output driver turn the truck ON while you
• If: An open circuit or a short circuit problem is found. push the up button and select PDS A3.4.16.
– Then repair or replace the wires. • To examine the output driver measure the voltage
between CA611-8 and -BV. Turn the truck ON while
• If: The wires = good.
you push the up and down buttons, select PDS
– Then examine TS1. A4.4.16 in the menu. Press and hold the ENTER
• If: The TS1 = bad. button (turns ON driver) 5 V = OFF and 0 V = ON.

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Event Code 332 • If: ALM2+ = 48 V (TSP 6500) or 72/80 V

(TSP 7000) but ALM2- near 0 V.
ACCESS 3 module ED has an open circuit or a – Then replace ALM2.
short circuit driver.
• If: ALM2+ and ALM2- the two = 48 V (TSP 6500) or
The steering, traction, and hydraulics do not operate. 72/80 V (TSP 7000) but CA401-4 near 0 V.
Step 1: Go to Event Code 541 for ED repair procedure. – Then a problem in the wires between ALM2- and
CA401-4.
Event Code 333
• If: ALM2+, ALM2-, and CA401-4 all = 48 V (TSP
ACCESS 3 module travel alarm (ALM2) wires have 6500) or 72/80 V (TSP 7000).
an open circuit or a short circuit. – Then continue to Step 3.
Full traction does not operate. Step 3: Go into the ANALYZER menu in the ALM2 test
Step 1: Is ALM2 ON continuously? menu. Measure the voltage from CA401-4 to -BV while
• If: ALM2 is ON continuously. the output is on.
– Then remove the wire from CA401-4. • If: The voltage = 0 V and ALM2 is not ON.
• If: ALM2 stays ON. – Then replace ALM2.
– Then a short circuit problem between -BV and • If: The voltage = 0 V and ALM2 sounds.
ALM2 or wire removed from CA401-4. – Then monitor for subsequent events as the event
• If: ALM2 = OFF. could be intermittent wires.
– Then replace ACCESS 3. • If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000) while the output is on.
Step 2: ALM2 is not ON continuously. Turn the truck
ON and measure the voltage between CA401-13 and – Then replace ACCESS 3.
-BV.
• If: The voltage = 0 V.
– Then turn the truck OFF and remove the wire ACCESS 3
TCM
from CA401-13. Turn the truck ON and measure CA401
the voltage at ACCESS 3, CA401-13. 5912 4 TRAVEL ALARM DRIVER
2940 13 +BV/SUPPRESSION FOR TCM DRIVERS
• If: The voltage = 0 V.
B+ B-
– Then replace ACCESS 3.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000) RES4 ALM2
– Then turn the truck OFF and connect the wire to
CA401-13 and remove the wire from CA401-4. Fig. 240 (27267)
Turn the truck ON.
• If: The voltage = 48 V (TSP 6500) or 72/80 V Event Code 334
(TSP 7000)
ACCESS 3 module pedestrian detection system
• Then replace ACCESS 3. (PDS) In Aisle driver CA401-3 has a short circuit or
• If: The voltage = 0 V. an open.
– Then a problem in the wires or ALM2 between Full traction does not operate.
CA401-13 and CA401-4. Note: The event code is recorded with these condi-
• If: The voltage = 48 V (TSP 6500) or 72/80 V tion(s).
(TSP 7000) • A short circuit between ACCESS 3, PDS, wires and
• Then measure the voltage from ALM2+, ALM2-, +B.
CA401-4 to -BV. • An open circuit internal to the PDS system or wires.
• If: ALM2+ ≠ 48 V (TSP 6500) or 72/80 V • A damaged PDS.
(TSP 7000).
Step 1: Turn the truck OFF. Measure for a short circuit
– Then a problem in the wires between CA401-13 of the wire between the PDS to CA611-7 and the wire
and ALM2+. from CA611-7 to CA401-3.

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• If: No short circuit wires are found. – Then an open ECR7 CH A or CH B problem. Ex-
– Then measure the wires for an open circuit. amine the wires between FSB (traction feedback
splitter) CA408 and ACCESS 3 CA401. The wire
• If: The wires are good and the event code contin-
from CA401-31 to CA408-7 and the wire from
ues.
CA401-32 to CA408-8.
– Then replace the PDS.
Step 3: Event Code 336.
• If: The PDS = good.
• If: Event Code 336 is recorded.
– Then replace ACCESS 3.
– Then turn the truck OFF then ON and command
Note: Go to the ANALYZER Menu. traction.
• To see the output driver turn the truck ON while you • If: Event Code 373 is recorded.
push the up arrow key, select PDS A3.4.17.
– Then an open ECR7 CH A or CH B problem. Ex-
• To examine the output driver measure the voltage amine the wires between FSB CA408 and
between CA611-7 and -BV. Turn the truck ON while ACCESS 3 CA401. The wire from CA401-31 to
you push the up and down arrow keys, select PDS CA408-7 and the wire from CA401-32 to
A4.4.17 in the menu. Press and hold the ENTER CA408-8.
button (turns ON the driver) 5 V = OFF and 0 V =
• If: The truck moves slowly then stops without an
ON.
event code recorded.
– Then examine the wires between FSB CA408
and ACCESS 3 CA401. The wire from CA401-26
ACCESS 3
to CA408-5 and the wire from CA401-7 to
TCM
CA611 CA408-6.
CA401
7 5999 3 • If: The wires = good.
8 59101 6 – Then replace FSB.
CA612 59103 19
59104 20 • If: The event code continues.
1
2 B+ B- – Then replace ECR7.

PDS
TRK GUIDANCE DETECT LOW=ACTIVE
TRK EAC DETECT LOW=IN TRK EAC ACCESS 3
901 TRK DETECTS PLATFORM LOWERED CA401 TCM
109 PDS CABIN QUIT BUTTON INPUT 7 I/O BATTERY NEGATIVE
26 +5V OUT
31 SPEED ENCODER CH B
Fig. 241 (27265) 32 SPEED ENCODER CH A
Event Code 336 B+ B-
Traction encoder (ECR7) count error. FSB
The traction does not operate. CA408
Step 1: Look for Event Codes 325, 369, 522, 523. If 702 1
511 2
these event codes have been recorded repair them be- 001 3 ECR7
fore you continue. 002 4 CA409
These event codes are all related to ECR7. 706 5 1 RED +5V
514 6 2 BLK BATT NEG
Event Code 336: ECR7 CH A or CH B were not found 009 7 3 BLU CH B
by ACCESS 3 during travel. 010 8 4 WHT CH A
103 9 5 BLK
Event Code 373: ECR7 CH A or CH B were not sensed 6 WHT
by ACCESS 3 at traction breakout. TS1
Event Code 565: ECR7 CH A or CH B were not sensed
by ACCESS 5. Fig. 242 (27264)
Step 2: Event Code 373.
• If: Event Code 373 is recorded.

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Event Code 337 – Then replace ACCESS 3.

ACCESS 3 module traction motor (M1) is open. Event Code 368

The traction does not operate.
ACCESS 3 module VCM program error.
Note: Event code is recorded if M1 is open.
Traction does not operate.
Step 1: Turn the truck OFF and measure for continuity
Step 1: Turn the truck OFF then ON.
between M1 and the ACCESS 3 terminals to the same
M1 terminals. • If: The event code does not continue.
• If: The connection has an open. – Then put the truck in operation.
– Then repair or replace the cable or connections. • If: The event code continues.
• If: All three cables = good. – Then replace ACCESS 3.
– Then measure for continuity at the M1 terminals Event Code 369
U - V, V - W and W - U.
• If: One or more terminals = open. ACCESS 3 module traction encoder (ECR7) 5 V is
out of range.
– Then replace M1.
Traction does not operate.
• If: All = good.
Step 1: Measure the voltage on the wire between
– Then replace ACCESS 3.
CA401-26 and -BV.
Event Code 346 • If: The voltage ≠ 5 V.
– Then continue to Step 2.
ACCESS 3 module default parameters are not in-
stalled. • If: The voltage = 5 V and the event code continues.
Traction does not operate. – Then replace ACCESS 3.
Step 1: Install ACCESS 3 software. Step 2: Turn the truck OFF and remove the wire from
CA401-26. Turn the truck ON and measure the voltage
• If: Event code continues after software is installed.
between CA401-26 and -BV.
– Then replace ACCESS 3.
• If: The voltage ≠ 5 V.
Event Code 347 – Then replace ACCESS 3.
• If: The voltage = 5 V.
ACCESS 3 module interlock sequence parameter
– Then turn the truck OFF and connect the wire to
setup event.
CA401-26 and disconnect ECR7 from CA409.
Traction does not operate. Turn the truck ON and measure the voltage be-
Step 1: Install ACCESS 3 software. tween CA401-26 and -BV.
• If: Event code continues after software is installed. • If: The voltage = 5 V.
– Then replace ACCESS 3. – Then replace ECR7 and its wires.
• If: The voltage < 5 V.
Event Code 349
– Turn the truck OFF and disconnect CA408 at
ACCESS 3 module parameter change during oper- FSB. Measure the voltage between CA401-26
ation. and -BV.
Traction does not operate. • If: The voltage = 5 V.
Step 1: Turn the truck OFF then ON. – Then replace FSB.
• If: The voltage ≠ 5 V.
Event Code 351 – Then repair or replace the wires between
ACCESS 3 module parameter incorrect value. ACCESS 3 and FSB.
Traction does not operate.
Step 1: Install ACCESS 3 software.
• If: Event code continues after software is installed.

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ACCESS 3 Power Unit ACCESS 5

CA401 TCM Distribution SCM
7 I/O BATTERY NEGATIVE Panel
CA402
26 +5V OUT CA201 003 4 CAN_H
31 SPEED ENCODER CH B 1 004 5 CAN_L
32 SPEED ENCODER CH A 2
7 B- B+
B+ B- 8
ACCESS 3
FSB
TCM
CA408
CA401
702 1
511 2 019 23 CAN_H
001 3 018 35 CAN_L
ECR7
002 4 CA409
706 5 1 RED +5V B- B+
514 6 2 BLK BATT NEG
009 7 3 BLU CH B
Fig. 244 (27268)
010 8 4 WHT CH A
103 9 5 BLK Event Code 373
6 WHT
TS1
Traction encoder (ECR7) incorrect count problem.
Traction does not operate.
Fig. 243 (27264) Step 1: Look for Event Codes 325, 369, 522, 523. If
Event Code 372 these event codes have been recorded repair them be-
fore you continue.
ACCESS 3 module CAN timeout. All of these event codes are related to ECR7.
The traction and lift do not operate. Event Code 336: ECR7 one or two channels are not
Step 1: Note event codes that are shown or flashed. found by ACCESS 3 during travel.
• If: Event Code 503 is shown on ACCESS 1 and Event Code 373: ECR7 one or two channels not
Event Code 272 is flashed on ACCESS 3. sensed by ACCESS 3 at traction start.
– Then examine the connection of the CAN wires Event Code 565: ECR7 one or two channels not
between the power unit distribution panel, sensed by ACCESS 5.
CA201-7 and ACCESS 3 CA401-23. The wire Step 2: Event Code 373.
between the power unit distribution panel
• If: Event Code 373 is recorded.
CA201-2 and ACCESS 3 CA401-35. Also refer to
the procedure for Event Code 503. – Then an open ECR7 channel problem. Examine
the wires between FSB (traction feedback split-
• If: Event Codes 408, 409, 605, 708, 709, are shown
ter) CA408 and ACCESS 3 CA401. Examine the
on ACCESS 1 and Event Code 272 is flashed on
wire from CA401-31 to CA408-7 and the wire
ACCESS 3.
from CA401-32 to CA408-8.
– Then examine the connection of the CAN wires
Step 3: Event Code 336.
between ACCESS 5 CA402-4 and power unit
distribution panel CA201-8. The wire between • If: Event Code 336 is recorded.
ACCESS 5 CA402-5 and the power unit distribu- – Then turn the truck OFF then ON and command
tion panel CA201-1. Also refer to the procedure traction.
for Event Code 605. • If: Event Code 373 is recorded.
– Then an open ECR7 channel problem. Examine
the wires between FSB CA408 and ACCESS 3
CA401. The wire from CA401-31 to CA408-7 and
the wire from CA401-32 to CA408-8.

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• If: The truck moves slowly then stops and does not
record an event code.
– Then examine the wires between FSB CA408
and ACCESS 3 CA401. The wire from CA401-26
to CA408-5 and the wire fromCA401-7 to
CA408-6.
• If: The wires = good.
– Then replace FSB.
• If: The event code continues.
– Then replace ECR7.

ACCESS 3
CA401 TCM
7 I/O BATTERY NEGATIVE
26 +5V OUT
31 SPEED ENCODER CH B
32 SPEED ENCODER CH A

B+ B-
FSB
CA408
702 1
511 2
001 3 ECR7
002 4 CA409
706 5 1 RED +5V
514 6 2 BLK BATT NEG
009 7 3 BLU CH B
010 8 4 WHT CH A
103 9 5 BLK
6 WHT
TS1

Fig. 245 (27264)

Event Code 378

ACCESS 3 module has an internal problem.
Traction does not operate.
Step 1: Turn the truck OFF then ON.
• If: The event code continues.
– Then replace ACCESS 3.

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EVENT CODE GROUP 400

Event Code Group 400 • If: The resistance = 120 Ω.

– Then examine RES3 in the wire harness be-
Event Code 400 tween CA703-1 and CA703-12.
• If: The resistance = 120 Ω and the event code con-
ACCESS 4 or ACCESS 8 module CAN problem. tinues.
The primary and auxiliary raise or lower do not operate. – Then replace ACCESS 8.
Note: ACCESS 4 CAN bus transmission with
ACCESS 8 has not occurred in a specified time.
Step 1: Turn the truck ON and look at the status of ACCESS 4
ACCESS 8 LED’s. VCM
• If: The ACCESS 8 LED’s = ON. CA314 (BRN)
029 3 CAN_H
– Then a problem in the wires between ACCESS 8
028 4 CAN_L
CA504-3 and CA504-4 and the platform distribu-
tion panel CA106-3 and CA603-10. Examine the
condition of the wires and connections. Platform Distribution Panel
• If: The ACCESS 8 LED’s = OFF. CA106 CA103
– Then measure for +BV between CA504-1 and 1 15
CA504-2. 036 3
9
• If: The voltage = 48 V (TSP 6500) or 72/80 V 037 10
(TSP 7000).
– Then replace ACCESS 8. 2963
ACCESS 8
• If: The voltage = 0 V.
OCM
– Then a problem in the wires. Examine the wire CA317 CA318 CA504 (BRN)
from CA504-1 to CA318-6 and the wire from 6 BLU 6 2995 1 +BV IN
CA318-6 to CA317-6. The wire from CA317-6 to 520 2 BATT COMM IN
CA103-15 and the wire from CA504-2 to 8 BRN 8 057 3 CAN_H
7 YEL 7 056 4 CAN_L
CA505-1. Repair or replace as is necessary. Ex-
amine FU18 on the platform distribution panel. 1
CA505
• If: The wires are good and the event code contin-
ues.
Fig. 246 (27269)
– Then examine ACCESS 4 wire from CA314-3 to
CA106-9 and the wire from CA314-4 to CA106-1.
CAN transmission line test: ACCESS 7
ACM
Turn the truck OFF and measure the resistance be-
CA703 (BLK)
tween CA504-3 (CAN_H) and CA504-4 (CAN_L) on RES3
059 1 CAN_H
ACCESS 8. The resistance must = 60 Ω. 12 CAN_L
058
• If: The resistance = 0 Ω.
– Then a short circuit problem between CAN_H Fig. 247 (27251)
and CAN_L. Examine the wires and for short cir-
cuits. Repair or replace as necessary. Event Code 402
• If: The resistance > 60 Ω. ACCESS 1 or ACCESS 4 module CAN problem.
– Then the CAN bus termination resistors could be Primary and auxiliary raise, lower do not operate.
open. Disconnect CA402 from ACCESS 5 and
Note: The ACCESS 4 CAN bus transmission with
measure the resistance between CA402-4 and
ACCESS 1 has not occurred in a specified time.
CA402-5 of ACCESS 5.
• If: Event Code 402 is shown on ACCESS 1.
• If: The resistance > 120 Ω.
– Then an intermittent connection problem. Refer
– Then replace the ACCESS 5 module.
to the intermittent connection test below.

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EVENT CODE GROUP 400

• If: Event Code 402 flashes on ACCESS 4 but is not • If: The resistance > 60 Ω.
shown on ACCESS 1. – Then the CAN bus termination resistors could be
– Then continue to Step 1. open. Remove CA402 from ACCESS 5 and
Step 1: Turn the truck ON and examine the status of measure the resistance between CA402-4 and
ACCESS 1 LED’s. CA402-5 of ACCESS 5.
• If: ACCESS 1 LED’s = ON. • If: The resistance = 120 Ω.
– Then the problem is in the wires between – Then examine RES3 in the wire harness be-
ACCESS 1 CA304-4 and CA304-5 and the plat- tween CA703-1 and CA703-12.
form distribution panel CA106-2 and CA106-8. • If: The resistance = 120 Ω and the event code con-
Examine the condition of the wires and connec- tinues.
tions. – Then replace ACCESS 1.
• If: ACCESS 1 LED’s = OFF. • If: The resistance > 120 Ω.
– Then turn the truck ON and measure for +BV be- – Then replace ACCESS 5.
tween CA304-1 and CA304-2.
Intermittent connection test.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
• If: Event Codes 501 or 702 are also shown.
(TSP 7000).
– Then an intermittent connection problem in the
– Then replace ACCESS 1.
ACCESS 1 wires. Examine the wire from
• If: The voltage = 0 V. CA304-5 to CA106-2 and the wire from CA304-4
– Then examine the wire from CA304-1 to to CA106-4.
CA103-12 and the wire from CA304-2 to • If: Event Codes 400, 403, 407, 408, or 409 are also
CA104-6. Repair or replace as is necessary. shown.
• If: The wires are good and the event code contin- – Then an intermittent connection problem in the
ues. ACCESS 4 wires. Examine the wire from
– Then examine ACCESS 4 CAN wire from CA314-3 to CA106-9 and the wire from CA314-4
CA314-3 to CA106-9 and the wire from CA314-4 to CA106-1.
to CA106-1. Repair or replace as is necessary.
Step 2: Turn the truck OFF. Measure the resistance be-
tween CAN_H CA304-4 and CAN_L CA304-5 of ACCESS 7
ACCESS 1. The resistance must = 60 Ω. ACM
• If: The resistance = 0 Ω. RES3 CA703 (BLK)
– Then a short circuit problem between CAN_H 059 1 CAN_H
058 12 CAN_L
and CAN_L. Examine the wires and access mod-
ules for short circuits. Repair or replace as is nec-
essary. Fig. 248 (27251)

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 400

– Then examine the ACCESS 4 wires. The wire

from CA314-3 to CA106-9 and the wire from
ACCESS 1 CA314-4 to CA106-1.
DCM ALM1 CAN transmission line test:
CA304 Turn the truck OFF and measure the resistance be-
2946 1 +BV (KYS) tween CA703-1 CAN_H and CA703-12 CAN_L. The
512 2 BATT NEG
027 4 CAN_H resistance must = 60 Ω.
022 5 CAN_L • If: The resistance = 0 Ω.
– Then a short circuit problem between CAN_H
and CAN_L. Examine the wires and access mod-
ules for short circuits. Repair or replace as is nec-
essary.
• If: The resistance > 60 Ω.
– Then the CAN bus termination resistors could be
ACCESS 4 open. Remove CA402 from ACCESS 5 and
VCM CA106 CA103 measure the resistance between CA402-4 and
1 12 CA402-5.
CA314 2
(BRN) 028 CA104 • If: The resistance = 120 Ω.
4
CAN_L 4 8 6
– Then examine RES3 in the wire harness be-
CAN_H 3 029 9
tween CA703-1 and CA703-12. Replace RES3
or the wire harness.
Fig. 249 (27270)
• If: The resistance = 120 Ω and event code contin-
Event Code 403 ues.
– Then replace ACCESS 7.
ACCESS 4 or ACCESS 7 module CAN problem.
• If: The resistance > 120 Ω.
All hydraulics do not operate, primary lower function is
decreased (limp mode). – Then replace ACCESS 5.
Note: ACCESS 4 CAN bus transmission with
ACCESS 7 has not occurred in a specified time.
ACCESS 7
Step 1: Turn the truck ON and look at the status of the ACM
ACCESS 7 LED’s. CA703 (BLK)
RES3
• If: ACCESS 7 LED’s = ON. 059 1 CAN_H
– Then a problem in the wires between ACCESS 7 058 12 CAN_L
CA703-1 and CA703-12 and the platform distri-
bution panel CA106-6 and CA106-7. Examine Fig. 250 (27251)
the condition of the wires and connections.
• If: ACCESS 7 LED’s = OFF.
Platform ACCESS 7
– Then measure for +BV between CA703-8 and
Distribution ACM
CA703-10. Panel
• If: The voltage = 48 V (TSP 6500) or 72/80 V CA105 CA701 CA703 (BLK)
(TSP 7000). 1 BLK 1 569 8 BATT NEG INPUT
CA106 3 RED 3 2975 10 +BV INPUT
– Then replace ACCESS 7. 1 9
• If: The voltage = 0 V.
ACCESS 4
– Then examine the wire from CA703-10 to VCM
CA701-3 and the wire from CA701-3 to CA105-3. CA314 (BRN)
The wire from CA703-8 to CA701-1 and the wire 029 3 CAN_H
from CA701-1 to CA105-1. Repair or replace as 028 4 CAN_L
is necessary.
• If: The event code continues. Fig. 251 (27271)

Crown 2012 PF25715-37 TSP 7000 SERIES M4.8-1970-047

401
ELECTRICAL SYSTEM
EVENT CODE GROUP 400

Event Code 406 – Then measure the resistance of RES3 in the wire
harness between CA703-1 and CA703-12. Re-
ACCESS 2 or ACCESS 4 module CAN problem. place RES3 or the wire harness.
All hydraulics do not operate. • If: The resistance = 120 Ω and the event code con-
Follow the procedures for Event Code 407. tinues.
– Then replace ACCESS 2.
Event Code 407 • If: The resistance > 120 Ω.
ACCESS 2 or ACCESS 4 module CAN problem. – Then replace ACCESS 5.
All hydraulics do not operate.
Note: ACCESS 2 CAN bus transmission with
ACCESS 4 has not occurred in a specified time. ACCESS 7
ACM
Step 1: Turn the truck ON and look at the status of the
RES3 CA703 (BLK)
ACCESS 2 LED’s.
059 1 CAN_H
• If: The ACCESS 2 LED’s = ON. 058 12 CAN_L
– Then the problem is in the wires between
ACCESS 2 CA411-23 and CA411-35 and the Fig. 252 (27251)
power unit distribution panel CA201-4 and
CA201-10. Examine the condition of the wires
and connections. Power Unit
• If: The ACCESS 2 LED’s = OFF. Distribution ACCESS 2
Panel HCM
– Then measure for +BV between CA411-1 and CA201 CA411
-BV. 4 024 35 CAN L
CA206 10 023
• If: The voltage = 48 V (TSP 6500) or 72/80 V 23 CAN H
10 1 +BV (KYS) INPUT
(TSP 7000).
– Then replace ACCESS 2. 2904
B- B+
• If: The voltage = 0 V.
– Then the problem is in the wire from CA411-1 to Fig. 253 (27261)
CA206-10 examine the wire.
• If: The event code continues.
– Then examine ACCESS 4 wire from CA314-3 to Platform ACCESS 4
Distribution
CA106-9 and the wire from CA314-4 to CA106-1. VCM
Panel
CAN transmission line test: CA106 CA314 (BRN)
Turn the truck OFF and measure the resistance be- 1 028 4 CAN_L
9 029 3 CAN_H
tween CA411-23 CAN_H and CA411-35 CAN_L. The
resistance must = 60 Ω.
• If: The resistance = 0 Ω. Fig. 254 (27262)

– Then a short circuit problems between CAN_H
and CAN_L. Examine the wire and access mod-
ules for short circuits. Repair or replace as is nec-
essary.
• If: The resistance > 60 Ω.
– Then the CAN bus termination resistors could be
open. Remove CA402 from ACCESS 5 and
measure the resistance between CA402-4 and
CA402-5.
• If: The resistance = 120 Ω.
Event Codes 408, 409
ACCESS 4 or ACCESS 5 module CAN problem.
Procedures apply to Event Codes 408, 409.
The primary raise or lower do not operate.
Note: ACCESS 4 CAN bus transmission with
ACCESS 5 has not occurred in a specified time.
Step 1: Turn the truck ON and look at the status of the
ACCESS 5 LED’s.
• If: ACCESS 5 LED’s = ON.

M4.8-1970-049 TSP 7000 SERIES Crown 2012 PF25715-38

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 400

– Then the problem is in the wire between • If: The resistance > 60 Ω.
ACCESS 5 CA402-4 and CA402-5 and the – Then the CAN bus termination resistors could be
power unit distribution panel CA201-8 and open. Remove CA402 from ACCESS 5 and
CA201-2. Examine the condition of the wires and measure the resistance between CA402-4 and
connections. CA402-5.
• If: ACCESS 5 LED’s = OFF. • If: The resistance = 120 Ω.
– Then measure for +BV between CA403-10 and – Then measure the resistance of RES3 in the wire
-BV. harness between CA703-1 and CA703-12. Re-
• If: The voltage = 48 V (TSP 6500) or 72/80 V place the resistor or wire harness.
(TSP 7000). • If: The resistance = 120 Ω and the event code con-
– Then replace ACCESS 5. tinues.
• If: The voltage = 0 V. – Then replace ACCESS 4.
– Then a problem in the wire from CA403-10 to • If: The resistance > 120 Ω.
CA206-9. – Then replace ACCESS 5.
• If: The event code continues.
– Then examine ACCESS 4 wire from CA314-3 to
CA106-9 and the wire from CA314-4 to CA106-1. ACCESS 7
CAN transmission line test: ACM
RES3 CA703 (BLK)
Turn the truck OFF and measure the resistance of
059 1 CAN_H
ACCESS 5 between CA402-4, CAN_H and CA402-5, 058 12 CAN_L
CAN_L. The resistance must = 60 Ω.
• If: The resistance = 0 Ω.
Fig. 255 (27251)
– Then a short circuit between CAN_H and
CAN_L. Measure the wires and the access mod-
ules for short circuits. Repair or replace as is nec- Platform ACCESS 4
essary. Distribution VCM
Panel
CA106 CA314 (BRN)
1 028 4 CAN_L
9 029 3 CAN_H

Fig. 256 (27262)

Power Unit
Distribution ACCESS 5
Panel SCM
CA201 CA402
8 003 4 CAN_H
CA206 2 004 5 CAN_L
9
CA403
2903 10 +BV INPUT
A1 B+ A2 B-

Fig. 257 (27272)

Event Codes 411 - 430

ACCESS 4 module internal problem.
The procedures below apply to Event Codes 411 - 430.

Crown 2012 PF25715-39 TSP 7000 SERIES M4.8-1970-051

403
ELECTRICAL SYSTEM
EVENT CODE GROUP 400

The primary raise or lower and auxiliary hydraulics do
not operate.
Step 1: Replace ACCESS 4.
Event Code 436
ACCESS 4 module seat solenoid current is too
high that locks the seat.
Note: Event code is recorded if too much current flows
through the module driver at CA312-7.
Step 1: Turn the truck OFF and remove the wire from
CA312-7. Turn the truck ON and operate the seat re-
lease switch (RSS).
• If: The event code is recorded.
– Then replace ACCESS 4.
• If: The event code is not recorded.
– Then a short circuit problem in the wires and or
solenoid. Turn the truck OFF and install the wire
into CA312-7 and continue to Step 2.
Step 2: Remove the wire from CA316-1. Turn the truck
ON and operate the seat release switch (RSS).
• If: The event code is not recorded.
– Then a short circuit problem in the solenoid that
locks the seat (EML). Replace the EML.
• If: The event code is recorded.
– Then examine the wire from CA316-1 to
CA312-7 and the wire from CA316-6 to CA312-8
for short circuits.
BLK
CA316
ACCESS 4
1
EML BLK 6 VCM
CA312 (BLK)
5913 7 SEAT REL SOLENOID OUTPUT
2989 8 +BV TO SEAT REL SOLENOID
Fig. 258 (27273)
Event Code 437
ACCESS 4 module primary height encoder ECR5
power supply wire has an open.
The traction, primary raise and lower, and auxiliary
raise functions are decreased (in limp mode).
Step 1: Examine the ECR5 wires. The wire from ECR5
to CA310-3 and the wire from CA310-3 to CA313-9.
The wire from ECR5 to CA310-4 and the wire from
CA310-4 to CA313-10.
• If: The wires are good and the event code contin-
ues.
– Then replace ECR5.
• If: The event code continues.
– Then replace ACCESS 4.
ACCESS 4
VCM
CA310 CA313 (GRN)
RED 3 709 9 HGT ENCODER +5V
BLK 4 519 10 HGT ENCODER BATT NEG
ECR5 ORG 1 032 11 HGT ENCODER CH A
WHT 2 033 12 HGT ENCODER CH B
Fig. 259 (27274)
Event Code 438
ACCESS 4 module primary height encoder ECR5
channel CH A or CH B open.
The traction, primary raise and lower, and auxiliary
raise functions are decreased (in limp mode).
Step 1: Examine the wires from ECR5 to CA310-1 and
the wire from CA310-1 to CA313-11.The wire from
ECR5 to CA310-2. The wire from CA310-2 to
CA313-12 and the wire from ECR5 to CA310-4. The
wire from CA310-4 to CA313-10.
• If: The wires are good and the event code contin-
ues.
– Then continue to Step 2.
Step 2: Look for more event codes.
• If: The Event Codes 437 or 447 have been re-
corded.
– Then repair them before you continue to Step 3.
• If: The Event Code 438 is recorded.
– Then continue to Step 3.
Step 3: Turn the truck OFF and disconnect the ECR5
wires from CA310-1 and CA310-2. Turn the truck ON
and measure the voltage from the ORG wire (CH A)
and to -BV, turn the truck ON and measure the voltage.
The voltage must = 0 V or 5 V because of the position
of the ECR5 rotor. Do the same test on the WHT wire
(CH B).
• If: The voltage ≠ 0 V or 5 V.
– Then replace ECR5.
• If: The voltage = 0 V or 5 V.
– Then turn the truck OFF and connect the ORG
(CA310-1) and WHT (CA310-2) wires. Turn the
truck ON and measure the voltage between the

M4.8-1970-052 TSP 7000 SERIES Crown 2012 PF25715-40

404
 ELECTRICAL SYSTEM
EVENT CODE GROUP 400

wire from CA310-1 to -BV and between the wire Event Code 440
from CA310-2 to -BV.
• If: The voltage = 5.5 V. ACCESS 4 module primary height encoder ECR5
set again to zero problem.
– Then replace ECR5.
The traction, primary raise or lower, and auxiliary raise
• If: The voltage = 0 V or 5 V and the event code con-
functions decreased (in limp mode).
tinues.
Step 1: Examine the ECR5 wires. The wire from ECR5
– Then replace ACCESS 4.
to CA310-1 and the wire from CA310-1 to CA313-11.
The wire from ECR5 to CA310-2 and the wire from
Event Code 439 CA310-2 to CA313-12. The wire from ECR5 to
ACCESS 4 module primary height encoder ECR5 CA310-3 and the wire from CA310-3 to CA313-9. The
count incorrect. wire from ECR5 to CA310-4 and the wire from
CA310-4 to CA313-10.
The traction, primary raise or lower and auxiliary raise
functions decreased (in limp mode). • If: The wires = bad.
Note: The event code will be recorded if the load is too – Then repair or replace the wires
large to prevent a primary raise movement. • If: The wires = good.
Step 1: Examine the operation of the primary raise and – Then examine the height reset switch HGTRS1
lower. and related wires. The wire from HGTRS1 to
• If: The primary raise and lower do not operate. CA308 and the wire to CA311-5. The wire from
HGTRS1 to CA308 and the wire from CA308 to
– Then examine the operation of PVMR, MVL, RV1
CA101-2.
also examine for contamination.
• If: The wires are good and the event code contin-
• If: The primary raise and lower do operate.
ues.
– Then examine the ECR5 wires. The wire from
– Then replace HGTRS1.
ECR5 to CA310-1 and the wire from CA310-1 to
CA313-11. The wire from ECR5 to CA310-2 and • If: The event code continues.
the wire from CA310-2 to CA313-12. The wire – Then replace ACCESS 4.
from ECR5 to CA310-3 and the wire from
CA310-3 to CA313-9. The wire from ECR5 to
CA310-4 and the wire from to CA313-10. Platform Distribution
• If: The wires are good and the event code contin- Panel
ues. CA101
– Then replace ECR5. 2
• If: The event code continues. 535
– Then replace ACCESS 4. ACCESS 4
CA308
BLK VCM
CA311 (GRY)
ACCESS 4 BLK 5920 5 HEIGHT RESET SW IN
VCM HGTRS1
CA310 CA313 (GRN)
CA310 CA313 (GRN) RED 3 709 9 HGT ENCODER +5V
RED 3 709 9 HGT ENCODER +5V BLK 4 519 10 HGT ENCODER BATT NEG
BLK 4 519 10 HGT ENCODER BATT NEG ECR5
ECR5 ORG 1 032 11 HGT ENCODER CH A
ORG 1 032 11 HGT ENCODER CH A WHT 2 033 12 HGT ENCODER CH B
WHT 2 033 12 HGT ENCODER CH B

Fig. 261 (27275)

Fig. 260 (27274)

Crown 2012 PF25715-41 TSP 7000 SERIES M4.8-1970-053

405
ELECTRICAL SYSTEM
EVENT CODE GROUP 400

Event Code 441 Event Code 442

ACCESS 4 module primary mast broken height
sensor cable.
The traction, primary raise or lower, and auxiliary raise
functions are decreased (in limp mode).
Note: The event code could be recorded if the truck is
in operation on a rough floor surface. A sudden raise or
lower in the handle movements.
Step 1: Turn the truck ON while you push the up but-
ton. Go to HCS (height cable switch) A2.4.13 in the AN-
ALYZER menu and look at the indication.
• If: The HCS switch shows closed.
– Then the status is correct. The event code could
have occurred because of the above note.
• If: The switch = open.
– Then raise the platform sufficient in free lift to put
the jack stands or hardwood blocks in the chan-
nels of the mast. Refer to SAFETY > Control of
Hazardous Energy > Jacking and Blocking >
Platform. Examine the primary mast height en-
coder ECR5 cable for all types of damage.
• If: The cable = good.
– Then examine the HCS wires. The ACCESS 2
wire from CA411-9 to CA414-7 and the wire from
CA414-7 to HCS. The wire from HCS to CA414-8
and the wire from CA414-8 to CA206-12.
• If: The wires = good.
– Then examine the adjustment of HCS.
• If: HCS adjustment is good and the event code con-
tinues.
– Then replace HCS.
• If: The event code continues.
– Then replace ACCESS 2.
COMM NO
WHT
HCS ACCESS 2
BLK HCM
CA411
7 2916 9 HCS SWITCH INPUT
8
CA414 B- B+
Power Unit
2918 Distribution
Panel
CA206
12
ACCESS 4 module primary height encoder ECR5
count problem.
The traction, primary raise or lower, and auxiliary raise
functions are decreased (in limp mode).
Step 1: Monitor the primary mast for movement (drift)
down.
• If: The primary mast has movement (drift) down.
– Then examine the hydraulic system. Manual low-
ering valve (MVL), defective or dirty SVML or
CV2 that do not close or open correctly.
• If: The primary mast has no movement (drift) down.
– Then examine if the primary mast has movement
up during auxiliary raise.
• If: The primary mast has movement up during aux-
iliary raise.
– Then examine the PVMR valve for correct opera-
tion.
• If: No mast movement and the event code contin-
ues.
– Then replace ECR5.
• If: The event code continues.
– Then replace ACCESS 4.
Event Code 443
ACCESS 4 module primary height encoder ECR5
count in the opposite direction.
The traction, primary raise or lower, and auxiliary raise
functions are decreased (in limp mode).
Note: Primary mast must be lowered then raised
through the HGTRS1 switch to reset the encoder
counts.
Step 1: Examine the ECR5 wires. The wire from ECR5
to CA310-1 and the wire from CA310-1 to CA313-11.
The wire from ECR5 to CA310-2 and the wire from
CA310-2 to CA313-12.
• If: The wires are not in the correct pin position.
– Then correct the wires pin connection.
• If: The wires = good.
– Then replace ECR5.
• If: The event code continues.
– Then replace ACCESS 4.

Fig. 262 (27276)

M4.8-1970-054 TSP 7000 SERIES Crown 2012 PF25715-42

406
 ELECTRICAL SYSTEM
EVENT CODE GROUP 400

ACCESS 4 COMM NO ACCESS 2

VCM
CA310 CA313 (GRN)
RED 3 709 9 HGT ENCODER +5V
BLK 4 519 10 HGT ENCODER BATT NEG
ECR5 ORG 1 032 11 HGT ENCODER CH A
WHT 2 033 12 HGT ENCODER CH B
Fig. 263 (27274)
Event Code 444
ACCESS 4 module cable tension slack.
The primary and auxiliary raise, lower do not operate.
Note: The event code could be recorded if the truck is
in operation on a rough floor surface. A sudden raise or
lower in the handle movements.
Step 1: Look at F2 in the Features menu and make
sure the correct mast type is set. If TF is set and the
mast type is TN or TT, Event Code 444 will be re-
corded.
• If: The mast type is correct and the event code con-
tinues.
– Then continue to Step 2.
Step 2: Turn the truck ON while you push the up but-
ton. Go to CTS A2.4.9 in the ANALYZER menu and
look at the indication.
• If: The CTS switch = closed.
– Then the status is correct. The event code could
have occurred because of the above note.
• If: The CTS switch = open.
– Then examine the hose take-up cable adjust-
ment (refer to Mast > Hose Take-Up Cable in the
Service and Parts manual).
• If: The cable tension adjustment is good and the
event code continues.
– Then examine the CTS wires. The wire from CTS
to CA416-1 and the wire from CA416-1 to
CA411-10. The wire from CTS to CA416-2 and
the wire from CA416-2 to CA206-15.
• If: The wires = bad.
– Then repair or replace wires.
• If: The wires are good and the event code contin-
ues.
– Then replace CTS.
• If: The event code continues.
– Then replace ACCESS 2.
CTS HCM
CA414 CA411
BLK 1 2915 10 CTS SWITCH INPUT
WHT 2
B- B+
Power Unit
2938 Distribution
Panel
CA206
15
Fig. 264 (27277)
Event Code 445
ACCESS 4 module primary chain slack.
The traction, primary and auxiliary lower, pivot, trav-
erse, fork extend or retract do not operate.
Note: Incorrect chain adjustment can cause this event
code to be recorded.
Step 1: Turn the truck ON while you push the up arrow
button. Go to CHS1-2 A2.2.6 in the ANALYZER menu
and look at the indication.
• If: The CHS1 and CHS2 switch = closed.
– Then the status is correct. The event code could
have occurred because of the above note.
• If: The CHS1 and CHS2 switch = open.
– Then examine the chain adjustment (refer to
Platform in the Service and Parts manual).
• If: The chain adjustment is good and the event code
continues.
– Then examine the CHS1 and CHS2 adjustment
(refer to Componentry in the Service and Parts
Manual).
• If: The CHS1 and CHS2 adjustment = good.
– Then turn the truck OFF and measure the resist-
ance of CHS1 and CHS2.
• If: CSH1 and CHS2 resistance = 0 Ω and the event
code continues.
– Then examine the CHS wires. ACCESS 4
CA311-12 wire to CA309-4 and the wire from
CA309-4 to CHS1. The wire between CHS1 to
CHS2 and the wire from CHS2 to CA309-1. The
wire from CA309-1 to CA101-4.
• If: The wires are good and the event code contin-
ues.

Crown 2012 PF25715-43 TSP 7000 SERIES M4.8-1970-056

407
ELECTRICAL SYSTEM
EVENT CODE GROUP 400

– Then replace CHS1 or CHS2. – Then examine the CHS3 and CHS4 wires.
ACCESS 4 CA311-11 wire to CA309-3 and the
wire from CA309-3 to CHS3 The wire between
ACCESS 4 CHS3 to CHS4. The wire from CHS4 to CA309-2
VCM and the wire to CA101-5.
CA311 (GRY)
5916 11 CHAIN BREAK SW IN
5917 12 CHAIN SLACK SW IN ACCESS 4
VCM
CA309 CA311 (GRY)
1 BLK 5916 11 CHAIN BREAK SW IN
2 BLK 5917 12 CHAIN SLACK SW IN
3 BLK BLK
4 CH3 BREAK CH4
RIGHT LEFT CA309
1 BLK
BLK BLK 2 BLK
CH1 SLACK CH2
CHS1 CHS2 3 BLK BLK
4 CH3 BREAK CH4
RT LT RIGHT LEFT
CHS3

CHS4

Platform Distribution
CHAIN CHAIN Panel BLK BLK
CA101 CH1 SLACK CH2
532 4 CHS1 CHS2
533 5 RT LT
CHS3

Fig. 265 (27278)
Event Code 446
ACCESS 4 module primary chain break.
The traction, primary and auxiliary raise or lower, pivot,
traverse, fork extend or retract do not operate.
Note: Incorrect chain adjustment can cause this event
code to be recorded.
Step 1: Examine the primary mast chains for damage
or breaks.
• If: The chains = good.
– Then continue to Step 2.
Step 2: Turn the truck ON while you push the up but-
ton. Go to CHS3-4 A2.2.8 in the ANALYZER menu and
look at the indication.
• If: The CHS3 and CHS4 switch = closed.
– Then status is normal. Event code may have oc-
curred due to the above note.
• If: The CHS3 and CHS4 switch = open.
– Then examine the CSH3 and CHS4 adjustment
(refer to Componentry in the Service and Parts
Manual).
• If: The CHS3 and CHS4 adjustment = good.
– Then turn the truck OFF and measure the resist-
ance of CHS3 and CHS4.
• If: The CHS3 and CHS4 resistance = 0 Ω and the
event code continues.
CHS4
Platform Distribution
CHAIN CHAIN Panel
CA101
532 4
533 5
Fig. 266 (27278)
Event Code 447
ACCESS 4 module primary height encoder ECR5
power supply is out of range.
The traction, primary raise, lower and auxiliary raise
functions are decreased (in limp mode).
Note: The event code is recorded if the ECR5 power
supply voltage = 4.75 V - 5.5 V range.
Step 1: Turn the truck ON and measure the voltage
from CA313-9 to -BV.
• If: The voltage ≠ 4.75 V - 5.5V.
– Then turn the truck OFF and disconnect the wire
from CA313-9. Turn the truck ON and measure
the voltage between CA313-9 and -BV.
• If: The voltage = 4.75 V - 5.5 V.
– Then a short circuit in the ECR5 wires. Examine
the wire from ECR5 to CA310-1 and the wire from
CA310-1 to CA313-11. The wire from ECR5 to
CA310-2 and the wire from CA310-2 to
CA313-12. The wire from ECR5 to CA310-3 and
the wire from CA310-3 to CA313-9. The wire from
ECR5 to CA310-4 and the wire to CA313-10.

M4.8-1970-057 TSP 7000 SERIES Crown 2012 PF25715-44

408
 ELECTRICAL SYSTEM
EVENT CODE GROUP 400

• If: The wires are good and the event code contin-
ues.
– Then replace ECR5.
• If: The voltage ≠ 4.75 V - 5.5 V.
– Then replace ACCESS 4.

ACCESS 4
VCM
CA310 CA313 (GRN)
RED 3 709 9 HGT ENCODER +5V
BLK 4 519 10 HGT ENCODER BATT NEG
ECR5 ORG 1 032 11 HGT ENCODER CH A
WHT 2 033 12 HGT ENCODER CH B

Fig. 267 (27274)

Event Codes 491 - 499

ACCESS 4 module internal problem.
The procedures below apply to Event Codes 491 - 499.
All hydraulic functions do not operate.
Step 1: Install the current software in to ACCESS 4.
• If: The event code continues.
– Then replace ACCESS 4.

Crown 2012 PF25715-45 TSP 7000 SERIES M4.8-1970-058

409
ELECTRICAL SYSTEM
EVENT CODE GROUP 500

Event Code Group 500 • If: The voltage = 0 V.

– Then examine the wire between CA103-12 and
Event Code 501 CA304-1 and the wire between CA104-6 and
CA304-2.
ACCESS 1 module CAN timeout. • If: ACCESS 1 is on and the ALM1 sounds continu-
The traction and hydraulics do not operate. ously.
Condition 1: Intermittent transmissions between – Then examine the CAN wires between the plat-
ACCESS 1 and ACCESS 5 can cause ACCESS 5 to form distribution panel and ACCESS 1. Examine
flash and record Event Code 501. ACCESS 1 must re- the wire between CA106-2 and CA304-4 and the
ceive the Event Code 501 from ACCESS 5 to illumi- wire between CA106-8 and CA304-5. The mast
nate the wrench light. When the wrench light is ON can cable 2 from CA107-7 & -8 to CA413-7 & -8. The
show that transmissions between the ACCESS 1 and wire from CA413-7 to CA201-9 and the wire from
ACCESS 5 were stopped. CA413-8 to CA210-3.
Condition 2: No transmissions between ACCESS 1 • If: ACCESS 1 wrench light illuminates and records
and ACCESS 5. ACCESS 5 will flash Event Code 501, Event Codes 104, 605.
but the event code will not be recorded and the wrench – Then examine the CAN wires between the power
light will not illuminate. Traction, hydraulics and steer- unit distribution panel and ACCESS 5. Examine
ing do not operate. the wire between CA201-8 and CA402-4. and the
Step 1: Event condition. wire between CA201-2 and CA402-5.
• If: ACCESS 1 wrench light is illuminated and the
Event Code 501 is recorded.
– Then continue to Step 2. ACCESS 1
DCM ALM1
• If: ACCESS 5 flashes Event Code 501 and the
CA304
wrench light is not illuminated.
2946 1 +BV (KYS)
– Then continue to Step 3. 512 2 BATT NEG
Step 2: Intermittent transmission between ACCESS 1 027 4 CAN_H
022 5 CAN_L
and ACCESS 5. Look for more event codes.
If: The Event Codes 402, 702 have been recorded.
– Then the problem is in the wires between the
platform distribution panel and ACCESS 1. Ex-
amine the wires and connections. The wire be-
tween CA103-12 and CA304-1 and the wire
between CA104-6 and CA304-2. The wire be-
tween CA106-8 and CA304-4 and the wire be-
CA106 CA103
tween CA106-2 and CA304-5.
2 12
• If: The wires are good and the event code contin- 8 CA104
ues.
6
– Then clean the wire connections and connectors.
• If: Event Codes 408, 409, 564, 605, 708, 709 have
Fig. 268 (27279)
been recorded.
– Then the problem is in the wires between the
power unit distribution panel and ACCESS 5. Ex- Power Unit ACCESS 5
amine the wire between CA201-8 and CA402-4 Distribution SCM
and the wire between CA201-2 and CA402-5. Panel CA402
Step 3: No transmission between ACCESS 1 and CA201 003 4 CAN_H
004 5 CAN_L
ACCESS 5. 2
• If: ACCESS 1 is not on. 8
B- B+
– Then turn the truck ON and measure for +BV be-
tween CA304-1 and -BV. Fig. 269 (27280)

M4.8-1970-003 TSP 7000 SERIES Crown 2012 PF25715-47

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 500

Event Code 502 and CA401-23. The wire and connection be-
tween CA201-1 and CA401-35.
ACCESS 2 transmission (CAN) with ACCESS 5 • If: The wires and connections = good.
module timeout.
– Then clean the wire connections and connectors.
The ED, steering, traction, and hydraulics do not oper-
• If: ACCESS 3 LED’s = OFF.
ate.
– Then the problem is in the wires between the
Step 1: Examine for power to ACCESS 2.
power unit distribution panel and ACCESS 3.
• If: ACCESS 2 LED’s = ON. Measure for +BV between CA401-1 and -BV.
– Then examine the wires and connections be- • If: The voltage = 48 V (TSP 6500) or 72/80 V
tween the power unit distribution panel and (TSP 7000).
ACCESS 2. The wire from CA201-10 to
– Then replace ACCESS 3.
CA411-23. and the wire fromCA201-4 to
CA411-35. The wire from CA206-10 to CA411-1. • If: The voltage = 0 V.
• If: The wires = bad. – Then the problem is in the wires or connections
between the power unit distribution panel and
– Then repair or replace the wires.
ACCESS 3. Examine the wire between CA206-8
• If: The ACCESS 2 LED’s = OFF. and CA401-1.
– Then measure for +BV between CA411-1 and
-BV.
• If: The voltage = 0 V. Power Unit
– Then examine the wire from CA206-10 to Distribution
CA411-1. Panel
ACCESS 3
CA206
• If: The wire = bad. 8 TCM
– Then repair or replace the wire. CA401
CA201 2902 1 +BV(KYS) INPUT
• If: The wire is good and the event code continues.
7 019 23 CAN_H
– Then replace ACCESS 2. 1 018 35 CAN_L

B- B+
Power Unit
Distribution ACCESS 2 Fig. 271 (27281)
Panel HCM Event Code 504
CA201 CA411
4 024 35 CAN L ACCESS 4 module CAN timeout.
CA206 10 023 23 CAN H
10 1 +BV (KYS) INPUT The traction, steering, lift hydraulics, and ED do not op-
erate.
2904
B- B+ Step 1: Examine for power to ACCESS 4.
• If: ACCESS 4 LED’s = ON.
Fig. 270 (27261) – Then the problem is in the wires between the
Event Code 503 platform distribution panel and ACCESS 4. Ex-
amine the wires and connections. The wire be-
ACCESS 3 module CAN timeout. tween CA314-2 and CA101-1 and the wire
The traction, steering, hydraulics, and ED do not oper- between CA314-4 and CA106-1. The wire be-
ate. tween CA314-3 and CA106-9 and the wire be-
tween CA314-1 and CA103-13.
Step 1: Examine for power to ACCESS 3.
• If: The wires = good.
• If: ACCESS 3 LED’s = ON.
– Then clean the wire connections and connectors.
– Then the problem is in the wires between the
power unit distribution panel and ACCESS 3. Ex- • If: ACCESS 4 LED’s = OFF.
amine the wire and connections between
CA206-8 and CA401-1 and between CA201-7

Crown 2012 PF25715-48 TSP 7000 SERIES M4.8-1970-060

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ELECTRICAL SYSTEM
EVENT CODE GROUP 500

– Then the problem is in the wires between the

platform distribution panel and ACCESS 4.
Measure for +BV between CA314-1 and -BV. Platform
• If: The voltage = 48 V (TSP 6500) or 72/80 V Distribution
(TSP 7000). Panel
CA106
– Then replace ACCESS 4.
6 ACCESS 7
• If: The voltage = 0 V. 7
ACM
– Then the problem is in the wires between the CA703 (BLK)
platform distribution panel and ACCESS 4. Ex- CA701 059 1 CAN_H
amine the wire between CA314-1 and CA103-13. BRN 7 046 058 12 CAN_L
The wire between CA314-2 and CA101-1. YEL 8 047

RES3
CA106 CA101 Fig. 273 (27283)
1 1
9 CA103 Event Code 507
13
ACCESS 7 module CAN timeout.
The traction, steering, hydraulics, and ED do not oper-
ate.
ACCESS 4 Step 1: Examine for power to ACCESS 7.
VCM • If: ACCESS 7 LED’s = ON.
CA314 (BRN) – Then the problem is in the wires between the
2950 1 +BV IN platform. Examine the wires and connections.
518 2 BATT COMM IN
029 3 CAN_H The wire between CA701-7 and CA106-6 and the
028 4 CAN_L wire between CA701-8 and CA106-7. The wire
between CA701-1 and CA105-1 and the wire be-
Fig. 272 (27282) tween CA701-3 and CA105-3. The wire between
CA701-7 and the junction of the wire connected
Event Code 505 to CA703-12. The wire between CA701-8 and the
junction of the wire connected to CA703-1. The
ACCESS 5 module CAN problem. wire between CA701-3 and CA703-10.
Note: The event code can occur because of an elec- • If: ACCESS 7 LED’s = OFF.
tronic noise or a timeout problem. With this condition
the truck will go back to operation with no effect on per- – Then the problem is in the wires between the
formance. platform distribution panel and ACCESS 7.
Measure for +BV between CA703-10 and -BV.
• If: The event code is frequent.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
– Then continue to Step 1. (TSP 7000).
Step 1: Examine the CAN_H and CAN_L wires and – Then replace ACCESS 7.
connections between the platform distribution panel
and ACCESS 7. The wire between CA703-1 and the • If: The voltage = 0 V.
wire between CA701-8 and RES3. Then examine the – Then the problem is in the wires between the
wires between CA703-12 and to CA701-7. platform distribution panel and ACCESS 7. Ex-
• If: The wires = good. amine the wires and connections. The wire be-
tween CA703-10 and CA701-3. The wire
– Then examine the wire between CA701-7 and between CA701-3 and CA105-3.
CA106-6. The wire between CA701-8 and
CA106-7.
• If: The wires = good.
– Then clean the wire connections and connectors.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 500

– Then replace ACCESS 8.

• If: The voltage = 0 V.
Platform – Then the problem is in the wires between the
Distribution platform distribution panel and ACCESS 8. Ex-
Panel amine the wire between CA103-15 and CA317-6
CA105
and the wire between CA317-6 and CA318-6.
1 BLK
3 RED The wire between CA504-1 and CA318-6.
CA106
6 BRN
7 YEL ACCESS 7 Platform Distribution Panel
ACM
CA703 (BLK) CA317 CA106 CA103
059 1 CAN_H 7 036 3 CA104 15
1 569 8 BATT NEG INPUT 8 037 10
7 8
3 2975 10 +BV INPUT 5 541
7 046 058 12 CAN_L 4
6 540
8 047
CA701 2963
RES3
ACCESS 8
Fig. 274 (27284) CA318 OCM
BLU 6 2995 CA504 (BRN)
Event Code 508 GRN 4 583 CA505 1 +BV IN
ORG 5 582 1 520 2 BATT COMM IN
ACCESS 8 module CAN timeout. BRN 8 057 3 CAN_H
YEL 7 056 4 CAN_L
The traction, steering, hydraulics, and ED do not oper-
ate.
Fig. 275 (27285)
Step 1: Examine for power to ACCESS 8.
• If: ACCESS 8 LED’s = ON. Event Codes 509, 510
– Then the problem is in the wires between the ACCESS 6 module CAN timeout.
platform distribution panel and ACCESS 8. Ex- The procedures below apply to Event Codes 509, 510.
amine the wires and connections. The wire be-
Step 1: Examine for power to ACCESS 6.
tween CA106-3 and CA317-7 and the wire
between CA317-7 and CA318-7. The wire be- • If: ACCESS 6 LED’s = ON.
tween CA318-7 and CA504-4 and the wire be- – Then the problem is in the wires between the
tween CA106-10 and CA317-8. The wire power unit distribution panel and ACCESS 6. Ex-
between CA317-8 and CA318-8 and the wire be- amine the wires and connections. The wire be-
tween CA318-8 and CA504-3. The wire between tween CA601-4 and CA201-11 and the wire
CA104-7 and CA317-5 and the wire between between CA601-5 and CA201-5. The wire be-
CA317-5 and CA318-5. The wire between tween CA601-1 and CA206-11 and the wire be-
CA318-5 and CA505-1 and the wire between tween CA601-2 and CA406 -BV.
CA104-8 and CA317-4. The wire between • If: The wires = good.
CA317-4 and CA318-4 and the wire between
– Then clean the wire connections and connectors.
CA318-4 and CA505-1. The wire between
CA505-1 and CA504-2. • If: ACCESS 6 LED’s = OFF.
• If: The wires = good. – Then the problem is in the wires between the
power unit distribution panel and ACCESS 6.
– Then clean the wire connections and connectors.
Measure +BV between CA601-1 and -BV.
• If: ACCESS 8 LED’s = OFF.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
– Then the problem is in the wires between the (TSP 7000).
platform distribution panel and ACCESS 8.
– Then replace ACCESS 6.
Measure for +BV between CA504-1 and -BV.
• If: The voltage = 0 V.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000).

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ELECTRICAL SYSTEM
EVENT CODE GROUP 500

– Then the problem is in the wires between the – Then turn the truck OFF and remove the wire
power unit distribution panel and ACCESS 6. Ex- from CA403-20. Turn the truck ON measure for
amine the wire between CA601-1 and CA206-11. 5 V between CA403-20 and -BV.
• If: The voltage = 5 V (± 0.1 V).
– Then the problem is in ECR6 or the wires. Turn
ACCESS 6 the truck OFF and connect the wire to CA403-20
GCM and continue to Step 2.
CA601
2905 1 +BVAK • If: The voltage ≠ 5 V.
507 2 BATT COMM – Then turn the truck OFF and remove wire from
011 4 CAN_H
012 5 CAN_L CA403-21.Measure for 5 V between CA403-21
and -BV.
Power Unit Distribution Panel • If: The voltage = 5 V (± 0.1 V).
CA201 – Then the problem is in ECR7 or the wires. Turn
012 5 the truck OFF and connect the wire to CA403 21
011 11
and continue to Step 3.
CA206 11 • If: The voltage ≠ 5 V and the event code continues.
2905 – Then replace ACCESS 5.
CA406
Step 2: Turn the truck OFF and disconnect CA410
from ECR6. Turn the truck ON and measure for 5 V
between CA403-20 and -BV.
NEG BUS • If: The voltage ≠ 5 V.
507
– Then the problem is in the wires between
ACCESS 5 and CA410. Examine the wire be-
Fig. 276 (27286)
tween CA403-20 and CA410-4 and the wire be-
Event Codes 511 - 521 tween CA403-12 and CA410-2.
• If: The voltage = 5 V.
ACCESS 5 module internal event.
– Then replace ECR6.
The procedures below apply to Event Codes 511 - 521.
Step 3: Turn the truck OFF and disconnect CA409
Note: All event codes shown are internal module from ECR7. Turn the truck ON and measure for 5 V
events that are not serviceable. between CA403-21 and -BV.
Event Codes 511, 512, 515-521: The traction, steering, • If: The voltage = 5 V.
and hydraulics do not operate.
– Then replace ECR7.
Event Codes 513, 514: No action taken.
Step 1: Replace ACCESS 5.

Event Codes 522, 523

ACCESS 5 Module 5 V power supply is out of
range.
The procedures below apply to Event Codes 522, 523.
The steering and traction do not operate.
Step 1: Measure for 5 V between CA403-20 and -BV
also between CA403-21 and -BV.
• If: The voltage = 5 V (± 0.1 V) and the event code
continues.
– Then replace ACCESS 5.
• If: The voltage ≠ 5 V.

M4.8-1970-065 TSP 7000 SERIES Crown 2012 PF25715-51

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 500

• If: The voltage ≠ 5 V. Step 1: Measure the voltage between ACCESS 5 +BV
– Then turn the truck OFF and disconnect CA408 and -BV.
from FSB. Turn the truck ON and measure for 5 V • If: The voltage = 48 V (TSP 6500) or 72/80 V
between CA403-21 and -BV. (TSP 7000).
• If: The voltage = 5 V. – Then monitor the voltage while you operate the
– Then replace FSB. truck.
• If: The voltage < 5 V. • If: The voltage is in a permitted range of 20–65 V
and the event code continues.
– Then the problem is in the wires between
ACCESS 5 and CA408. Examine the wire be- – Then replace ACCESS 5.
tween CA403-21 and CA408-1 and the wire be- • If: The voltage is below the permitted range of 20–
tween CA403-22 and CA408-2. 65 V.
– Then examine the power cables, the battery con-
dition of charge, and battery condition.
CA410 ECR6
1 BLU CH A Event Codes 526, 527
2 BLK BATT COMM
3 ORG CH B ACCESS 5 module +BV brake voltage is out of
4 RED +5V range.
5 YEL INDEX
The procedures below apply to Event Codes 526, 527.
ACCESS 5 The brake +BV is above range: Full Traction does not
SCM operate.
CA403
516 12 STEER ENCODER COMM The brake +BV is below range: Traction does not oper-
707 20 +5V TO STEER ENCODER ate.
21 +5V TO TRACTION ENCODER Note: Event code 527 is recorded when the inner and
22 TRACTION ENCODER COMM outer brake coils are below range.
A1 B+ A2 B- Event Code 526 is recorded when one or both of the
FSB inner or outer brake coil is above range.
CA408 Step 1: Examine the status of Event Codes 528, 529,
702 1 530, 531, 540. If one or more of these event codes
511 2 were recorded, then repair them before you continue
001 3 ECR7 with Event Codes 526, 527.
002 4 CA409
706 5 1 RED +5V • If: The Event Codes 526, 527 are recorded on reg-
514 6 2 BLK BATT NEG ular intervals.
009 7 3 BLU CH B
010 8 4 WHT CH A – Then replace ACCESS 5.
103 9 5 BLK
6 WHT Event Codes 528, 529
TS1
ACCESS 5 module inner brake +BV is out of range.
Fig. 277 (27287) The procedures below apply to Event Codes 528, 529.
Event Codes 524, 525 Event Code 528: Inner brake +BV is above range: Full
Traction does not operate.
ACCESS 5 module +BV is out of range.
Event Code 529: Inner brake +BV is below range: Trac-
The procedures below apply to Event Codes 524, 525. tion does not operate.
Full Traction does not operate. Step 1: Examine the status of Event Code 540.
Note: Examine the status of Event Code 540 (incorrect • If: Event Code 540 is recorded.
battery voltage detected). Repair Event Code 540 be-
– Then repair Event Code 540 before you continue
fore you continue with Event Codes 524, 525. Events
with Event Codes 528, 529.
540, 524, 525 are from ACCESS 5, +BV. Event Code
540 is an indicator of a problem with a system test. Step 2: Examine FU9.
• If: FU9 = open.

Crown 2012 PF25715-52 TSP 7000 SERIES M4.8-1970-066

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ELECTRICAL SYSTEM
EVENT CODE GROUP 500

– Then replace FU9. Event Code 530: The outer brake +BV is above range:
• If: FU9 = good. Full Traction does not operate.
– Then continue to Step 3. Event Code 531: The outer brake +BV is below range:
Traction does not operate.
Step 3: Examine the operation of ED1.
Step 1: Examine the status of Event Code 540.
• If: ED1 closes.
• If: Event Code 540 is recorded.
– Then measure the voltage between CA403-7 and
-BV. – Then repair Event Code 540 before you continue
with Event Codes 530, 531.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000). Step 2: Examine FU10.
– Then replace ACCESS 5. • If: FU10 = open
• If: The voltage ≠ 48 V (TSP 6500) or 72/80 V – Then replace FU10.
(TSP 7000). • If: FU10 = good.
– Then turn the truck OFF and remove the wire – Then continue to Step 3.
from CA403-7. Turn the truck ON and measure Step 3: Examine the operation of ED1.
the voltage on the wire removed from CA403-7
• If: ED1 closes.
and -BV.
– Then measure the voltage between CA403-9 and
• If: The voltage = 48 V (TSP 6500) or 72/80 V
-BV.
(TSP 7000).
• If: The voltage = 48 V (TSP 6500) or 72/80 V
– Then replace ACCESS 5.
(TSP 7000).
• If: The voltage is less than 48 V (TSP 6500) or 72/
– Then replace ACCESS 5.
80 V (TSP 7000).
• If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
– Then problem is in the ED load buss. Refer to
(TSP 7000).
Event Code 541 repair procedures.
– Then turn the truck OFF and remove the wire
• If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
from CA403-9. Turn the truck ON and measure
(TSP 7000).
the voltage from the wire removed from CA403-9
– Then refer to Event Code 540 repair procedures. and -BV.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000).
Power Unit Distribution Panel – Then replace ACCESS 5.
TP2
CA206 FU10 • If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
4 (TSP 7000).
6 – Then the problem is in the ED load buss. Refer to
FU9
TP3 Event Code 541 repair procedures.
CA204 6 • If: The voltage > 48 V (TSP 6500) or 72/80 V
(TSP 7000).
ACCESS 5
SCM – Then refer to Event Code 540 repair procedures.
CA403
2911 7 INNER BRAKE +BV
2910 9 OUTER BRAKE +BV
A1 B+ A2 B-

Fig. 278 (27288)

Event Codes 530, 531

ACCESS 5 module outer brake +BV is out of range.
The procedures below apply to Event codes 530, 531.

M4.8-1970-068 TSP 7000 SERIES Crown 2012 PF25715-53

416

Power Unit Distribution Panel
TP2
CA206 FU10
4 2 BRN
6 3 GRN
FU9
TP3
CA204 6
ACCESS 5
SCM
CA403
2911 7 INNER BRAKE +BV
2910 9 OUTER BRAKE +BV
A1 B+ A2 B-
Fig. 279 (27288)
Event Codes 532, 533
ACCESS 5 module 5 V battery current sensor
(CS1) supply is out of range.
The procedures below apply to Event Codes 532, 533.
Step 1: Measure the voltage between CA403-27 and
-BV.
• If: The voltage = 5 V (± 0.1 V).
– Then monitor the event code.
• If: The voltage ≠ 5 V.
– Then turn the truck OFF and remove the wire
from CA403-27 connector. Turn the truck ON and
measure for 5 V between CA403-27 and -BV.
• If: The voltage = 5 V.
– Then problem is CS1 or the wires between CS1
and ACCESS 5. Turn the truck OFF and connect
the wire in CA403-27 and continue to Step 2.
• If: The voltage ≠ 5 V.
– Then replace ACCESS 5.
Step 2: Turn the truck OFF and disconnect CS1 from
CA406. Measure the voltage between CA403-27 and
-BV.
• If: The voltage ≠ 5 V.
– Then examine the wire between CA403-27 and
CA403-24. The wire between CA403-28 and
CA406-1 and the wire CA406-2 and CA406-3.
• If: The voltage = 5 V.
– Then replace CS1.
Crown 2012 PF25715-54 TSP 7000 SERIES
ELECTRICAL SYSTEM
EVENT CODE GROUP 500
CA406
1 VIO + VIO
I o BRN
GRN
CS1
ACCESS 5
CA403 SCM
101 24 CURRENT SENSOR ANALOG INPUT
701 27 CURRENT SENSE/BDI (+5V)
510 28 CURRENT SENSE/BDI (-)
A1 B+ A2 B-
Fig. 280 (27289)
Event Codes 534, 535
ACCESS 5 module battery current is out of range.
The procedures below apply to Event Codes 534, 535.
The traction, steering, and hydraulics do not operate.
Note: Examine the status of Event Codes 532, 533,
536, 537. If recorded, repair them before you continue
with Event Codes 534, 535.
Step 1: Examine the wires between ACCESS 5
CA403-27, CA403-24, CA403-28, CA406-1, CA406-2,
and CA406-3. The wires between CA406 and CS1.
• If: The wires = bad.
– Then repair or replace the wires.
• If: The wires are good and the event code contin-
ues.
– Then replace CS1.
Event Code 536
ACCESS 5 module battery current sensor (CS1)
not installed correctly.
If Event Code 537 is recorded then repair this event
code before Event Code 536.
Step 1: Go to the ANALYZER menu A2.4.4 to CS1
sensor input. Command full traction then plug while
you monitor the CS1 values.
• If: The current value is negative during accelera-
tion.
– Then examine the installation of CS1 to the bus
bar and the wires between ACCESS 5
CA403-27, CA403-24, CA403-28, and CA406-1.
The wires between CA406-2 and CA406-3. The
wires between CA406 and CS1.
• If: CS1 is not installed correctly or the wires = bad.
M4.8-1970-069
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ELECTRICAL SYSTEM
EVENT CODE GROUP 500

– Then repair or replace the wires or correctly in-

stall CS1.
• If: CS1 is installed correctly, the wires are good and
the event code continues. CA406
1 VIO + VIO
– Then replace CS1. 2 BRN I o BRN
3 GRN GRN
CS1
CA406 ACCESS 5
1 VIO + VIO SCM
2 BRN I o BRN CA403
3 GRN GRN 101 24 CURRENT SENSOR ANALOG INPUT
701 27 CURRENT SENSE/BDI (+5V)
CS1 510 28 CURRENT SENSE/BDI (-)

ACCESS 5
CA403 SCM
101 24 CURRENT SENSOR ANALOG INPUT
701 27 CURRENT SENSE/BDI (+5V)
510 28 CURRENT SENSE/BDI (-)
A1 B+ A2 B-
Fig. 281 (27289)
Event Code 537
ACCESS 5 module battery current sensor (CS1)
zero indication is out of range.
Look to see if Event Codes 532, 533 have been re-
corded. Repair those event codes before Event Code
537.
Step 1: Step off of the truck to let the ED contacts open.
Wait two minutes for the ED bus to discharge. Measure
the voltage between CA403-24 to -BV.
• If: The voltage = 2.4 V - 2.6 V and the event code
continues.
– Then replace ACCESS 5.
• If: The voltage ≠ 2.4 V to 2.6 V.
– Then turn the truck OFF and remove the wire
from CA403-24 Turn the Truck ON and measure
the voltage between the wire end and -BV.
• If: The voltage ≠ 2.4 V to 2.6 V.
– Then replace CS1.
• If: The voltage = 2.4 V - 2.6 V.
– Then replace ACCESS 5.
A1 B+ A2 B-
Fig. 282 (27289)
Event Codes 538, 539
ACCESS 5 module BDI voltage is out of range.
The procedures below apply to Event Codes 538, 539.
Event Code 538: Lift does not operate.
Event Code 539: Full traction and lift do not operate.
Step 1: Make sure the correct battery is installed.
Step 2: Turn the truck OFF and examine FU2.
• If: FU2 = open.
– Then replace FU2.
Step 3: Turn the truck ON and measure for +BV be-
tween CA403-25 and CA403-26.
• If: The voltage < 48 V (TSP 6500) or 72/80V
(TSP 7000).
– Then examine the wires between the battery and
ACCESS 5.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000) and the event continues.
– Then replace ACCESS 5.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 500

– Then the ED bus is open. Refer to Event Code

541 for repair.
ACCESS 5 Step 4: Turn the truck OFF. Remove the +BV cable
CA403 SCM from ACCESS 5 power terminal. Turn the truck ON and
205 25 BATTERY VOLTAGE SENSE/BDI (+) measure the voltage between ACCESS 5 +BV cable
509 26 BATTERY VOLTAGE SENSE/BDI (-) end and the -BV terminal while the ED is pulled in (1/2
A1 B+ A2 B- to 1 second).
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000).
Power Unit Distribution Panel
CA205 FU2 – Then turn the truck OFF and connect the
15 ACCESS 5 +BV cable. Turn the truck ON and
measure the voltage between ACCESS 5 +BV
TP11 terminal and the -BV terminal.
CA204 1 2
201 • If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
208 (TSP 7000).
– Then examine the ED power supply as you refer
CA406 to the procedure for Event Code 541.
NEG BUS
• If: The voltage = 48 V (TSP 6500) or 72/80 V
BATT (TSP 7000) and the event continues.
+
– Then replace ACCESS 5.

ED1 Event Code 541

FU13
+ - ACCESS 5 module ED contactor does not energize.
The traction, steering, and hydraulics do not operate.
Fig. 283 (27290) Note: Before you continue, look at the status of Event
Event Code 540 Codes 540, 546. If one or more event codes have been
recorded repair that event code before Event Code
ACCESS 5 +BV is out of range. 541.
Steering, traction, and hydraulics do not operate. Step 1: Turn the truck ON. When the start up test is
Step 1: Disconnect the battery and measure the bat- complete, step on the brake pedals to energize the ED
tery voltage. contactor.
• If: The voltage = 48 V (TSP 6500) or 72/80 V • If: The ED does not energize.
(TSP 7000) (all cells good). – Then measure for +BV between the ACCESS 5
– Then continue to Step 2. +BV CA403-19 and -BV.
• If: The voltage = 24 V or 36 V. • If: The voltage = 0 V.
– Then install a 48 V (TSP 6500) or 72/80 V – Then replace ACCESS 5.
(TSP 7000) battery. • If: The voltage = 48 V (TSP 6500) or 72/80 V
Step 2: Examine the condition of FU9, FU10, FU13. (TSP 7000).
• If: The fuses = good. – Then measure for +BV between ACCESS 3 -BV
CA401-5 and +BV.
– Then continue to Step 3.
• If: The voltage = 0 V.
• If: The fuse(s) = open.
– Then replace ACCESS 3.
– Then replace the fuse(s).
• If: The voltage = 48 V (TSP 6500) or 72/80 V
Step 3: Turn the truck ON and look at the pull in of the
(TSP 7000).
ED contacts.
– Then measure for +BV across the ED contactor
• If: The ED pulls in momentarily.
coil.
– Then the ED system is good, continue to Step 4.
• If: The voltage = 0 V.
• If: The ED does not pull in.

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– Then examine the wire connections between Event Code 542

ACCESS 5 CA403-19 and ACCESS 3 CA401-5.
• If: The voltage = 48 V (TSP 6500) or 72/80 V An open fuse.
(TSP 7000). The steering, traction, and hydraulics do not operate.
– Then turn the truck OFF and disconnect the wires Step 1: Turn the truck OFF and examine FU9, FU10,
and from the ED coil. Measure the resistance of FU13.
the coil. • If: The fuses = good.
• If: The resistance = ∞ Ω. – Then continue to Step 2.
– Then replace the ED contactor. • If: The fuse(s) = open.
– Then replace the fuse(s).
Step 2: Examine the wire between CA206-6 and
Power Unit Distribution Panel CA403-7 and the wire between CA206-4 and CA403-9.
TP2 The cable from FU13 to ACCESS 5 +B terminal.
CA206 FU10
4 • If: The connections = bad.
6 – Then repair or replace the connections.
FU9
TP3
CA204 5 6
2912 Power Unit Distribution Panel
2987 TP2
CA206 FU10
ACCESS 5 4
CA403 SCM 6
2911 7 INNER BRAKE +BV FU9
2910 9 OUTER BRAKE +BV TP3
18 ED HIGH SIDE DR INPUT CA204 5 6
19 ED HIGH SIDE DR TO CONTACTOR 2912
2987
A1 B+ A2 B-
ACCESS 5
+
CA406 BATT CA403 SCM
2911 7 INNER BRAKE +BV
2906 2910 9 OUTER BRAKE +BV

K2 + - A1 B+ A2 B-

2987 +
CA406 +
2912
BATT
FU13 ED1
+ - 2987
2912 ED1
FU11
+ -
2907 FU13

ACCESS 3 Fig. 285 (27292)

TCM Event Code 543
CA401
5907 5 ED1 COIL DRIVER ACCESS 5 module ED1 tips are welded.
B+ B- The traction, steering, and hydraulics do not operate.
Step 1: Examine ED1 for welded tips.
Fig. 284 (27291) • If: ED1 tips = welded.
– Then repair or replace the tips.
• If: ED1 tips are not welded.

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– Then turn the truck OFF and measure the resist-

Chart 1
ance between ED1 load bus and +BV.
• If: The circuit is not open. Outer Brake FU10 ACCESS 5
– Then the problem is a connection between the M3 FU13 ACCESS 5
+BV terminal of ED1 and the load side ED1. Ex-
amine the wire connections. M1 FU11 ACCESS 3
M2 FU12 ACCESS 2
Event Code 544
Step 2: When the ED bus resistance goes back to
ACCESS 5 module ED turn ON problem.
usual, note the last fuse removed and replace all the
The traction does not operate. others. Make sure the bus resistance is good.
Note: ACCESS 5 internal switch is in the OFF condi- Step 3: Replace the module that agrees with ACCESS
tion and does not come on to the ON command. Module column in the same row as the last fuse that
Step 1: Follow the procedure for Event Code 541. was disconnected.

Event Code 545

ACCESS 5 module ED turn OFF problem. Power Unit Distribution Panel
The traction does not operate. TP2
CA206 FU10
Step 1: Follow the procedure for Event Code 541 ED 4
System repair. 6
FU9
TP3
Event Codes 546 - 550 CA204 5 6
ACCESS 2 module or ACCESS 3 module did not ACCESS 5
2912
load an ED bus pre-charge. A1 B+ A2 B-
2987 +
The procedures below apply to Event Codes 546 - 550. FU13
BATT
The traction, steering, hydraulics, and ED do not oper-
ate. ACCESS 2
ED1
Event Code 546: ED did not pre-charge. B+ B-
Event Code 547: ACCESS 3 pre-charge power is out FU12 + -
of range.
Event Code 548: ACCESS 3 did not pre-charge. ACCESS 3
Event Code 549: ACCESS 2 pre-charge power is out B+ B- ED Load Bus
of range. FU11
Event Code 550: ACCESS 2 did not pre-charge.
Step 1: Turn the truck OFF and measure the resist- Fig. 286 (27293)
ance from the ED buss output contact to -BV. Event Code 551
• If: The resistance ≠ 25 Ω.
– Then remove the bus load fuse's one at a time ACCESS 5 module internal problem.
until the resistance increases to a usual value of Full Traction does not operate.
approximately 1 K Ω. Step 1: Turn the truck OFF then ON.
• If: The event code does not continue.
Chart 1 – Then the truck can be put into operation.
Disconnection Related AC- • If: The event code continues.
Load Re-
Port CESS – Then replace ACCESS 5.
moved
Module
Inner Brake
FU9 ACCESS 5
@ PVML

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Event Codes 552, 553 CA410-5 and the wire between CA410-5 and
ECR6.
ACCESS 5 module internal problem. • If: The wires are good and the event code contin-
The procedures below apply to Event Codes 552, 553. ues.
Step 1: Install the ACCESS 5 software and make sure – Then replace ECR6.
the software installed correctly. • If: ECR6 is good and the event code continues.
Event Code 554 – Then replace ACCESS 5.
• If: The ECR6 counts change smoothly but the count
ACCESS 5 module EAC parameter problem. is not at zero at the zero position.
Full Traction does not operate. – Then exit the ANALYZER menu and do the
Step 1: Move the truck above the EAC magnets to set ECR6 calibration procedure in the Calibration
the data. Menu C4.
• If: The event code does not continue.
– Then the truck can be put into operation.
ECR6
• If: The event code continues. CA410
– Then replace ACCESS 5. 1 BLU CH A
2 BLK BATT COMM
3 ORG CH B
Event Codes 555, 556 4 RED +5V
5 YEL INDEX
ACCESS 5 module steering feedback encoder
(ECR6) counts is out of range.
The procedures below apply to Event Codes 555, 556. ACCESS 5
SCM
Traction does not operate. CA403
Step 1: Examine the status of Event Codes 522, 523. 013 13 STEER ENCODER CH A
014 14 STEER ENCODER CH B
• If: The Event Codes 522, 523 are recorded. 015 23 STEER ENCODER INDEX
– Then repair them before you continue with Event
Codes 555, 556. A1 B+ A2 B-
Step 2: Measure for 5 V between CA410-2 -BV and
Fig. 287 (27294)
CA410-4 +BV.
• If: The voltage is < 4.75 V or > 5.25 V. Event Code 557
– Then follow the procedures for Event Codes 522, ACCESS 5 module steering feedback encoder
523. (ECR6) index line problem.
• If: The voltage = 5 V. Full Traction does not operate.
– Then continue to Step 3. Note: ECR6 count shows that the wheel has went
Step 3: Look to see if the steered wheel is synchro- through the zero position but the index signal has not
nized. Go to the ANALYZER A2.4.1 menu to show the shown the same.
ECR6 counts. Turn the steer tiller in the two directions Step 1: Examine the status of Event Codes 522, 523.
while you monitor the counts. The ECR6 counts must If one or more have been recorded then repair them
change smoothly and continuously as the steered before you continue with Event Code 557.
wheel moves. Record the ECR6 counts after the
Step 2: Measure for 5 V between CA410-4 +BV and
steered wheel is at the zero position.
CA410-2 -BV.
• If: The ECR6 count change is irregular or does not
• If: The voltage is < 4.75 V or > 5.25 V.
change.
– Then follow the procedure for Event Codes 522,
– Then examine the wire between CA403-13 and
523.
CA410-1 and the wire between CA410-1 and
ECR6. The wire between CA403-14 and • If: The voltage = 5 V.
CA410-3 and the wire between CA410-3 and – Then continue to Step 3.
ECR6. The wire between CA403-23 and

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Step 3: Examine the ECR6 index wires between Event Codes 558 - 561
CA403-23 and CA410-5. The wire between CA410-5
and ECR6. ACCESS 5 module steering feedback encoder
• If: The wires = good. (ECR6) problem.
– Then continue to Step 4. The procedures below apply to Event Codes 558 - 561.
Step 4: Look to see if the steered wheel is synchro- The traction and steering do not operate.
nized. Go to the ANALYZER A2.4.1 menu to show the Note: The event code will occur if there is no wheel
ECR6 counts. Turn the steer tiller in the two directions movement with a traction command.
while you monitor the counts. The ECR6 counts must Step 1: Look at the status of Event Codes 522, 523. If
change smoothly and continuously as the steered one or more have been recorded then repair them be-
wheel moves. fore you continue with Event Codes 558, 559, 560,
• If: The ECR6 count change is irregular or does not 561.
change. Step 2: Measure for 5 V between CA410-4 +BV and
– Then examine the wire between CA403-13 and CA410-2 -BV.
CA410-1 and the wire between CA410-1 and • If: The voltage is < 4.75 V or > 5.25 V.
ECR6. The wire between CA403-14 and CA4103
– Then follow the procedures for Event Codes 522,
and the wire between CA410-3 and ECR6. The
523.
wire between CA403-23 and CA410-5 and the
wire between CA410-5 and ECR6. • If: The voltage = 5 V.
• If: The wires are good and the event code contin- – Then continue to Step 3.
ues. Step 3: Examine the wire connections between
– Then replace ECR6. ACCESS 5 A1 & A2 terminals and M3.
• If: ECR6 is good and the event code continues. • If: The wires = good.
– Then replace ACCESS 5. – Then continue to Step 4.
• If: ECR6 counts change smoothly but the count is Step 4: Look to see if the steered wheel is synchro-
not at zero at the zero position. nized. Go to the ANALYZER A2.4.1 menu to show the
ECR6 counts. Turn the steer tiller in the two directions
– Then exit the ANALYZER menu and do the
while you monitor the counts. The ECR6 counts must
ECR6 calibration procedure in the Calibration
change smoothly and continuously as the steered
Menu C4.
wheel moves. Record the ECR6 counts after the
steered wheel is at the zero position.
• If: The ECR6 count change is irregular or does not
CA410 ECR6 change
1 BLU CH A – Then examine the wire between CA403-13 and
2 BLK BATT COMM
CA410-1 and the wire between CA410-1 and
3 ORG CH B
4 RED +5V ECR6. The wire between CA403-14 and
5 YEL INDEX CA410-3. The wire between CA410-3 and ECR6.
The wire between CA403-23 and CA410-5 and
the wire between CA410-5 and ECR6.
ACCESS 5
SCM • If: The wires are good and the event code contin-
CA403 ues.
013 13 STEER ENCODER CH A – Then replace ECR6.
014 14 STEER ENCODER CH B
015 23 STEER ENCODER INDEX • If: ECR6 is good and the event code continues.
– Then replace ACCESS 5.
A1 B+ A2 B-

Fig. 288 (27294)

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• If: ECR6 counts change smoothly but the count is Event Code 563
not at the zero position.
– Then exit the ANALYZER menu and do the ACCESS 5 module ACCESS 6 transmission prob-
ECR6 calibration procedure in the Calibration lem.
Menu C4. The traction does not operate.
Note: ACCESS 5 received a wire guidance command
from the guidance switch but has not seen a transmis-
ECR6 sion with the ACCESS 6 module.
CA410
1 BLU CH A Step 1: Make sure the truck has the guidance feature.
2 BLK BATT COMM • If: The guidance feature is not installed.
3 ORG CH B
4 RED +5V – Then go to the Features menu F17.1 and turn the
5 YEL INDEX guidance to OFF.
• If: The guidance feature is installed.
ACCESS 5 – Then examine the hardware for the guidance
SCM system.
CA403
013 13 STEER ENCODER CH A • If: The Event Code 563 continues.
014 14 STEER ENCODER CH B – Then refer to Event Code 509.
015 23 STEER ENCODER INDEX
Event Code 564
A1 B+ A2 B-
ACCESS 5 module wire guidance can not be set to
Fig. 289 (27294) ON problem.

Event Code 562 The traction does not operate.

ACCESS 5 module steer system has a short circuit.
The traction and steering do not operate.
Step 1: Look at the status of Event Codes 524, 525,
540.
• If: Event codes 524, 525, 540 are recorded.
– Then repair Event Codes 524, 525, 540 before
you continue with Event Code 562.
Step 2: Turn the truck OFF. Remove the +B and -BV
cables from ACCESS 5.
Step 3: Install a wire between +B and -BV and meas-
ure for the below resistances:
Terminal A1 to +BV - 15 K Ω.
Terminal A1 to -BV - 15 K Ω.
Terminal A2 to +BV - 15 K Ω.
Terminal A2 to -BV - 15 K Ω.
Terminal A1 to A2 - 30 K Ω.
• If: One or more are 5 K Ω below the value shown.
– Then replace ACCESS 5.
• If: The resistances are good.
– Then connect the cables and continue to Step 4.
Step 4: Measure the A1, A2 cables for a short circuit.
• If: The cables are good and the event continues.
– Then replace ACCESS 5.
Note: ACCESS 5 received a wire guidance command
from the guidance switch but the wire guidance feature
is not ON.
Step 1: Go to the Features menu F17.2 and set the
guidance feature to ON.
Event Code 565
ACCESS 3 and ACCESS 5 module traction sensor
ECR7 problem.
The traction, steering, and hydraulics do not operate.
Step 1: Look at the status of Event Codes 325, 369,
522, 523.
Event Codes 336, 373, 565 all pertain to ECR7.
Event Code 336: One or two signals are not received
at ACCESS 3 while the truck travels.
Event Code 373: One or two signals are not received
at ACCESS 3 at traction start.
Event Code 565: One or two signals are not received
at ACCESS 5 if the truck sets or travels.
• If: One or more of the above event codes are re-
corded.
– Then repair them before you continue with Event
Code 565.
Step 2: Remove the event code. Turn the truck OFF
then ON and command traction.

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• If: Event Code 565 is recorded. Step 1: Make sure the truck has the EAC feature.
– Then examine the wires between FSB CA408 • If: The truck does not have the EAC feature.
and ACCESS 5 CA403. – Then go to the Features menu F19.1 and set
• If: The wires = good. EAC to OFF.
– Then replace the FSB. • If: The truck has the EAC feature.
• If: The event code continues. – Then look for Event Code 105.
– Then replace ACCESS 5. • If: Event Code 105 is recorded.
• If: Event Code 373 is recorded. – Then examine the connections to ACCESS 6.
– Then examine the wires between the FSB CA408 • If: the connections are good.
and ACCESS 3 CA401. – Then look for Event Code 509.
• If: The wires = good. • If: The Event Code 509 is recorded.
– Then replace the FSB. – Then refer to the repair procedures for Event
• If: The event code continues. Code 509.
– Then replace ACCESS 3.
Event Codes 567 - 570
ACCESS 5 module End Aisle Control (EAC) sensor
ACCESS 5 latched ON problem.
CA403 Full Traction does not operate.
001 3 TRACTION ENCODER CH B
002 4 TRACTION ENCODER CH A Note: EAC sensor event codes: Event Code 567 - A1,
702 21 +5V TO TRACTION ENCODER Event Code 568 - B1, Event Code 569 - A2, and Event
511 22 TRACTION ENCODER COMM Code 570 - B2
A1 B+ A2 B- Step 1: Look at the status of Event Codes 625, 626. If
FSB one or two have been recorded. Then repair them be-
CA408 fore you continue with Event Codes 567 - 570.
702 1 Step 2: To examine the EAC sensors, place the truck
511 2 so no sensor is on a magnet. Turn the truck OFF, refer
001 3
002 4 to the above event code.
706 5 • If: The Event Code 567 for sensor A1 is recorded.
514 6
009 7 – Then disconnect CA602 from ACCESS 6 and ex-
010 8 amine sensor A1. Measure from the positive test
103 9 pin to CA602-3 (EAC A1 test) of ACCESS 6 and
the negative test pin to CA602-2. Turn the truck
ACCESS 3 ON and monitor the display.
CA401
514 7 I/O BATTERY NEGATIVE • If: The voltage > 1 V.
103 8 TRACTION MOTOR TEMP SENSE INPUT – Then replace ACCESS 6.
706 26 +5V OUT
009 31 SPEED ENCODER CH B
010 32 SPEED ENCODER CH A
B+ B-

Fig. 290 (27295)

Event Code 566

ACCESS 5 module End Aisle Control (EAC) enable
problem.
Full Traction does not operate.
Note: The EAC feature is ON and the hardware is not
found.

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• If: The voltage = 0 V. • If: All four magnets are sensed.

– Then turn the truck OFF and connect CA602. Re-
move the wire (EAC 1A digital) from CA607 3,
measure from the positive test pin to the wire and
the negative test pin to -BV. Turn the truck ON.
• If: The voltage = 5 V.
– Then replace the EAC distribution panel.
• If: The voltage = 0 V.
– Then replace ACCESS 6.
Note: Follow the above instructions for all EAC sen-
sors. Refer to EAC sensor test and digital connections.
Refer to Figure 291.
– Then continue to Step 3.
Step 3: Turn the truck ON. The truck will sense the wire
or rail and stop the truck out of the EAC zones. Stop the
truck and stay on the brake. Wait 20 seconds for the
system to do a function test on the sensors.
• If: The sensors fail.
– Then an Event Code 500 or 600 level will be re-
corded. Follow the procedures for that event
code.
• If: The event code does not continue.
– Then the system is good, continue to monitor.

Event Codes 576 - 581

EAC ACCESS 6 ACCESS 5 module brake current or resistance
CA607 CA602 problem.
1 901 3 EAC A1 TEST The procedures below apply to Event Codes 576 - 581.
3 052 5 EAC A1 DIGITAL
4 902 6 EAC A2 TEST Traction does not operate.
6 053 8 EAC A2 DIGITAL Step 1: Let the brake cool. Remove the brake from the
7 903 9 EAC B1 TEST
9 054 11 EAC B1 DIGITAL traction motor and disassemble to a level that the coils
10 904 12 EAC B2 TEST can be examined.
12 055 14 EAC B2 DIGITAL Step 2: Examine the coils for heat damage.
• If: The lamination material has broken down.
Fig. 291 (27296) – Then replace the brake coils.
Event Codes 571, 572 • If: The coils are not damaged.
– Then with the coils at external environment tem-
ACCESS 5 module End Aisle Control (EAC) mag- perature measure the resistance of the coil(s).
net problem. The resistance of the inner coil = 3.5 Ω and the
The procedures below apply to Event Codes 571, 572. outer coil = 1.5 Ω.
Full Traction does not operate. • If: One or two coils are above the resistance value.
Event Code 571: Inner magnet problem. – Then replace the coil.
Event Code 572: Outer magnet problem.
Event Codes 582 - 585
Step 1: Move the truck out of the guided row and then
in the row. ACCESS 5 module brake current is out of range.
• If: The event does not continue. The procedures below apply to Event Codes 582 - 585.
– Then monitor. Traction does not operate.
• If: The event continues. Step 1: Identify Event Codes 582, 583, 584, 585.
– Then continue to Step 2. • If: Event Codes 582 or 583 has occurred.
Step 2: Turn the truck ON and go into the ANALYZER – Then an inner brake low resistance occurred.
menu and go to the EAC sensor status A2.4.7. The Turn the truck OFF and measure the resistance
truck will sense the wire or rail as you move the truck in of the wires and the inner coil. The wire from
an EAC zone. Show the condition of the related sen- CA206-5 to CA407-2 and the wire from CA403-6
sors. Slowly move above the EAC magnets while you to CA407-3. The wire fromCA204-5 to the ED
monitor the sensor condition on the display. The condi- contactor and wire from CA204-6 to the ED con-
tion will be closed if not sensed, open if sensed. tactor. Disconnect CA407 and measure the inner
• If: One or more magnet is not sensed. coil resistance between pins 2 and 3. The resist-
– Then examine the wires of the related sensor.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 500

ance must = 3.5 Ω at external environment tem-

perature.
• If: The resistance < 3.5 Ω. BRK
– Then replace the inner brake coil. CA407
Outer Brake
• If: The resistance = 3.5 Ω and the event code con- 2908 1 + WHT
tinues. 2909 2 + BLU Inner
5901 3 YEL Brake
– Then replace ACCESS 5. 5902 4 ORG
• If: Event Code 584 or 585 have occurred. 5 5971
6
– Then outer brake low resistance occurred. Turn
the truck OFF and measure the resistance of the Power Unit Distribution Panel
wires and the outer coil. The wire from CA206-3 TP2
to CA407-1 and the wire from CA403-8 to CA206 FU10
2908 3
CA407-4. The wire from CA204-5 to the ED con- 2910 4
tactor and the wire from CA204-6 to the ED con- 2909 5
tactor. Disconnect CA407 and measure the outer 2911 6 FU9
coil resistance between pins 1 and 4. The resist- TP3
ance must = 1.5 Ω at external environment tem- TP7
perature.
• If: The resistance < 1.5 Ω. CA204 5 6
– Then replace the outer brake coil.
• If: The resistance = 1.5 Ω and the event code con- ACCESS 5 2912
tinues. SCM
CA403 2987
– Then replace ACCESS 5. 5901 6 INNER BRAKE LO
2911 7 INNER BRAKE +BV
5902 8 OUTER BRAKE LO
2910 9 OUTER BRAKE +BV
A1 B+ A2 B-

ED1 +
- +
BATT

Fig. 292 (27297)

Event Codes 586, 587

ACCESS 5 module brake load problem.
The procedures below apply to Event Codes 586, 587.
The traction does not operate.
Step 1: Identify Event Code 586 or 587.
• If: Event Code 586 occurred.
– Then turn the truck OFF and measure the resist-
ance of the wires and the inner coil. The wire from
CA206-5 to CA407-2 and the wire from CA206-6
to CA403-7. Disconnect CA407 and measure the
resistance of the inner coil between pins 2 & 3.
The resistance must = 3.5 Ω at external environ-
ment temperature.
• If: The resistance < 3.5 Ω.
– Then replace the inner brake coil.

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• If: The resistance = 3.5 Ω and the event code con- Event Codes 588, 589
tinues.
– Then replace ACCESS 5. ACCESS 5 module brake supply voltage problem.
• If: Event Code 587 has occurred. The procedures below apply to Event Codes 588, 589.
– Then turn the truck OFF, and measure the resist- Traction does not operate.
ance of the wires and of the outer coil. The wire Note: The brake power supply voltage problem could
from CA206-3 to CA407-1 and the wire from be because the ED contactor does not close. Other
CA206-4 to CA403-9. Disconnect CA407 and event codes are used to make sure that the ED contac-
measure the resistance of the outer coil between tor does close. If an event code has been recorded that
pins 1 & 4. The resistance must = 1.5 Ω at exter- is related to the ED contactor. Repair it before you con-
nal environment temperature. tinue with Event Codes 588, 589.
• If: The resistance is < 1.5 Ω. Event Code 588: Inner brake voltage problem.
– Then replace the outer brake coil. Event Code 589: Outer brake voltage problem.
• If: The resistance = 1.5 Ω and the event code con- Step 1: Identify Event Code 588 or 589.
tinues. • If: Event Code 588 occurred.
– Then replace ACCESS 5. – Then examine FU9.
• If: FU9 = open.
– Then replace FU9.
BRK
• If: FU9 = good.
CA407
Outer Brake – Then measure the voltage between CA403-7 and
2908 1 + WHT
2909 2 + BLU Inner -BV.
5901 3 YEL Brake • If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
5902 4 ORG (TSP 7000).
5 5971
6 – Then examine the wire from CA204-5 to the ED
contactor and the wire from CA204-6 to the ED
Power Unit Distribution Panel contactor. The wire from CA206-6 to CA403-7.
TP2 • If: Event Code 589 has occurred.
CA206 FU10
2908 3 – Then examine FU10.
2910 4
2909 5 • If: FU10 = open.
2911 6 FU9 – Then replace FU10.
TP3
TP7 • If: FU10 = good.
– Then measure the voltage between CA403-9 and
-BV.
CA204 5 6
• If: The voltage ≠ 48 V (TSP 6500) or 72/80 V
(TSP 7000).
ACCESS 5 2912
SCM – Then examine the wire from CA204-5 to the ED
CA403 2987 contactor and the wire from CA204-6 to the ED
5901 6 INNER BRAKE LO contactor. The wire from CA206-4 to CA403-9.
2911 7 INNER BRAKE +BV
5902 8 OUTER BRAKE LO
2910 9 OUTER BRAKE +BV
A1 B+ A2 B-

ED1 +
- +
BATT

Fig. 293 (27297)

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– Then replace ACCESS 5.

BRK Event Codes 592, 593

CA407 ACCESS 5 module brake driver problem.
Outer Brake
2908 1 + WHT The procedures below apply to Event Codes 592, 593.
2909 2 + BLU Inner
5901 3 YEL Brake The traction does not operate.
5902 4 ORG Event Code 592: Inner brake driver problem.
5 5971
6 Event Code 593: Outer brake driver problem.
Step 1: Refer to the procedures for Event Codes 582,
Power Unit Distribution Panel
583, 584, 585. Use the event code that is related to the
TP2 specified driver (inner or outer brake coil).
CA206 FU10
2908 3 • If: Step 1 does not show a low brake resistance.
2910 4
2909 5 – Then replace ACCESS 5.
2911 6 FU9
TP3
TP7

CA204 5 6

ACCESS 5 2912
SCM
CA403 2987
5901 6 INNER BRAKE LO
2911 7 INNER BRAKE +BV
5902 8 OUTER BRAKE LO
2910 9 OUTER BRAKE +BV
A1 B+ A2 B-

ED1 +
- +
BATT

Fig. 294 (27297)

Event Codes 590, 591

ACCESS 5 module brake driver problem.
The procedures below apply to Event Codes 590, 591.
Traction does not operate.
Event Code 590: Inner brake driver problem.
Event Code 591: Outer brake driver problem.
Step 1: Refer to the procedure for Event Codes 588,
589. Use the event code that is related to a specified
driver (inner or outer brake coil).
Step 2: Refer to the procedures for Event Codes 586,
587. Use event code that is related to a specified driver
(inner or outer brake coil).
• If: Steps 1 and 2 do not show a brake voltage prob-
lem or a short circuit brake load.

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ELECTRICAL SYSTEM
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Event Code Group 600 Event Code 612: The traction does not operate.
Event Code 621 - 628: The traction does not operate.
Event Code 605 Step 1: Replace ACCESS 6.

ACCESS 6 module CAN timeout. Event Code 631

Step 1: Make sure of the source of the event code.
ACCESS 6 module wire guidance sensor amplifier
• If: ACCESS 6 flashes an event code but it is not
internal problem.
shown by ACCESS 1.
The traction does not operate.
– Then a problem is in the CAN wires between
ACCESS 6 and the power unit distribution panel. Step 1: This is an internal ACCESS 6 problem replace
Examine the connectors CA201, CA601, and the ACCESS 6.
wire from CA201-11 to CA601-4. The wire from
CA201-5 to CA601-5. Event Code 632
• If: ACCESS 1 shows Event Code 605. ACCESS 6 module load wheel wire guidance sen-
– Then examine for power to ACCESS 5. sor bar problem.
• If: ACCESS 5 power LED’s = ON. The traction does not operate.
– Then the problem is in the CAN wires between Note: Event Code 632 will also be recorded if the wire
ACCESS 5 and the power unit distribution panel. guidance feature is ON and the sensor bars are not
Examine the connectors CA201, CA402, and the installed. Make sure sensor bars are installed before
wire from CA201-8 to CA402-4. The wire from you continue.
CA201-2 to CA402-5. Step 1: Turn the truck ON and measure the sensor bar
• If: ACCESS 5 power LED’s = OFF. 5 V supply between CA602-22 and -BV.
– Then the problem is in the wires between the If: The sensor bar = 5 V.
power unit distribution panel and ACCESS 5. Ex- – Then continue to Step 2.
amine the wire from CA206-9 to CA403-10. • If: The voltage = 0 V.
– Then turn the truck OFF and remove the wire
from CA602-15. Turn the truck ON and measure
Power Unit the voltage between CA602-22 and -BV.
Distribution ACCESS 5
Panel • If: The voltage = 5 V then the problem is in GS1 or
CA402
CA201 the wires from ACCESS 6 to GS1.
003 4 CAN_H
2 004 5 CAN_L – Then repair or replace the wires or GS1.
5 • If: The voltage = 0 V.
8 CA403
CA206
11 10 +BV INPUT – Then turn the truck OFF and remove the wire
9
from CA602-22. Turn the truck ON and measure
A1 B- A2 B+
2903 the voltage between CA602-22 and - BV at
ACCESS 6 ACCESS 6.
CA601 • If: The voltage = 0 V.
011 4 CAN_H – Then replace ACCESS 6.
012 5 CAN_L
• If: The voltage = 5 V then the problem is in GS2 or
the wires from ACCESS 6 to GS2.
Fig. 295 (27299)
– Then repair or replace the wires or GS2.
Event Codes 611, 612 & Step 2: Go to the ANALYZER menu A2.4.6 and look at
Event Codes 621 - 628 the GS2 sensor values while you move slowly above
the wire. The values must increase and decrease as
ACCESS 6 module internal problem. you go across the wire.
The procedures below apply to Event Codes 611, 612, • If: One or more of the four coil signals do not show
621 - 628. the that the wire is sensed.
Event Code 611: All functions do not operate.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 600

– Then examine the wires that are related to that • If: The voltage = 0 V.
coil for a short circuit or an open circuit problem. – Then turn the truck OFF and remove the wire
• If: The wires = good. from CA602-22. Measure the voltage between
– Then replace GS2. CA602-22 and - BV at ACCESS 6.
• If: The event code continues. • If: The voltage = 0 V.
– Then replace ACCESS 6. – Then replace ACCESS 6.
• If: The voltage = 5 V then the problem is in GS2 or
the wires from ACCESS 6 to GS2.
CA603 – Then repair or replace the wires or GS2.
1 Step 2: Go to the ANALYZER menu A2.4.5 and look at
2
GS1 5 the GS1 sensor values while you move slowly above
7 ACCESS 6 the wire. The values must increase and decrease as
8 GCM you go across the wire.
CA602
717 15 STR WHL GUIDE BAR +5V • If: One or more of the four coil signals do not show
113 17 STR WHL GUIDE BAR COIL 1 the that the wire is sensed.
114 18 STR WHL GUIDE BAR COIL 2 – Then examine the wires that are related to that
115 19 STR WHL GUIDE BAR COIL 3
116 20 STR WHL GUIDE BAR COIL 4 coil for a short circuit or an open circuit problem.
718 22 LD WHL GUIDE BAR +5V • If: The wires = good.
117 24 LD WHL GUIDE BAR COIL 4
118 25 LD WHL GUIDE BAR COIL 3 – Then replace GS1.
119 26 LD WHL GUIDE BAR COIL 2 • If: The event code continues.
120 27 LD WHL GUIDE BAR COIL 1
– Then replace ACCESS 6.
CA604
1
2 CA603
GS2 5 1
7 2
8 GS1 5
7 ACCESS 6
Fig. 296 (27300) 8 GCM
CA602
Event Code 633 717 15 STR WHL GUIDE BAR +5V
113 17 STR WHL GUIDE BAR COIL 1
ACCESS 6 module the steered wheel wire guid- 114 18 STR WHL GUIDE BAR COIL 2
115 19 STR WHL GUIDE BAR COIL 3
ance sensor bar problem. 116 20 STR WHL GUIDE BAR COIL 4
The traction does not operate. 718 22 LD WHL GUIDE BAR +5V
117 24 LD WHL GUIDE BAR COIL 4
Note: Event Code 633 will also be recorded if the wire 118 25 LD WHL GUIDE BAR COIL 3
guidance feature is ON and the sensor bars are not 119 26 LD WHL GUIDE BAR COIL 2
installed. Make sure the sensor bars are installed be- 120 27 LD WHL GUIDE BAR COIL 1
fore you continue.
Step 1: Turn the truck ON and measure the sensor bar CA604
5 V supply between CA602-15 and - BV. 1
2
• If: The sensor bar voltage = 5 V. GS2 5
– Then continue to Step 2. 7
8
• If: The voltage = 0 V.
– Then turn the truck OFF and remove the wire Fig. 297 (27300)
from CA602-15. Turn the truck ON and measure
the voltage between CA602-22 and - BV.
• If: The voltage = 5 V then the problem is in GS1 or
the wires from ACCESS 6 to GS1.
– Then repair or replace the wires or GS1.

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Event Code 636 • If: The line driver power = good.

ACCESS 6 module permitted the truck angle as it is
related to the guide wire to go more than the set
limits.
The brakes are applied and the traction does not oper-
ate.
Note: The Event Code 636 could record if the truck is
moved off of the end of the wire in automatic guide
mode.
• If: The event code is recorded as you move away
from the end of the wire in the automatic guide
mode.
– Then the wire guidance = good.
• If: Event Codes 632, 633 were also recorded.
– Then follow the procedures for these event codes
before you continue.
• If: The event code was recorded while in the aisle.
– Then examine to see ECR6 is aligned.
• If: It is necessary to align ECR6.
– Then calibrate the truck.
• If: The event code was not caused because ECR6
was not aligned or not calibrated.
– Then use the Crown field signal test device to
measure the wire guide signal intensity (6.25
KHz, 168 ma to 190 ma, 5.2 KHz, 100 ma to 118
ma).
• If: The signal intensity is good and the event code
continues.
– Then examine the floor.
Note: Irregular floor surfaces, can cause the signal to
be weak because of items below the floor surface (re-
bar, metal pipes, underground electrical wires in metal
or plastic conduit). One or all of these can decrease the
wire guidance performance. This could be in one sec-
tion or in many sections of the floor.
– Then examine the guide wire condition.
Event Codes 638, 639
ACCESS 6 module wire guidance system does not
have a wire signal from one of the two sensor bars.
The procedures below apply to Event Codes 638, 639.
The brakes are applied and the Traction does not op-
erate.
Step 1: Look for Event Codes 632 or 633.
• If: Event Code 632 or 633 has been recorded.
– Then follow the procedures for these event codes
before you continue.
• If: Event Code 638, load wheel sensor bar contin-
ues.
– Then examine the wire from CA604-1 to
CA602-27 and the wire fromCA604-2 to
CA602-26. The wire from CA604-7 to CA602-25
and the wire from CA604-8 to CA602-24. Repair
or replace as is necessary.
• If: The Event Code 639, steered wheel sensor bar
continues.
– Then examine the wire from CA603-1 to
CA602-20 and the wire from CA603-2 to
CA602-19. The wire from CA603-7 to CA602-18
and the wire from CA603-8 to CA602-17. Repair
or replace as is necessary.
• If: Event Code 638 or 639 continues.
– Then replace the sensor bar.
• If: Event Code 638 or 639 continues after you re-
place the sensor bar.
– Then replace ACCESS 6.

Event Code 637

ACCESS 6 module wire guidance system does not
have a wire signal at the two sensor bars.
The brakes are applied and the traction does not oper-
ate.
Step 1: Look for Event Codes 632 or 633.
• If: Event Code 632 or 633 has been recorded.
– Then follow the procedures for those event codes
before you continue.
• If: Event codes 632 or 633 have not been recorded.
– Then measure the line driver power.

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EVENT CODE GROUP 600

– Then examine the sensor wires.

• If: The wires = good.
CA603 – Then replace the EAC sensor that goes with the
1 event code.
2
GS1 5 • If: The signal is near the 40% range and the signal
7 ACCESS 6 intensity is near the lower range value.
8 GCM
CA602 – Then examine the sensor wires, the magnet loca-
717 15 STR WHL GUIDE BAR +5V tion, and the floor conditions around the magnet.
113 17 STR WHL GUIDE BAR COIL 1 • If: The wires, magnet locations, and floor conditions
114 18 STR WHL GUIDE BAR COIL 2
115 19 STR WHL GUIDE BAR COIL 3 = good.
116 20 STR WHL GUIDE BAR COIL 4 – Then replace the EAC sensor that goes with the
718 22 LD WHL GUIDE BAR +5V event code.
117 24 LD WHL GUIDE BAR COIL 4
118 25 LD WHL GUIDE BAR COIL 3 • If: The the event code continues.
119 26 LD WHL GUIDE BAR COIL 2
27 LD WHL GUIDE BAR COIL 1 – Then replace ACCESS 6.
120

CA604
1 EAC
2 CA608
GS2 5 ACCESS 6
1
7 2 CA602
8 314 1 EAC SENSORS +12V
CA607 575 2 EAC SENSORS BATT NEG
Fig. 298 (27300) 1 901 3 EAC A1 TEST
2 109 4 EAC A1 ANALOG
Event Codes 652 - 659 3 052 5 EAC A1 DIGITAL
4 902 6 EAC A2 TEST
5 110 7 EAC A2 ANALOG
ACCESS 6 module EAC sensor signal is out of 053
6 8 EAC A2 DIGITAL
range. 7 903 9 EAC B1 TEST
The procedures below apply to Event Codes 652 - 659. 8 111 10 EAC B1 ANALOG
9 054 11 EAC B1 DIGITAL
Full Traction does not operate. 10 904 12 EAC B2 TEST
Event Code 652 or 653: Sensor A1 above or below 11 112 13 EAC B2 ANALOG
12 055 14 EAC B2 DIGITAL
range.
Event Code 654 or 655: Sensor B1 above or below
range. Fig. 299 (27301)
Event Code 656 or 657: Sensor A2 above or below Event Codes 660 - 663
range.
ACCESS 6 module EAC sensor digital signal prob-
Event Code 658 or 659: Sensor B2 above or below
lem.
range.
The procedures below apply to Event Codes 660 - 663.
Step 1: Go to the ANALYZER menu A2.4.7 and look at
the EAC signal levels. The one shown value is the sig- Full Traction does not operate.
nal intensity in a % of the full scale for the sensor that Event Code 660: Sensor A1 digital signal problem.
is ON. The display will hold the highest sensed value Event Code 661: Sensor B1 digital signal problem.
until the next magnet found cycle occurs.
Event Code 662: Sensor A2 digital signal problem.
Step 2: The truck will sense the magnet as you move
Event Code 663: Sensor B2 digital signal problem.
the truck above the magnet in the position of the defec-
tive sensor. Monitor the sensor signal intensity. The Step 1: Go to the ANALYZER menu A2.4.7 and look at
signal intensity will be more to the lower range value the EAC digital signal condition that goes with the de-
than the higher range value. fective sensor. The digital condition will show opened if
the magnet is not sensed and closed if it is sensed.
• If: The signal is near the 100% range and the event
continues. Step 2: The truck will sense the wire as you slowly
move the truck above the magnet in the position of the

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ELECTRICAL SYSTEM
EVENT CODE GROUP 600
defective sensor while you monitor the sensor digital
condition.
• If: The digital condition switches from opened to
closed, back to opened as the sensor goes above
the magnet. Then the digital sense mechanism is
good.
– Then go to the ANALYZER menu A2.4.7 to see
the EAC signal intensity that goes with the event
code.
• If: The signal is near the 40% range and the inten-
sity is near the lower range.
– Examine the sensor wires and examine the mag-
net location and the floor conditions around the
magnet.
• If: The sensor wires, magnet location and floor con-
ditions are good and the event code continues.
– Then replace the EAC sensor that goes with the
event code.
• If: The digital condition shows an open all the time
as the sensor goes above the magnet.
– Then make sure that the magnet is installed and
examine the sensor wires and connections.
• If: The magnet is present and the wires and connec-
tions are good.
– Then replace the EAC sensor that goes with the
event code.
• If: The event code continues.
– Replace ACCESS 6.
Event Codes 664 - 667
ACCESS 6 module EAC magnet field intensity is
weak.
The procedures below apply to Event Codes 664 - 667.
Full Traction does not operate.
Step 1: Examine the magnet location(s) for an incor-
rect installation or damage (i.e. an incorrect magnet in-
stalled, magnet not aligned, floor crack through the
magnet, etc.).
Event Codes 668 - 671
ACCESS 6 module EAC sensor internal test prob-
lem.
The procedures below apply to Event Codes 668- 671.
Full Traction does not operate.
Event Code 668: Sensor A1.
Event Code 669: Sensor B1.
Event Code 670: Sensor A2.
M4.8-1970-092 TSP 7000 SERIES
434
Event Code 671: Sensor B2.
Step 1: Examine the sensor(s) wires and connections
as it applies to the event code(s).
• If: The wires or connections = bad.
– Then repair or replace the wires.
• If: The wires are good and the event code contin-
ues.
– Then replace the EAC sensor that goes with the
event code.
• If: The event code continues.
– Then replace ACCESS 6.
Event Code 672
ACCESS 6 module multiple EAC sensors are ac-
tive.
Full Traction does not operate.
Step 1: Examine the EAC sensors for damage.
• If: The sensor(s) = damaged.
– Then replace the damaged sensor(s).
• If: The sensor(s) = good.
– Then move the truck away from the EAC zone
where all the sensors will be off. Examine the dig-
ital signal voltages from CA602-5, CA602-8,
CA602-11, CA602-14 to -BV.
• If: One or more of the digital signals ≠ 1 V.
– Then turn the truck OFF and remove the wire
from CA602 that goes with the digital signal wire
from CA602. Turn the truck ON and measure the
voltage at ACCESS 6, CA602 where the digital
signal wire was removed.
• If: The voltage ≠ 1 V.
– Then replace ACCESS 6.
• If: The voltage > 3.5 V.
– Then measure the voltage that goes with the test
signal at CA602.
• If: The voltage at CA602-1 or CA602-2 = 0 V.
– Then replace the EAC sensor that goes with the
0 V that was measured.
• If: The voltage at CA602-1 or CA602-2 > 5 V.
– Then replace ACCESS 6.
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 ELECTRICAL SYSTEM
EVENT CODE GROUP 600

EAC
CA608
ACCESS 6
1
2 CA602
314 1 EAC SENSORS +12V
CA607 575 2 EAC SENSORS BATT NEG
1 901 3 EAC A1 TEST
2 109 4 EAC A1 ANALOG
3 052 5 EAC A1 DIGITAL
4 902 6 EAC A2 TEST
5 110 7 EAC A2 ANALOG
6 053 8 EAC A2 DIGITAL
7 903 9 EAC B1 TEST
8 111 10 EAC B1 ANALOG
9 054 11 EAC B1 DIGITAL
10 904 12 EAC B2 TEST
11 112 13 EAC B2 ANALOG
12 055 14 EAC B2 DIGITAL

Fig. 300 (27301)

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EVENT CODE GROUP 700

Event Code Group 700 • If: The resistance = ∞ Ω and the event code contin-
ues.
Event Code 700 – Then there are two 60 Ω resistors. One is in the
wire harness near CA703 and one is internal to
ACCESS 7 and ACCESS 8 module CAN timeout. ACCESS 5. Measure the resistance between
The traverse, pivot, fork extend, or retract do not oper- ACCESS 7 CA703-1 and CA703-12.
ate. • If: The resistance = 0 Ω.
Step 1: Turn the truck ON and examine the status of – Then disconnect CA402 from ACCESS 5 and
the ACCESS 8 LED’s. measure the resistance between ACCESS 7,
• If: The ACCESS 8 LED’s = ON. CA703-1 and CA703-2.
– Then examine the wires between ACCESS 8 • If: The resistance = 0 Ω.
CA504-3, CA504-4 and the platform distribution – Then the resistor in the wire harness is bad. Re-
panel CA106-3 and CA106-10. Make sure that place the resistor or the wire harness.
the CAN_H and CAN_L wires are connected to
correct pin. Repair or replace as is necessary.
• If: ACCESS 8 LED’s = OFF. ACCESS 7
– Then measure for +BV between CA504-1 and CA703 (BLK)
CA504-2 on ACCESS 8. CA701 059 1 CAN H
BRN 7 046 058 12 CAN L
• If: The voltage = 48 V (TSP 6500) or 72/80 V YEL 8 047
(TSP 7000).
– Then replace ACCESS 8.
• If: The voltage = 0 V. RES3
– Then examine the wires connected to CA504-1 Platform Distribution Panel
and CA504-2 and repair or replace the wires.
CA106 CA103
• If: The wires = good and the event code continues. 036 3 15
– Then examine the wires between ACCESS 7 6
CA703-1, CA703-12, and the platform distribu- 7
tion panel CA106-6 and CA106-7. Repair or re- 037 10
place as is necessary. 2963
Step 2: If the event code continues, turn the truck OFF. ACCESS 8
Measure the resistance between CAN_H CA504-3 and
CA317 CA318 CA504 (BRN)
CAN_L CA540-4. The resistance = 60 Ω.
6 BLU 6 2995 1 +BV IN
• If: The resistance = 0 Ω. 520 2 BATT COMM IN
– Then a short circuit problem between CAN_H 8 BRN 8 057 3 CAN H
7 YEL 7 056 4 CAN L
and CAN_L. Disconnect CA504 from ACCESS 8
and measure the resistance between module 1
pins CA504-3 and CA504-4. CA505
• If: The resistance = 0 Ω.
Fig. 301 (27302)
– Then replace ACCESS 8.
• If: The resistance = 120 Ω.
• If: The resistance = ∞ Ω. Connect CA504 to
ACCESS 8. – Then the resistor in ACCESS 5 is bad, replace
the ACCESS 5 module.
– Then disconnect CA703 from ACCESS 7. Meas-
ure the resistance between module pin CA703-1 Event Code 701
and CA703-12.
• If: The resistance = 0 Ω. ACCESS 4 and ACCESS 7 module CAN timeout.
– Then replace ACCESS 7. The auxiliary raise, lower, traverse, pivot, fork extend,
and retract are do not operate.

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EVENT CODE GROUP 700

Step 1: Turn the truck ON and look at the status of the • If: The resistance = ∞ Ω.
ACCESS 4 LED’s. – Then there are two 60 Ω resistors. One is in the
• If: The ACCESS 4 LED’s = ON. wire harness near CA703 and one is internal to
– Then examine the wires between ACCESS 4 ACCESS 5. Measure the resistance between
CA314-3, CA314-4, and the platform distribution ACCESS 7 CA703-1 and CA703-12.
panel CA106-1 and CA106-9. Make sure that • If: The resistance = 0 Ω.
CAN_H and CAN_L wires are connected to the – Then disconnect CA402 from ACCESS 5 and
correct pin. Repair or replace as is necessary. measure the resistance between ACCESS 7,
• If: The ACCESS 4 LED’s = OFF. CA703-1, CA703-2.
– Then measure for +BV between CA314-1 and • If: The resistance = 0 Ω.
CA314-2. – Then the resistor in the wire harness is bad. Re-
• If: The voltage = 48 V (TSP 6500) or 72/80 V place the resistor or the wire harness.
(TSP 7000). • If: The resistance = 120 Ω.
– Then replace ACCESS 4. – Then the resistor in ACCESS 5 is bad. Replace
• If: The voltage = 0 V. ACCESS 5.
– Then examine the wire from CA314-1 to
CA103-13 and the wire from CA314-2 to
CA101-1. Repair or replace as is necessary. ACCESS 7
• If: The wires are good and the event code contin- CA701 CA703 (BLK)
2975
ues. RED 3 059 1 CAN_H
– Then examine the wires between ACCESS 7 BRN 7 046 058 10 +BV INPUT
CA703-1 and CA703-12 and the platform distri- YEL 8 047 12 CAN_L
bution panel CA106-6 and CA106-7. Repair or
replace as is necessary.
RES3
Step 2: If the event code continues then turn the truck
OFF. Measure the resistance between CAN_H, Platform Distribution Panel
CA314-3 and CAN_L CA314-4. The resistance = 60 Ω. CA106 CA101
• If: The resistance = 0 Ω. 1 1
6
– Then a short circuit problem between CAN_H 7 CA103
CA105
and CAN_L. Disconnect CA314 from ACCESS 4 9 13
3
and measure the resistance between module
pins CA314-3 and CA314-4.
• If: The resistance = 0 Ω. ACCESS 4
– Then replace ACCESS 4. CA314 (BRN)
• If: The resistance = ∞ Ω, then connect CA314 to 2950 1 +BV IN
518 2 BATT COMM IN
ACCESS 4. 029 3 CAN H
– Then disconnect CA703 from ACCESS 7 and 028 4 CAN L
measure the resistance between module pins
CA703-1, CA703-12. Fig. 302 (27303)
• If: The resistance = 0 Ω.
Event Code 702
– Then replace ACCESS 7.
ACCESS 1 and ACCESS 7 module CAN timeout.
The auxiliary raise, lower, traverse, pivot, fork extend,
and retract do not operate.
• If: The event code is shown on ACCESS 1.
– Then the event code was caused by an intermit-
tent open wire condition. Examine the wire con-

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700

nections between the ACCESS 1 and • If: The resistance = 0 Ω.

ACCESS 7 modules. – Then replace ACCESS 1.
• If: Event Code 702 is does flash on ACCESS 7 in- • If: The resistance = ∞ Ω then connect CA304 to
dicator lights but is not shown on ACCESS 1. ACCESS 1.
– Then continue to Step 1. – Then disconnect CA703 from ACCESS 7. Meas-
Step 1: Turn the truck ON and look at the status of ure the resistance between module pins
ACCESS 1 LED’s. CA703-1 and CA703-12.
• If: The ACCESS 1 LED’s = ON. • If: The resistance = 0 Ω.
– Then examine the wires between ACCESS 1, – Then replace ACCESS 7.
CA304-3 and CA304-5 and CA106-2 and • If: The resistance = ∞ Ω.
CA106-8 of the platform distribution panel. Make
– Then there are two 60 Ω resistors. One is in the
sure that CAN_H and CAN_L wires are con-
wire harness near CA703 and one is internal to
nected to the correct pin. Repair or replace as is
ACCESS 5. Measure the resistance between
necessary.
ACCESS 7, CA703-1 and CA703-12
• If: The ACCESS 1 LED’s = OFF.
• If: The resistance = 0 Ω.
– Then measure for +BV between CA304-1 and
– Then disconnect CA402 from ACCESS 5. Meas-
CA304-2 at ACCESS 1.
ure the resistance between CA703-1 and CA703-
• If: The voltage = 48 V (TSP 6500) or 72/80 V 12 on ACCESS 7.
(TSP 7000).
• If: The resistance = 0 Ω.
– Then replace ACCESS 1.
– Then the resistor in the wire harness is bad. Re-
• If: The voltage = 0 V. place the resistor or the wire harness.
– Then examine the wires connected to CA304-1 • If: The resistance = 120 Ω.
and CA304-2 and to CA103-12 and FU8 on the
– Then the resistor in ACCESS 5 is bad. Replace
platform distribution panel.
ACCESS 5.
• If: The wires are good and the event code contin-
ues.
– Then examine the wires between ACCESS 7
CA703-1 and CA703-12 and the platform distri-
bution panel CA106-6 and CA106-7. Repair or
replace as is necessary.
Step 2: The event code continues. Turn the truck OFF
and measure the resistance on ACCESS 1 between
CA304-4 CAN_H and CA304-5 CAN_L. The resist-
ance must = 60 Ω.
• If: The resistance = 0 Ω.
– Then a short circuit problem between CAN_H
and CAN_L. Disconnect CA304 from ACCESS 1
and measure the resistance between module
pins CA304-4 and CA304-5.

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 ELECTRICAL SYSTEM
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• If: The wires are good and the event code contin-
ues.
ACCESS 7 – Then examine the wires between ACCESS 7
CA703-1 and CA703-12 and the platform distri-
CA703 (BLK
CA701 bution panel CA106-6 and CA106-7. Repair or
059 1 CAN_H
BRN 7 046 058 12 CAN_L replace as is necessary.
YEL 8 047 Step 2: The event code continues then turn the truck
OFF. Measure the resistance on ACCESS 2 between
RES3
CA411-23 CAN_H and CA411-35 CAN_L. The resist-
Platform Distribution Panel ance must = 60 Ω.
CA106 CA103 • If: The resistance = 0 Ω.
2 12
6 – Then a short circuit problem between CAN_H
7 CA104 and CAN_L. Disconnect CA411 from ACCESS 2
8 6 and measure the resistance between module
pins CA411-23 and CA411-35.
• If: The resistance = 0 Ω.
ACCESS 1 – Then replace ACCESS 2.
ALM1
• If: The resistance = ∞ Ω. Then connect CA411 to
CA304 ACCESS 2.
2946 1 +BV (KYS)
512 2 BATT NEG – Then disconnect CA703 from ACCESS 7. Meas-
027 4 CAN_H ure the resistance between module pins
022 5 CAN_L CA703-1 and CA703-12.
• If: The resistance = 0 Ω.
– Then replace ACCESS 7.
Fig. 303 (27304) • If: The resistance = ∞Ω.
Event Code 707 – Then there are two 60 Ω resistors. One is in the
wire harness near CA703 and one is internal to
ACCESS 2 and ACCESS 7 module CAN timeout. the ACCESS 5 module. Measure the resistance
The traverse, pivot, fork extend, and retract do not op- between ACCESS 7 CA703 -1 and CA703-12.
erate. • If: The resistance = 0 Ω.
Step 1: Turn the truck ON and look at the status of the – Then disconnect CA402 from ACCESS 5. Meas-
ACCESS 2 LED’s. ure the resistance between ACCESS 7 CA703-1
• If: The ACCESS 2 LED’s = ON. and CA703-12.
– Then examine the wire from CA411-23 to • If: The resistance = 0 Ω.
CA201-10 and the wire from CA411-35 to – Then the wire harness resistor is bad. Replace
CA201-4. Make sure that the CAN_H and CAN_L the resistor in the wire harness or replace the
wires are connected to the correct pins. Repair or wire harness.
replace as is necessary.
• If: The resistance = 120 Ω.
• If: The ACCESS 2 LED’s = OFF.
– Then the resistor in ACCESS 5 is bad. Replace
– Then measure for +BV between CA411-1 and ACCESS 5.
-BV.
• If: The voltage = 48 V (TSP 6500) or 72/8V
(TSP 7000).
– Then replace ACCESS 2.
• If: The voltage = 0 V.
– Then examine the wire from CA411-1 to
CA205-10 and FU8 on the platform distribution
panel. Repair or replace as is necessary.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700

– Then examine the wire from CA403-10 to

CA206-9 and FU8 on the power unit distribution
Power Unit panel.
Distribution ACCESS 2 • If: The wires and FU8 are good and the event code
Panel HCM continues.
CA201 CA411
– Then examine the wires between ACCESS 7
4 024 35 CAN L
CA206 10 023 CA703-1 and CA703-12 and the platform distri-
23 CAN H
10 1 +BV (KYS) INPUT bution panel CA106-6 and CA106-7. Repair or
replace as is necessary.
2904
B- B+ Step 2: The event code continues then turn the truck
OFF. Measure the resistance on ACCESS 5 between
Fig. 304 (27261) CA402-4 CAN_H and CA402-5 CAN_L. The resist-
ance must = 60 Ω.
• If: The resistance = 0 Ω.
Platform
– Then a short circuit problem between CAN_H
Distribution
Panel and CAN_L. Disconnect CA402 from ACCESS 5.
CA106 Measure the resistance between module pins
6 CA402-4 and CA402-5.
ACCESS 7
7 ACM • If: The resistance = 0 Ω.
CA703 (BLK) – Then replace ACCESS 5.
CA701 059 1 CAN_H • If: The resistance = ∞ Ω.
BRN 7 046 058 12 CAN_L
YEL 8 047 – Then disconnect CA703 from ACCESS 7. Meas-
ure the resistance between the module pins
CA703-1 and CA703-12.
RES3 • If: The resistance = 0 Ω.
– Then replace ACCESS 7.
Fig. 305 (27283)
• If: The resistance = ∞ Ω.
Event Codes 708, 709 – Then there are two 60 Ω resistors that connect
CAN_H and CAN_L. One is in the wire harness
ACCESS 5 and ACCESS 7 module CAN timeout. near CA703 and one is internal to ACCESS 5.
The procedures below apply to Event Codes 708, 709. Measure the resistance between ACCESS 7
The traverse, pivot, fork extend, and retract do not op- CA703 -1 and CA703-12.
erate. • If: The resistance = 0 Ω.
Step 1: Turn the truck ON and look at the status of the – Then disconnect CA402 from ACCESS 5. Meas-
ACCESS 5 LED’s. ure the resistance between ACCESS 7 CA703-1
• If: The ACCESS 5 LED’s = ON. and CA703-12.
– Then examine the wire from CA402-4 to • If: The resistance = 0 Ω.
CA201-8 and the wire from CA402-5 to CA201-2. – Then the wire harness resistor is bad. Replace
Make sure that the CAN_H and CAN_L wires are the resistor in the wire harness or replace the
connected to the correct pins. Repair or replace wire harness.
as is necessary. • If: The resistance = 120 Ω.
• If: The ACCESS 5 LED’s = OFF. – Then the resistor in ACCESS 5 is bad. Replace
– Then measure for +BV between CA403-10 and ACCESS 5.
-BV.
• If: The voltage = 48 V (TSP 6500) or 72/80 V
(TSP 7000).
– Then replace ACCESS 5.
• If: The voltage = 0 V.

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 ELECTRICAL SYSTEM
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– Then replace ACCESS 7.

• If: The Event Code 736 is not the last event code
Power Unit recorded.
Distribution ACCESS 5
SCM – Then a short circuit problem in the wires or sole-
Panel noid. Connect the wire removed from CA702-1
CA201 CA402 and continue to Step 2.
8 003 4 CAN_H
CA206 2 004 5 CAN_L Step 2: The auxiliary fork carriage must not be at max-
9 imum height. Turn the truck OFF and remove the wire
CA403 from PVAR. Turn the truck ON and try an auxiliary raise
2903 10 +BV INPUT and look at the event code.
A1 B+ A2 B- • If: The Event Code 736 is the last event code re-
corded.
Fig. 306 (27272)
– Then a short circuit problem in the wires. Exam-
ine for short circuits between the wires 5958 and
Platform 2976.
Distribution • If: The Event Code 736 is not the last event code
Panel recorded.
CA106 – Then a short circuit problem in the PVAR valve.
6
7
ACCESS 7 Replace the PVAR.
ACM
CA703 (BLK) Event Code 737
CA701 059 1 CAN_H
BRN 7 046 058 12 CAN_L ACCESS 7 module proportional flow valve auxil-
YEL 8 047 iary lower (PVAL) is above current.
The auxiliary lower is does not operate.
RES3 Note: The vent code is recorded if too much current
flows through the module driver at CA702-2.
Fig. 307 (27283) Step 1: Turn the truck OFF and remove the wire from
connector CA702-2. Turn the truck ON and try an aux-
Event Codes 711 - 720 iliary lower and look at the event code.
ACCESS 7 module internal problem found during • If: The Event Code 737 is the last event code re-
an internal test. corded.
The procedures below apply to Event Codes 711 - 720. – Then replace ACCESS 7.
The auxiliary raise or lower, traverse, pivot, extend, and • If: The Event Code 737 is not the last event code
retract do not operate. recorded.
Step 1: Replace ACCESS 7. – Then a short circuit problem in the wires or sole-
noid. Connect the wire to CA702-2 and continue
Event Code 736 to Step 2.
Step 2: Turn the truck OFF and disconnect the two
ACCESS 7 module proportional flow valve auxil-
wires from PVAL. Turn the truck ON and try an auxiliary
iary raise (PVAR) is above current.
lower and look at the event code.
The auxiliary raise is does not operate.
• If: The Event Code 737 is the last event code re-
Note: The event code is recorded if too much current corded.
flows through the module driver at CA702-1.
– Then a short circuit problem in the wires. Meas-
Step 1: The auxiliary fork carriage must not be at max- ure for short circuits between the wire 5959 and
imum height. Turn the truck OFF and remove the wire the wires 2979, 2978.
from connector CA702-1. Turn the truck ON and try an
• If: The Event Code 737 is not the last event code
auxiliary raise and look at the event code.
recorded.
• If: The Event Code 736 is the last event code re-
corded.

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– Then a short circuit problem in the PVAL. Re- • If: The Event Code 738 is the last event code re-
place the PVAL. corded.
– Then replace ACCESS 7.
• If: The Event Code 738 is not the last event code
ACCESS 7 recorded.
PVAR CA702 (GRAY) – Then a short circuit problem in the wires or sole-
5958 1 AUX RAISE PROPOR VALVE DR noid. Turn the truck OFF and connect the wire to
5959 2 AUX LOWER PROPOR VALVE DR CA702-4 and continue to Step 2.
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
5961 4 TRAVERSE PROPOR VALVE 1 DR Step 2: Remove the wires 2977, 2984 from PVT1. Turn
5962 5 AUX MAST LWR VALVE DRIVER the truck ON and try a traverse right and look at the
5989 6 LOAD HANDLER PROPOR VALVE event code.
5963 7 PIVOT VALVE 2 DRIVER (PVP)
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP) • If: The Event Code 738 is the last event code re-
5966 9 EXT FKS PROPOR VALVE 1 DR corded.
5965 10 EXT FKS PROPOR VALVE 2 DR
2976 – Then measure for short circuits between the wire
11 +BV & SUPP TO PVAR VALVE
2977 12 +BV & SUPP TO VALVES 5961 and wires 2977, 2984.
CA703 (BLK) • If: The Event Code 738 is not the last event code
7 +BV INPUT recorded.
– Then a short circuit problem in the PVT1 valve.
Platform Replace the PVT1.
CA701 CA105 Distribution
2974 2 WHT 2 Panel
Event Code 739
5965
PVF2 ACCESS 7 module proportional flow valve traverse
2982
5966 2981 motor (PVT2) is above current.
PVF1
The traverse left is does not operate.
5964
PVP1
2980 Note: The event code is recorded if too much current
flows through the module driver at CA702-3.
5963 2983
PVP2
29106 Step 1: Turn the truck OFF and remove the wire from
connector CA702-3. Turn the truck ON and try a trav-
5989
PVLH 2979 erse left and look at the event code.
5960 • If: The Event Code 739 is the last event code re-
PVT2
corded.
5959
PVAL 2978 – Then replace ACCESS 7.
2984

CA708 SVAL
3 RED
5962 4 GRN

Fig. 308 (27305)

Event Code 738

ACCESS 7 module proportional flow valve traverse
motor (PVT1) is above current.
The traverse right is does not operate.
Note: The event code is recorded if too much current
flows through the module driver at CA702-4.
Step 1: Turn the truck OFF and remove the wire from
connector CA702-4. Turn the truck ON and try a trav-
erse right and look at the event code.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

• If: The Event Code 739 is not the last event code
recorded.
– Then a short circuit problem in the wires or sole- ACCESS 7
noid. Turn the truck OFF and connect the wire to PVAR CA702 (GRAY)
CA702-3 and continue to Step 2. 5958 1 AUX RAISE PROPOR VALVE DR
Step 2: Remove the wires 2983, 2984 from PVT2. Turn 5959 2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
the truck ON and try a traverse left and look at the
5961 4 TRAVERSE PROPOR VALVE 1 DR
event code. 5962 5 AUX MAST LWR VALVE DRIVER
• If: The Event Code 739 is the last event code re- 5989 6 LOAD HANDLER PROPOR VALVE
corded. 5963 7 PIVOT VALVE 2 DRIVER (PVP)
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
– Then measure for short circuit problems between 5966 9 EXT FKS PROPOR VALVE 1 DR
the wire 5960 and the wires 2984, 2983. 5965 10 EXT FKS PROPOR VALVE 2 DR
2976 11 +BV & SUPP TO PVAR VALVE
• If: The Event Code 739 is not the last event code 2977 12 +BV & SUPP TO VALVES
recorded.
CA703 (BLK)
– Then a short circuit problem in the PVT2 valve.
7 +BV INPUT
Replace the PVT2.
Platform
Event Code 740 CA701 CA105 Distribution
2974 2 WHT 2 Panel
ACCESS 7 module proportional flow valve pivot
(PVP1) is above current. 5965
PVF2
The pivot clockwise does not operate. 2982
5966 2981
Note: The event code is recorded if too much current PVF1
flows through the module driver at CA702-8. 5964
PVP1
2980
Step 1: Turn the truck OFF and remove the wire from
connector CA702-8. Turn the truck ON and try a pivot 5963 2983
PVP2
clockwise and look at the event code. 29106
• If: The Event Code 740 is the last event code re- 5989
PVLH 2979
corded. 5960
PVT2
– Then replace ACCESS 7.
5959
• If: The Event Code 740 is not the last event code PVAL 2978
recorded. 2984
– Then a short circuit problem in the wires or sole-
CA708 SVAL
noid. Turn the truck OFF and connect the wire to
CA702-8 and continue to Step 2. 3 RED
5962 4 GRN
Step 2: Remove the wires 2980, 2981 from PVP1. Turn
the truck ON and try a pivot clockwise and look at the Fig. 309 (27305)
event code.
• If: The Event Code 740 is the last event code re-
Event Code 741
corded. ACCESS 7 module proportional flow valve pivot
– Then measure for short circuits between the wire (PVP2) is above current.
5964 and the wires 2980, 2981. The pivot counter clockwise does not operate.
• If: The Event Code 740 is not the last event code Note: The event code is recorded if too much current
recorded. flows through the module driver at CA702-7.
– Then a short circuit problem in the PVP1 valve. Step 1: Turn the truck OFF and remove the wire from
Replace the PVP1. connector CA702-7. Turn the truck ON and try to pivot
counter clockwise and look at the event code.
• If: The Event Code 741 is the last event code re-
corded.

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– Then replace ACCESS 7.
• If: The Event Code 741 is not the last event code
recorded.
– Then a short circuit problem in the wires or sole-
noid. Turn the truck OFF and connect the wire to
CA703-7 and continue to Step 2.
Step 2: Remove the wires 2980, 29106 from the PVP2
valve. Turn the truck ON and try to pivot counter clock-
wise and look at the event code.
• If: The Event Code 741 is the last event code re-
corded.
– Then measure for short circuits between the wire
5963 and the wires 2980, 29106.
• If: The Event Code 741 is not the last event code
recorded.
– Then a short circuit problem in PVP2 valve. Re-
place the PVP2.
Event Code 742
ACCESS 7 module proportional flow fork extend
(PVF1) is above current.
The fork extend does not operate.
Note: The event code is recorded if too much current
flows through the module driver at CA702-9.
Step 1: Turn the truck OFF and remove the wire from
connector CA702-9. Turn the truck ON and try a fork
extend and look at the event code.
• If: The Event Code 742 is the last event code re-
corded.
– Then replace ACCESS 7.
M4.8-1970-105 TSP 7000 SERIES
444
• If: The Event Code 742 is not the last event code
recorded.
– Then a short circuit problem in the wires or sole-
noid. Turn the truck OFF and connect the wire to
CA702-9 and continue to Step 2.
Step 2: Remove the wires 2982, 2983 from the PVF1
valve. Turn the truck ON and try a fork extend and look
at the event code.
• If: The Event Code 742 is the last event code re-
corded.
– Then measure for short circuits between the wire
5966 and the wires 2982, 2983.
• If: The Event Code 742 is not the last event code
recorded.
– Then a short problem in the PVF1 valve. Replace
the PVF1.
Event Code 743
ACCESS 7 module proportional flow fork retract
(PVF2) is above current.
The fork retract does not operate.
Note: The event code is recorded if too much current
flows through the module driver at CA702-10.
Step 1: Turn the truck OFF and remove the wire from
connector CA702-10. Turn the truck ON and try a fork
retract and look at the event code.
• If: The Event Code 743 is the last event code re-
corded.
– Then replace ACCESS 7.
• If: The Event Code 743 is not the last event code
recorded.
– Then a short circuit problem in the wires or sole-
noid. Turn the truck OFF and connect the wire to
CA702-10 and continue to Step 2.
Step 2: Remove the wires 2981, 2982 from the PVF2
valve. Turn the truck ON and try a fork retract and look
at the event code.
• If: The Event Code 743 is the last event code re-
corded.
– Then measure for short circuits between the wire
5965 and the wires 2981, 2982.
• If: Event code 743 is not the last event code re-
corded.
– Then a short circuit problem in the PVF2 valve.
Replace the PVF2.
Crown 2012 PF25715-82
 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

– Then replace ACCESS 7.

• If: The Event Code 744 is not the last event code
ACCESS 7 recorded.
PVAR CA702 (GRAY) – Then a short circuit problem in the wires or sole-
5958 1 AUX RAISE PROPOR VALVE DR noid. Turn the truck OFF and connect the wire to
5959 2 AUX LOWER PROPOR VALVE DR CA702-5 and continue to Step 2.
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
5961 4 TRAVERSE PROPOR VALVE 1 DR Step 2: Remove the RED wire from the SVAL valve.
5962 5 AUX MAST LWR VALVE DRIVER Turn the truck ON and try an auxiliary lower and look at
5989 6 LOAD HANDLER PROPOR VALVE the event code.
5963 7 PIVOT VALVE 2 DRIVER (PVP)
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP) • If: The Event Code 744 is the last event code re-
5966 9 EXT FKS PROPOR VALVE 1 DR corded.
5965 10 EXT FKS PROPOR VALVE 2 DR – Then measure for short circuits between the
2976 11 +BV & SUPP TO PVAR VALVE
2977 12 +BV & SUPP TO VALVES wires 5962 and the wire 2978. A short circuit
could also be between the RED and GRN wires
CA703 (BLK) on the SVAL valve.
7 +BV INPUT
• If: The Event Code 744 is not the last event code
Platform recorded.
CA701 CA105 Distribution
2974 2 WHT 2 – Then a short circuit problem in the SVAL valve.
Panel Replace the SVAL.
5965
PVF2
2982 Event Code 745
5966 2981
PVF1 ACCESS 7 module proportional flow auxiliary relief
5964 (PVLH) is above current.
PVP1
2980 The auxiliary raise, traverse, pivot, fork extend, and re-
5963 2983 tract do not operate.
PVP2
29106 Note: The event code is recorded if too much current
5989
PVLH flows through the module driver at CA702-6.
2979
5960 Step 1: The auxiliary fork carriage must not be at max-
PVT2 imum height. Turn the truck OFF and remove the wire
5959 from connector CA702-6. Turn the truck ON and try an
PVAL 2978 auxiliary raise and look at the event code.
2984
• If: The Event Code 745 is the last event code re-
CA708 SVAL corded.
3 RED – Then replace ACCESS 7.
5962 4 GRN
• If: The Event Code 745 is not the last event code
recorded.
Fig. 310 (27305)
– Then a short circuit problem in the wires or sole-
Event Code 744 noid. Turn the truck OFF and connect the wire to
CA702-6 and continue to Step 2.
ACCESS 7 module auxiliary cylinder lower sole-
noid valve (SVAL) is above current. Step 2: The auxiliary fork carriage must not be at max-
imum height. Remove the wires 2979, 29106 from the
The auxiliary lower does not operate.
PVLH valve. Turn the truck ON and try an auxiliary
Note: The event code is recorded if too much current raise and look at the event code.
flows through the module driver at CA702-5.
• If: The Event Code 745 is the last event code re-
Step 1: Turn the truck OFF and remove the wire from corded.
connector CA702-5. Turn the truck ON and try an aux-
– Then measure for short circuits between the
iliary lower and look at the event code.
wires 5989 and the wires 2979, 29106.
• If: The Event Code 744 is the last event code re-
• If: The Event Code 745 is not the last event code
corded.
recorded.

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ELECTRICAL SYSTEM
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– Then a short circuit problem in the PVLH valve.

Replace the PVLH.
ACCESS 7
Event Code 746
PVAR CA702 (GRAY)
ACCESS 7 module proportional flow auxiliary raise 5958 1 AUX RAISE PROPOR VALVE DR
(PVAR) is above current. 5959 2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
The auxiliary raise, traverse, pivot and fork extend do 5961 4 TRAVERSE PROPOR VALVE 1 DR
not operate. 5962 5 AUX MAST LWR VALVE DRIVER
5989 6 LOAD HANDLER PROPOR VALVE
Note: The event code is recorded if the current that 5963 7 PIVOT VALVE 2 DRIVER (PVP)
flows through the module driver supply at CA702-11 2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
when the driver is to be off. 5966 9 EXT FKS PROPOR VALVE 1 DR
5965 10 EXT FKS PROPOR VALVE 2 DR
Step 1: Measure the voltage across the PVAR coil ter- 2976 11 +BV & SUPP TO PVAR VALVE
minals. Turn the truck ON and look at the voltage read- 2977 12 +BV & SUPP TO VALVES
ing.
CA703 (BLK)
• If: The voltage > 1 V. 7 +BV INPUT
– Then a short circuit problem. Turn the truck OFF
and remove the wire from CA702-1 and turn the Platform
CA701 CA105 Distribution
truck ON. 2974 2 WHT 2 Panel
• If: The voltage = 0 V.
– Then a short circuit problem inside the module. 5965
PVF2
Replace ACCESS 7. 2982
5966 2981
• If: The voltage > 1 V. PVF1
– Then measure for short circuits between the 5964
PVP1
2980
wires 5958, 2976.
5963 2983
PVP2
29106
5989
PVLH 2979
5960
PVT2
5959
PVAL 2978
2984

CA708 SVAL
3 RED
5962 4 GRN

Fig. 311 (27305)

Event Codes 747 - 749

ACCESS 7 module internal driver short circuit
found by an internal test.
The procedures below apply to Event Codes 747 - 749.
Event Code 747: Auxiliary lower does not operate.
Event Codes 748, 749: The auxiliary raise, traverse,
pivot, fork extend and retract do not operate.
Step 1: Replace ACCESS 7.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

Event Code 750 • If: The voltage = 24 V for three seconds then goes
to 0 V.
ACCESS 7 module auxiliary cylinder lower sole- – Then the circuit is good. Look for an intermittent
noid valve (SVAL) driver has short circuit or load or dirty connections.
open.
Short circuit test:
The primary raise, lower, auxiliary raise is decreased
Measure the voltage across the SVAL coil terminals
(in limp mode), and auxiliary lower do not operate if the
with the wires connected. Turn the truck ON and look
SVAL valve is open.
at the indication.
Note: Event Code 750 will be recorded with the below
• If: The voltage > 1 V.
conditions:
– Then a short circuit problem. Turn the truck OFF
• An open in the SVAL valve or wires connected to
and remove the wire from CA702-5. Turn the
the SVAL to stop current flow when the SVAL driver
truck ON.
is on.
• If: The voltage = 0 V.
• A short circuit between the - BV and CA702-5, this
will put voltage across the SVAL valve when the – Then a short circuit is internal to ACCESS 7, re-
truck is ON. A short circuit could be internal or ex- place ACCESS 7.
ternal to the module. • If: The voltage > 1 V.
Step 1: Turn the truck OFF and remove the wires from – Then measure for short circuits between the
CA708-3 and CA708-4. Measure the resistance of the wires. The GRN wire from SVAL to CA708-4 and
SVAL valve. the wire from CA708-4 to CA702-5.
• If: The resistance ≠ 20 - 40 Ω.
– Then replace the SVAL valve.
• If: The resistance = ∞ Ω.
– Then replace the SVAL valve.
• If: The resistance = 20 - 40 Ω and the event code
continues.
– Then connect the wires to CA708-3 and
CA708-4. Measure the voltage across the SVAL
coil terminals. Turn the truck ON and look at the
voltage indication.
• If: The voltage > 1 V.
– Then a short circuit problem, refer to the short cir-
cuit test below.
Step 2: Measure the voltage between -BV and the
SVAL positive terminal with the GRN wire. Go to the
ANALYZER menu SVAL A4.1.10 on the display. Push
and hold the ENTER button (drives component), look
at the indication.
• If: The voltage = 0 V.
– Then the positive is missing. Examine the RED
wire from SVAL to CA708-3 and the wire from
CA708-3 to PVAL wire 2979.
• If: The voltage = +BV.
– Then the negative is missing. Examine the GRN
wire from SVAL to CA708-4 and the wire from
CA708-4 to CA702-5.

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EVENT CODE GROUP 700

• A short circuit between the - BV and CA702-6, puts

voltage across the PVLH when the truck is ON. A
ACCESS 7 short circuit could be internal or external to the mod-
ule.
PVAR CA702 (GRAY)
5958 Step 1: Turn the truck OFF and remove the wires from
1 AUX RAISE PROPOR VALVE DR
5959 2 AUX LOWER PROPOR VALVE DR the PVLH valve. Measure the coil resistance.
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR • If: The resistance = 20 - 40 Ω.
5961 4 TRAVERSE PROPOR VALVE 1 DR
5962 5 AUX MAST LWR VALVE DRIVER – Then the coil is good, continue to Step 2.
5989 6 LOAD HANDLER PROPOR VALVE • If: The resistance = 0 Ω.
5963 7 PIVOT VALVE 2 DRIVER (PVP)
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP) – Then replace the PVLH valve.
5966 9 EXT FKS PROPOR VALVE 1 DR • If: The resistance = ∞ Ω.
5965 10 EXT FKS PROPOR VALVE 2 DR
2976 11 +BV & SUPP TO PVAR VALVE – Then replace the PVLH valve.
2977 12 +BV & SUPP TO VALVES Step 2: Connect the wires to the PVLH valve. Measure
CA703 (BLK) the voltage between - BV and the PVLH valve terminal
7 +BV INPUT with wires 2979, 29106. Turn the truck ON and look at
the indication.
Platform
CA701 CA105 Distribution • If: The voltage ≠ +BV.
2974 2 WHT 2 Panel – Then an open circuit problem. Examine the con-
nections of wires 2979, 29106.
5965
PVF2 • If: The voltage = +BV.
2982
5966 2981 – Then continue to Step 3.
PVF1
5964 Step 3: Measure the voltage across the PVLH coil (do
PVP1 not remove wires). Go to the ANALYZER menu A4.1.3
2980
5963 2983 on the display and push and hold the ENTER button
PVP2
29106 (drives component) and look at the indication.
5989 • If: The voltage = 0 V.
PVLH 2979 – Then the negative is missing. Examine the wire
5960
PVT2 5989.
5959 • If: The voltage = 24 V for three seconds and drops
PVAL 2978 to 0 V.
2984
– Then the circuit is good. Look for an intermittent
CA708 SVAL or dirty connections.
3 RED • If: The voltage = +BV.
5962 4 GRN
– Then a short circuit problem in the wire from the
PVLH valve to CA702-6.
Fig. 312 (27305)
• If: The voltage = 0 V.
Event Code 751 – Then the short circuit is internal to the module,
ACCESS 7 module proportional flow auxiliary relief replace ACCESS 7.
(PVLH) driver has a short circuit or load open. • If: The voltage = +BV.
The primary raise, lower are decreased (in limp mode), – Then a short circuit problem in the wires look at
and auxiliary raise does not operate. wire 5989.
If the PVLH valve is open, all auxiliary functions do not
operate.
Event Code 752
Note: Event Code 751 will be recorded with the below ACCESS 7 module proportional flow valve auxil-
conditions: iary raise (PVAR) driver or load open.
• An open in the PVLH or wires to the PVLH that The auxiliary raise does not operate.
stops current flow when the PVLH driver is on.

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Note: The event code is recorded if there is an open • If: The voltage = 0 V.
circuit problem between the PVAR valve and the driver – Then an open is internal to the module, replace
CA702-1. ACCESS 7.
Step 1: Measure the voltage across the PVAR coil ter-
minals. Go to the ANALYZER menu A4.1.2 on the dis-
play and push and hold the ENTER button (drives ACCESS 7
component) and look at the indication.
PVAR CA702 (GRAY)
• If: The voltage = +BV. 5958 1 AUX RAISE PROPOR VALVE DR
– Then the PVAR valve is open then replace the 5959 2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
PVAR.
5961 4 TRAVERSE PROPOR VALVE 1 DR
• If: The voltage = 0 V. 5962 5 AUX MAST LWR VALVE DRIVER
– Then a positive or negative signal is missing, 5989 6 LOAD HANDLER PROPOR VALVE
5963 7 PIVOT VALVE 2 DRIVER (PVP)
continue to Step 2. 2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
Step 2: Measure the voltage between -BV and the 5966 9 EXT FKS PROPOR VALVE 1 DR
PVAR wire 5958 (wires connected to coil). Go to the 5965 10 EXT FKS PROPOR VALVE 2 DR
2976 11 +BV & SUPP TO PVAR VALVE
ANALYZER menu A4.1.2 on the display and push and 2977 12 +BV & SUPP TO VALVES
hold the ENTER button (drives component), look at the
indication. CA703 (BLK)
7 +BV INPUT
• If: The voltage = 0 V.
– Then a positive is missing, refer to the positive Platform
CA701 CA105 Distribution
test below. 2974 2 WHT 2 Panel
• If: The voltage = +BV.
– Then a negative is missing, refer to the negative 5965
PVF2
test below. 2982
5966 2981
• If: The voltage = 24 V for three seconds and drops PVF1
to 0 V. 5964
PVP1
– Then the circuit is good. The problem could be an 2980
intermittent because of loose or dirty connection. 5963 2983
PVP2
29106
Missing positive test:
5989
Measure the wire from PVAR to CA702-11 and the wire PVLH 2979
from CA703-7 to CA701-2. The wire from CA701-2 to 5960
CA105-2. PVT2
5959
Missing negative test: PVAL 2978
Measure the voltage between the PVAR terminal with 2984
wire 5958 and CA702-1. Go to the ANALYZER menu
to A4.1.2 on the display and push and hold the ENTER CA708 SVAL
button (drives component), look at the indication. 3 RED
5962 4 GRN
• If: The voltage = +BV.
– Then the wires are open between ACCESS 7 Fig. 313 (27305)
and the PVAR. Repair or replace the wires.
Event Code 753
ACCESS 7 module proportional flow valve auxil-
iary lower (PVAL) driver or load open.
The auxiliary lower does not operate.
Note: The event code is recorded if an open circuit
problem between the PVAL and driver at CA702-2.
Step 1: Measure the voltage across the PVAL coil
(wires connected). Go to the ANALYZER menu to

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A4.1.1 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then the PVAL valve = open, replace the PVAL.
• If: The voltage = 0 V.
– Then a positive or negative signal is missing,
continue to Step 2.
Step 2: Measure the voltage between -BV and the
PVAL valve wire 5959. Go to the ANALYZER menu to
A4.1.1 on the display and push and hold the ENTER
button (drives component), look at the indication.
• If: The voltage = 0 V.
– Then a positive is missing, refer to the positive
test below.
• If: The voltage = +BV.
– Then a negative is missing, refer to the negative
test below.
• If: The voltage = 24 V for three seconds and drops
to 0 V.
– Then the circuit is good. The problem could be an
intermittent because of a loose or dirty connec-
tion.
Missing positive test:
Examine PVAL to the wires 2979 to 29106 to 2980 to
2981 to 2982 to 2983 to 2984 to 2977 to CA702-12.
The wire from CA703-7 to CA701-2 and the wire from
CA701-2 to CA105-2.
Missing negative test:
Measure the voltage between the PVAL terminal with
wire 5959 and CA702-2. Go to the ANALYZER menu
to A4.1.1 on the display and push and hold the ENTER
button (drives component), look at the indication.
• If: The voltage = +BV.
– Then the wires are open between ACCESS 7
and the PVAL then repair or replace the wires.
M4.8-1970-112 TSP 7000 SERIES
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• If: The voltage = 0 V.
– Then an open circuit is internal to the ACCESS 7
then replace ACCESS 7.
Event Code 754
ACCESS 7 module proportional flow valve traverse
motor (PVT2) driver or load open.
The traverse left does not operate.
Note: The event code is recorded if an open problem
does not let current flow through the driver at CA702-3.
Step 1: Measure the voltage across the PVT2 coil ter-
minals (wires connected). Go to the ANALYZER menu
to A4.1.5 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then the PVT2 valve is open then replace the
PVT2.
• If: The voltage = 0 V.
– Then a positive or negative signal is missing con-
tinue to Step 2.
Step 2: Measure the voltage between - BV and the
PVT2 valve wire 5960. Go to the ANALYZER menu to
A4.1.5 on the display and push and hold the ENTER
button (drives component), look at the indication.
• If: The voltage = 0 V.
– Then a positive is missing. Refer to the positive
test below.
• If: The voltage = +BV.
– Then a negative is missing, refer to the negative
test below.
• If: The voltage = 24 V for three seconds and drops
to 0 V.
– Then the circuit is good. The problem could be an
intermittent because of a loose or dirty connec-
tion.
Missing positive test:
Examine PVT2 to the wires 2984 to 2977 to CA702-12.
The wire from CA703-7 to CA701-2 and the wire from
CA701-2 to CA105-2.
Missing negative test:
Measure the voltage between PVT2 terminal with wire
5960 and CA702-3. Go to the ANALYZER menu to
A4.1.5 on the display and push and hold the ENTER
button (drives component), look at the indication.
• If: The voltage = +BV.
– Then the wire is open between ACCESS 7 and
PVT2. Repair or replace the wires.
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EVENT CODE GROUP 700

• If: The voltage = 0 V. to A4.1.4 on the display and push and hold the ENTER
– Then an open is internal to the module then re- button (drives component) and look at the indication.
place ACCESS 7. • If: The voltage = +BV.
– Then the PVT1 is open. Replace the PVT1.
• If: The voltage = 0 V.
ACCESS 7
– Then a positive or negative signal is missing con-
PVAR CA702 (GRAY) tinue to Step 2.
5958 1 AUX RAISE PROPOR VALVE DR
5959 Step 2: Measure the voltage between -BV and the
2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR PVT1 wire 5961. Go to the ANALYZER menu to A4.1.4
5961 4 TRAVERSE PROPOR VALVE 1 DR on the display and push and hold the ENTER button
5962 5 AUX MAST LWR VALVE DRIVER (drives component) and look at the indication.
5989 6 LOAD HANDLER PROPOR VALVE
5963 7 PIVOT VALVE 2 DRIVER (PVP) • If: the voltage = 0 V.
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP) – Then a positive is missing. Refer to the positive
5966 9 EXT FKS PROPOR VALVE 1 DR test below.
5965 10 EXT FKS PROPOR VALVE 2 DR
2976 11 +BV & SUPP TO PVAR VALVE • If: The voltage = +BV.
2977 12 +BV & SUPP TO VALVES – Then a negative is missing. Refer to the negative
CA703 (BLK) test below.
7 +BV INPUT • If: The voltage = 24 V for three seconds and drops
Platform to 0 V.
CA701 CA105 Distribution – Then the circuit is good. The problem could be an
2974 2 WHT 2 Panel intermittent because of a loose or dirty connec-
tion.
5965
PVF2 Missing positive test:
2982
5966 2981 Examine the wire from PVT1 to CA702-12 and the wire
PVF1
from CA703-7 to CA701-2 The wire from CA701-2 to
5964
PVP1
2980 CA105-2.
5963 2983 Missing negative test:
PVP2 Measure the voltage between PVT1 terminal with wire
29106
5989 5961 and CA702-4. Go to the ANALYZER menu to
PVLH 2979 A4.1.4 on the display and push and hold the ENTER
5960 button (drives component) and look at the indication.
PVT2
5959 • If: The voltage = +BV.
PVAL 2978 – Then the wire is open between ACCESS 7 and
2984 the PVT1. Repair or replace the wires.
CA708 SVAL
3 RED
5962 4 GRN

Fig. 314 (27305)

Event Code 755

Access 7 module proportional flow valve traverse
motor (PVT1) driver or load open.
The traverse right does not operate.
Note: The event code is recorded if an open problem
does not let current flow through the driver at CA702-4.
Step 1: Measure the voltage across the PVT1 coil ter-
minals (wires connected). Go to the ANALYZER menu

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• If: The voltage = 0 V. • If: The voltage = 0 V.

– Then an open is internal to ACCESS 7 then re- – Then an open is internal to ACCESS 7. Replace
place ACCESS 7. ACCESS 7.

Event Code 756

ACCESS 7 module proportional flow valve pivot ACCESS 7
(PVP1) driver or load open. PVAR CA702 (GRAY)
The pivot clockwise does not operate. 5958 1 AUX RAISE PROPOR VALVE DR
5959 2 AUX LOWER PROPOR VALVE DR
Note: The event code is recorded if an open problem PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
does not let the current flow through the driver at 5961 4 TRAVERSE PROPOR VALVE 1 DR
CA702-8. 5962 5 AUX MAST LWR VALVE DRIVER
5989 6 LOAD HANDLER PROPOR VALVE
Step 1: Measure the voltage across the PVP1 coil ter- 5963 7 PIVOT VALVE 2 DRIVER (PVP)
minals (wires connected). Go to the ANALYZER menu 2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
to A4.1.8 on the display and push and hold the ENTER 5966 9 EXT FKS PROPOR VALVE 1 DR
5965 10 EXT FKS PROPOR VALVE 2 DR
button (drives component) and look at the indication. 2976 11 +BV & SUPP TO PVAR VALVE
• If: The voltage = +BV. 2977 12 +BV & SUPP TO VALVES
– Then the PVP1 is open then replace the PVP1. CA703 (BLK)
• If: The voltage = 0 V. 7 +BV INPUT
– Then a positive or negative signal is missing, Platform
continue to Step 2. CA701 CA105 Distribution
2974 2 WHT 2 Panel
Step 2: Measure the voltage between - BV and the
PVP1 wire 5964. Go to the ANALYZER menu to A4.1.8 5965
on the display and push and hold the ENTER button PVF2
2982
(drives component) and look at the indication. 5966 2981
PVF1
• If: The voltage = 0 V.
5964
– Then a positive is missing, refer to the positive PVP1
2980
test below. 2983
5963
• If: The voltage = +BV. PVP2
29106
– Then a negative is missing. Refer to the negative 5989
test below. PVLH 2979
5960
• If: The voltage = 24 V for three seconds and drops PVT2
to 0 V. 5959
PVAL 2978
– Then the circuit is good. The problem could be an
intermittent because of a loose or dirty connec- 2984
tion. CA708 SVAL
Missing positive test: 3 RED
Examine from the PVP1 wires 2981 to 2982, to 2983 to 5962 4 GRN
2984, and 2977 to CA702-12. The wire from CA703-7
to CA701-2 and the wire from CA701-2 to CA105-2. Fig. 315 (27305)

Missing negative test: Event Code 757

Measure the voltage between PVP1 terminal with the
wire 5964 and CA702-8. Go to the ANALYZER menu
to A4.1.8 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then the wires are open between ACCESS 7
and PVP1. Repair or replace the wires.
ACCESS 7 module auxiliary cylinder lower sole-
noid valve (SVAL) open driver.
The auxiliary lower does not operate.
Note: The event code is recorded if an open does not
let the current flow through the driver at CA702-5.
Step 1: Replace ACCESS 7.

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Event Code 758
ACCESS 7 module proportional flow auxiliary relief
(PVLH) driver open.
The auxiliary raise, pivot, extend, retract, and traverse
do not operate.
Note: Event code is recorded if an open does not let
the current flow through the driver CA702-6.
Step 1: Replace the ACCESS 7 module.
to A4.1.9 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then the wires are open between ACCESS 7
and the PVP2. Repair or replace the wires.
• If: The voltage = 0 V.
– Then an open is internal to the module then re-
place ACCESS 7.

Event Code 759

ACCESS 7
ACCESS 7 module proportional flow valve pivot PVAR CA702 (GRAY)
(PVP2) driver or load open. 5958 1 AUX RAISE PROPOR VALVE DR
The pivot counter clockwise does not operate. 5959 2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
Note: The event code is recorded if an open does not 5961 4 TRAVERSE PROPOR VALVE 1 DR
let the current flow through the driver at CA702-7. 5962 5 AUX MAST LWR VALVE DRIVER
Step 1: Measure the voltage across the PVP2 coil ter- 5989 6 LOAD HANDLER PROPOR VALVE
5963 7 PIVOT VALVE 2 DRIVER (PVP)
minals (wires connected). Go to the ANALYZER menu 2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
to A4.1.9 on the display and push and hold the ENTER 5966 9 EXT FKS PROPOR VALVE 1 DR
button (drives component) and look at the indication. 5965 10 EXT FKS PROPOR VALVE 2 DR
2976 11 +BV & SUPP TO PVAR VALVE
• If: The voltage= +BV. 2977 12 +BV & SUPP TO VALVES
– Then the PVP2 = open. Replace the PVP2. CA703 (BLK)
• If: The voltage = 0 V. 7 +BV INPUT
– Then a positive or negative signal is missing,
Platform
continue to Step 2. CA701 CA105 Distribution
Step 2: Measure the voltage between -BV and the 2974 2 WHT 2 Panel
PVP2 wire 5963. Go to the ANALYZER menu to A4.1.9
on the display and push and hold the ENTER button 5965
PVF2
(drives component) and look at the indication. 2982
5966 2981
• If: The voltage = 0 V. PVF1
– Then a positive is missing. Refer to the positive 5964
PVP1 2980
test below.
5963 2983
• If: The voltage = +BV. PVP2
29106
– Then a negative is missing. Refer to the negative
5989
test below. PVLH 2979
• If: The voltage = 24 V for three seconds and drops 5960
PVT2
to 0 V.
5959
– Then the circuit is good. The problem could be an PVAL 2978
intermittent loose or dirty connection. 2984
Missing positive test: SVAL
CA708
Examine the PVP2 wires from 2980 to 2981 and to 3 RED
2982 to 2983. The wire 2984 to 2977 and to CA702-12. 5962 4 GRN
The wire from CA703-7 to CA701-2 and the wire from
CA701-2 to CA105-2. Fig. 316 (27305)
Missing negative test:
Measure the voltage between the PVP2 terminal with
wire 5963 and CA702-7. Go to the ANALYZER menu

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Event Code 760
ACCESS 7 module proportional flow fork extend
(PVF1) driver or load open.
The fork extend does not operate.
Note: The event code is recorded if an open does not
let the current flow through the driver at CA702-9.
Step 1: Measure the voltage across PVF1 coil termi-
nals (wires connected). Go to the ANALYZER menu to
A4.1.6 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then PVF1 = open then replace PVF1.
• If: The voltage = 0 V.
– Then a positive or negative signal is missing,
continue to step 2.
Step 2: Measure the voltage between - BV and the
PVF1 wire 5966. Go to the ANALYZER menu A4.1.6
on the display and push and hold the ENTER button
(drives component) and look at the indication.
• If: The voltage = 0 V.
– Then a positive is missing. Refer to the positive
test below.
• If: The voltage = +BV.
– Then a negative is missing. Refer to the negative
test below.
• If: The voltage = 24 V for three seconds and drops
to 0 V.
– Then the circuit is good. The problem could be an
intermittent loose or dirty connection.
Missing positive test:
Examine the PVF1 wires 2983 to 2984 to 2977 to
CA702-12. The wire from CA703-7 to CA701-2 and the
wire from CA701-2 to CA105-2.
Missing negative test:
Measure the voltage between PVF1 terminal with wire
5966 and CA702-9. Go to the ANALYZER menu to
A4.1.6 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then the wires are open between ACCESS 7
and the PVF1. Repair or replace the wires.
• If: The voltage = 0 V.
– Then an open is internal to the ACCESS 7. Re-
place ACCESS 7.
M4.8-1970-117 TSP 7000 SERIES
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Event Code 761
ACCESS 7 module proportional flow fork retract
(PVF2) driver or load open.
The fork retract does not operate.
Note: The event code is recorded if an open does not
let the current flow through the driver at CA702-10.
Step 1: Measure the voltage across the PVF2 coil ter-
minals (wires connected). Go to the ANALYZER menu
to A4.1.7 on the display and push and hold the ENTER
button (drives component) and look at the indication.
• If: The voltage = +BV.
– Then PVF2 = open. Replace PVF2.
• If: The voltage = 0 V.
– Then a positive or negative signal is missing,
continue to Step 2.
Step 2: Measure the voltage between the - BV and the
PVF2 wire 5965. Go to the ANALYZER menu to A4.1.7
on the display and push and hold the ENTER button
(drives component) and look at the indication.
• If: The voltage = 0 V.
– Then a positive is missing. Refer to the positive
test below.
• If: The voltage = +BV.
– Then a negative is missing. Refer to the negative
test below.
• If: The voltage = 24 V for three seconds and drops
to 0 V.
– Then the circuit is good. The problem could be an
intermittent loose or dirty connection.
Missing positive test:
Examine the wires to the PVF2. The wires 2982 to
2983 to 2984 and the wire 2977 to CA702-12 The wire
from CA703-7 to CA701-2 and the wire from CA701-2
to CA105-2.
Missing negative test:
Measure the voltage between the PVF2 terminal with
the wire 5965 and CA702-10. Turn the truck ON while
you push the up and down arrow buttons go to the AN-
ALYZER menu A4.1.7 on the display menu. Push and
hold the ENTER button (drives component) and look at
the indication.
• If: The voltage = +BV.
– Then the wire is open between ACCESS 7 and
PVF2. Repair or replace the wires.
Crown 2012 PF25715-92
 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

• If: The voltage = 0 V. Step 1: Measure the voltage between - BV and

– Then an open is internal to ACCESS 7. Replace CA704-2 (wires connected). Turn the truck ON and
ACCESS 7. look at the indication.
• If: The voltage = 12–15 V.
– Then an open circuit problem is internal to the
ACCESS 7 ACCESS 7 then replace ACCESS 7.
PVAR CA702 (GRAY) • If: The voltage = 0 V.
5958 1 AUX RAISE PROPOR VALVE DR – Then an open circuit problem in the wires or the
5959 2 AUX LOWER PROPOR VALVE DR LS is bad. Examine the wire from the LS to
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
5961 4 TRAVERSE PROPOR VALVE 1 DR CA711 and the wire from CA711 to CA708-1. The
5962 5 AUX MAST LWR VALVE DRIVER wire from CA708-1 to CA704-2 and the wire from
5989 6 LOAD HANDLER PROPOR VALVE the LS to CA711. The wire from CA711 to
5963 7 PIVOT VALVE 2 DRIVER (PVP) CA708-2 and the wire from CA708-2 to CA704-3.
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
5966 9 EXT FKS PROPOR VALVE 1 DR • If: The wires = good.
5965 10 EXT FKS PROPOR VALVE 2 DR – Then replace the LS.
2976 11 +BV & SUPP TO PVAR VALVE
2977 12 +BV & SUPP TO VALVES • If: The voltage = 0.8–5 V and the event code contin-
CA703 (BLK) ues.
7 +BV INPUT – Then the circuit is good. The problem could be an
intermittent loose or dirty connection.
Platform
CA701 CA105 Distribution
2974 2 WHT 2
Event Code 763
Panel
ACCESS 7 module load sense transducer (LS) has
5965 a short circuit.
PVF2
2982
5966 2981 The traction is decreased (in limp mode).
PVF1
Note: The event code is recorded if a short circuit prob-
5964 lem lets too much current flow through the LS at
PVP1
2980
CA704-2.
5963 2983
PVP2 Step 1: Turn the truck OFF and remove the wire from
29106
CA704-2. Turn the truck ON and measure the voltage
5989 on the wire removed from CA704-2 and - BV and look
PVLH 2979
5960 at the indication.
PVT2
• If: The voltage = 12–15 V.
5959
PVAL 2978 – Then replace the wire and continue to Step 2.
2984

CA708 SVAL
3 RED
5962 4 GRN

Fig. 317 (27305)

Event Code 762

ACCESS 7 module load sense transducer (LS) is
open.
The traction is decreased (in limp mode).
Note: The event code is recorded if an open does not
let the current flow through the load sense pressure
transducer at CA704-2.

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• If: The voltage = +BV. the wires to POT5 and CA704-7, CA704-8 and
– Then a short circuit problem. The wire from CA704-9.
CA711 to CA708-1. The wire from CA708-1 to • If: The wires = good.
CA704-2 and the wire from the LS to CA711. The – Then replace POT5.
wire from CA711 to CA708-2 and the wire from
• If: The voltage = 0.5 - 4.5 V
CA708-2 to CA704-3.
– Then the circuit = good.
Step 2: Turn the truck OFF and connect the wire into
the CA704-2. Turn the truck ON and measure the volt-
age between CA704-2 and - BV and look at the indica-
tion. ACCESS 7
• If: The voltage = 12–15 V. CA706 CA704 (GRY)
– Then the LS = bad then replace the LS. POT5 C 107 7 PIVOT POS POT INPUT
B 722 8 PIVOT POS POT +5V
• If: The voltage = 0.8–5 V and the event code contin- A 570 9 PIVOT POS POT BATT NEG
ues.
– Then the circuit is good. The problem could be an Fig. 319 (27307)
intermittent loose or dirty connection.
Event Code 765
ACCESS 7 module pivot potentiometer (POT5)
ACCESS 7 voltage is not constant.
CA704 (GRY) The traction is decreased (in limp mode).
121 2 LOAD SENSE INPUT Note: The event code is recorded if a voltage change
401 3 LOAD SENSOR +14V
does occur at CA704-7 with no pivot command.
CA708 CA711 Step 1: Examine the pivot cable.
1 BLK BLK LS • If: The cable is off of the pulley.
2 WHT RED
– Then install the cable and look for a cause.
Fig. 318 (27306) • If: The cable is on the pulley.
– Then continue to Step 2.
Event Code 764
Step 2: Make sure the pivot occurs when other hydrau-
ACCESS 7 module pivot position potentiometer lic functions are done.
(POT5) is above or below the electrical limit. • If: The forks do not pivot and the event code is re-
The traction is decreased (in limp mode). corded.
Note: The event code is recorded if the voltage at – Then replace POT5.
CA704-7 is above or below the electrical limit. • If: The clockwise pivot occurs and the event code is
Step 1: Turn the truck ON while you push the up arrow recorded.
button. Go to the ANALYZER menu to see POT5 – Then examine the wire from CA702-8 to PVP1 for
A2.1.3 on the display. Look at the indication. a short circuit to the frame.
• If: The voltage = 0 V. • If: The wires = good.
– Then an open circuit problem between CA704-7 – Then examine for contamination in the PVP or
or CA704-9 and POT5 or a wire between POT5 CBV4.
and CA704-7. CA704-9 has a short circuit to the • If: The counter clockwise pivot occurs and the event
truck frame or - BV. Examine the wires. code is recorded.
• If: The wires = good. – Then examine the wire from CA702-7 to the
– Then replace POT5. PVP2 for a short circuit to the frame.
• If: The voltage = 5 V or more. • If: The wires = good.
– Then an open circuit or a short circuit to the frame – Then examine for contamination in the PVP or
problem between POT5 and CA704-8. Examine CBV3.

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• If: No contamination is found and the event code Event Code 768
continues.
– Then replace ACCESS 7. ACCESS 7 module pivot potentiometer (POT5)
turns in the incorrect direction.
The traction, primary raise, lower are decreased (in
limp mode), and the pivot does not operate.
ACCESS 7
Note: The event code is recorded if the voltage at
PVP2 CA702 (GRAY)
PVP1 CA704-7 does change opposite of the pivot command.
5963 7 PIVOT VALVE 2 DRIVER (PVP)
5964 8 PIVOT VALVE 1 DRIVER (PVP) Step 1: Examine the POT5 wires. The wire from
CA706-A to CA704-9 and the wire from CA706-B to
CA706 CA704 (GRY) CA704-8.
POT5 C 107 7 PIVOT POS POT INPUT • If: The wires are not installed on the correct pin.
B 722 8 PIVOT POS POT +5V
A 570 9 PIVOT POS POT BATT NEG – Then correct the wires and calibrate POT5.
• If: The wires = good.
Fig. 320 (27308) – Then continue to Step 2.
Event Code 767 Step 2: Examine the wire from PVP1 to CA702-8 and
the wire from PVP2 to CA702-7.
ACCESS 7 module pivot potentiometer (POT5) • If: The wires are not installed on the correct pin.
voltage changes to fast.
– Then install the wires on the correct pin.
The traction is decreased (in limp mode) and the pivot
• If: The wires = good.
does not operate.
– Measure the voltage between the PVP1 terminal
Note: The event code is recorded if the voltage at
with the wire 5964 and - BV. Turn the truck ON
CA704-7 does change to fast.
and look at the indication.
Step 1: Examine the pivot cable.
• If: The voltage = +BV.
• If: The cable is off of the pulley.
– Then continue to Step 3.
– Then install the cable and look for a cause.
• If: The voltage = 0 V.
• If: The cable is on the pulley.
– Then a short circuit in the wire between PVP1
– Then continue to Step 2. and CA702-8.
Step 2: Examine the wires and connections between Step 3: Measure the voltage between the PVP2 termi-
the PVP1, PVP2, and ACCESS 7. nal with the wire 5963 and - BV. Turn the truck ON and
• If: The wires are good and the event code contin- look at the indication.
ues. • If: The voltage = +BV and the event code continues.
– Then examine the POT5 wires between – Then replace the POT5 and calibrate the pivot
CA706-A, -B, -C, CA704-7, CA704-8, and function.
CA704-9.
• If: The voltage = 0 V.
• If: The wires are good and the event code contin-
– Then a short circuit in the wire between the PVP2
ues.
and CA702-7.
– Then replace ACCESS 7.

ACCESS 7
CA706 CA704 (GRY)
POT5 C 107 7 PIVOT POS POT INPUT
B 722 8 PIVOT POS POT +5V
A 570 9 PIVOT POS POT BATT NEG

Fig. 321 (27307)

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700

Note: The event code is recorded if the voltage at

CA704-7 is out of the set calibration value.
ACCESS 7 Step 1: If The Event Code 764 is recorded then repair
Event Code 764 before you continue with Event Code
PVP2 CA702 (GRAY)
PVP1 770.
5963 7 PIVOT VALVE 2 DRIVER (PVP)
5964 8 PIVOT VALVE 1 DRIVER (PVP) • If: Event Code 764 was not recorded but POT5 was
replaced or adjusted.
CA706 CA704 (GRY)
– Then examine the POT5 wires and cable. Cali-
POT5 C 107 7 PIVOT POS POT INPUT
B 722 8 PIVOT POS POT +5V brate the pivot function.
A 570 9 PIVOT POS POT BATT NEG Step 2: Turn the truck ON while you push the up arrow
button. Go to the ANALYZER menu to POT5 A2.1.3 on
the display. Pivot the forks and look at the indication on
Fig. 322 (27308)
the display.
Event Code 769 • If: The voltage = 0.5–1.5 V.
ACCESS 7 module pivot potentiometer (POT5) the – Then the pivot must be fully clockwise.
voltage change is to slow. • If: The voltage = 3.3–4.5 V.
The traction is decreased (in limp mode) and the pivot – Then the pivot must be fully counter clockwise.
does not operate. • If: One or two of the voltages is out range.
Note: The event code is recorded if the voltage at – Then calibrate POT5 pivot function.
CA704-7 change is too slow.
• If: The event code continues after calibration.
Step 1: Examine the pivot POT5 cable.
– Then replace the POT5.
• If: The cable is off of the pulley.
– Then install the cable and look for a cause.
• If: The cable = good. ACCESS 7
– Then turn the truck ON and try a pivot. CA706 CA704 (GRY)
• If: The forks do not pivot. POT5 C 107 7 PIVOT POS POT INPUT
– Then examine for contamination and operation of B 722 8 PIVOT POS POT +5V
A 570 9 PIVOT POS POT BATT NEG
PVP1, PVP2, PVLH, SVAL, RV1.
Note: PVLH problem: The traverse, auxiliary raise, and
fork extend will not operate. Fig. 323 (27307)
RV1 problem: The primary raise will not operate. Event Code 771
• If: The forks pivot and the event code continues.
ACCESS 7 module auxiliary height encoder (ECR3)
– Then examine the POT5 wires between
count change with no auxiliary movement.
CA706-A, -B, -C and CA704-7, CA704-8, and
CA704-9. The traction is decreased (in limp mode) and the auxil-
iary lower does not operate.
• If: The wires are good and the event code contin-
ues. Step 1: Examine the ECR3 cable.
– Then replace the POT5 and calibrate the pivot • If: The cable = damaged.
function. – Then repair or replace the cable.
• If: The event code continues. Step 2: Examine the auxiliary mast.
– Then replace ACCESS 7. • If: The auxiliary mast moves down (drifts).
– Then examine the SVAL, CV3 valves.
Event Code 770 • If: The auxiliary mast moves (drifts) up during the
ACCESS 7 module pivot potentiometer (POT5) traverse function.
voltage is out of the calibration limit. – Then examine the PVAR valve.
The traction is decreased (in limp mode). • If: There is no movement and the event code con-
tinues.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

– Then replace ECR3. Step 1: Examine the wire from ECR3 to CA710-2 and
• If: The event code continues. the wire from CA710-2 to CA708-6. The wire from
CA708-6 to CA703-4 and the wire from ECR3 to
– Then replace ACCESS 7.
CA710-3. The wire from CA710-3 to CA708-7 and the
wire from CA708-9 to CA703-5. The wire from ECR3 to
Event Code 772 CA710-4 and the wire from CA710-4 to CA708-8. The
ACCESS 7 module auxiliary height encoder (ECR3) wire from CA708-8 to CA703-9.
count goes in the incorrect direction. • If: The wires = good.
The traction is decreased (in limp mode) and the auxil- – Then look for more event codes.
iary lower does not operate. • If: The Event Code 774 or 775 or the two codes
Note: The event code is recorded if the input signal at have been recorded.
CA703-4 and CA703-5 shows that the mast raises or – Then repair these event codes before you con-
lowers opposite of the command. tinue with Event Code 773.
Step 1: Examine the wire from ECR3 to CA710-2 and Step 2: Turn the truck OFF and disconnect the GRN
the wire from CA710-2 to CA708-6. The wire from and WHT wires from ECR3 at CA710. Turn the truck
CA708-6 to CA703-4 and the wire from ECR3 to ON and measure the voltage from the GRN and WHT
CA710-3. The wire from CA710-3 to CA708-7 and the wires to - BV. The voltage must = 0 V or 5 V which is an
wire from CA708-7 to CA710-3. indication of the position of the encoder wire cable.
• If: Examine to see if the wires are installed on the • If: The voltage ≠ 0 V or 5 V. (encoder GRN and
correct pin. WHT wires must be disconnected from the har-
– Then install the wires on the correct pins. ness).
Note: The auxiliary mast must be lowered fully then – Then replace ECR3.
raised to set the ECR3 count to zero. • If: The voltage = 0 V or 5 V.
• If: The wires are good and the event code contin- – Then connect the GRN wire to the BLU wire and
ues. the WHT wire to the BRN wire. Measure the volt-
– Then replace ECR3. age from the GRN and the WHT wires to - BV.
• If: The event code continues. • If: The voltage > 5.5 V.
– Then replace ACCESS 7. – Then replace ECR3.
• If: The problem continues.
– Then replace ACCESS 7.
ACCESS 7
• If: The voltage = 0 V or 5 V or the wires between
CA708 CA703 (BLK) ECR3 and CA703 are good.
6 048 4 AUX HGT ENCODER CH B – Then replace ACCESS 7.
7 049 5 AUX HGT ENCODER CH A
5 715 6 AUX HGT ENCODER +5V
8 565 9 AUX HGT ENCODER BATT NEG Event Code 774
ACCESS 7 module auxiliary height encoder (ECR3)
CA710 power supply wire is open.
ORG 1 RED +5
BLU 2 GRN CH B The traction is decreased (in limp mode) and the auxil-
BRN ECR3 iary lower does not operate.
3 WHT CH A
YEL 4 BLK NEG Step 1: Examine the wire from ECR3 to CA710-1 and
the wire from CA710-1 to CA708-5. The wire from
Fig. 324 (27309) CA708-5 to CA703-6 and the wire from ECR3 to
Event Code 773 CA710-4. The wire from CA710-4 to CA708-8 and the
wire from CA708-8 to CA703-9.
ACCESS 7 module auxiliary height encoder (ECR3) • If: The wires = bad.
CH A or CH B is open.
– Then repair or replace the wires.
The traction is decreased (in limp mode) and the auxil-
• If: The wires are good and the event code contin-
iary lower does not operate.
ues.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700
– Then replace ECR3.
• If: The event code continues.
– Then replace ACCESS 7.
ACCESS 7
CA708 CA703 (BLK)
6 048 4 AUX HGT ENCODER CH B
7 049 5 AUX HGT ENCODER CH A
5 715 6 AUX HGT ENCODER +5V
8 565 9 AUX HGT ENCODER BATT NEG
CA710
ORG 1 RED +5
BLU 2 GRN CH B
BRN ECR3
3 WHT CH A
YEL 4 BLK NEG
Fig. 325 (27309)
Event Code 775
ACCESS 7 module auxiliary height encoder (ECR3)
power supply is out of range.
The traction is decreased (in limp mode) and the auxil-
iary lower does not operate.
Note: The event code is recorded when the power sup-
ply drops below 4.75–5.5 V.
Step 1: Measure the voltage between CA703-6 and
-BV. Turn the truck ON and look at the indication.
• If: The voltage ≠ 4.75–5.5 V.
– Then turn the truck OFF and disconnect the wire
from CA703-6. Turn the truck ON and measure
the voltage between CA703-6 and - BV.
• If: The voltage = 4.75–5.5 V.
– Then a short circuit problem in the wires or
ECR3. Examine the wire from CA703-6 to
CA708-5 and the wire from CA708-5 to CA710-1.
The wire from CA710-1 to ECR3 and the wire
from CA703-4 to CA708-6. The wire from
CA708-6 to CA710-2 and the wire from CA710-2
to ECR3. The wire from CA703-5 to CA708-7 and
the wire from CA708-7 to CA710-3. The wire from
CA710-3 to ECR3.
• If: The wires = good.
– Then replace ECR3.
• If: The voltage ≠ 4.75–5.5 V.
– Then replace ACCESS 7.
M4.8-1970-124 TSP 7000 SERIES
460
ACCESS 7
CA708 CA703 (BLK)
6 048 4 AUX HGT ENCODER CH B
7 049 5 AUX HGT ENCODER CH A
5 715 6 AUX HGT ENCODER +5V
8 565 9 AUX HGT ENCODER BATT NEG
CA710
ORG RED +5
1
BLU 2 GRN CH B
BRN ECR3
3 WHT CH A
YEL 4 BLK NEG
Fig. 326 (27309)
Event Code 776
ACCESS 7 module traverse encoder (ECR4) does
not count.
The traction is decreased (in limp mode) and the trav-
erse is does not operate.
Step 1: Look for other event codes.
• If: More event codes have been recorded.
– Then repair them before you continue with Event
Code 776.
• If: No other event codes are recorded.
– Then continue to step 2.
Step 2: Turn the truck ON and try to traverse.
• If: The forks do not traverse.
– Then examine the operation of PVT1, PVLH,
SVAL, and RV1 and look for contamination.
• If: The forks do traverse.
– Then examine the wire from ECR4 to CA705-1
and the wire from CA705-1 to CA704-4. The wire
from ECR4 to CA705-2 and the wire from
CA705-2 to CA704-10. The wire from ECR4 to
CA705-3 and the wire from CA705-3 to
CA704-11. The wire from ECR4 to CA705-4 and
the wire from CA705-4 to CA704-12.
• If: The wires = good.
– Then replace ECR4.
• If: Event code continues.
– Then replace ACCESS 7.
Crown 2012 PF25715-98
 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

ACCESS 7 ACCESS 7
CA704 (GRY) PVAR CA702 (GRAY)
716 4 TRAV POS ENCODER +5V 5958 1 AUX RAISE PROPOR VALVE DR
050 10 TRAV POS ENCODER CH A 5959 2 AUX LOWER PROPOR VALVE DR
051 11 TRAV POS ENCODER CH B PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR
571 12 TRAV POS ENCODER BATT NEG 5961 4 TRAVERSE PROPOR VALVE 1 DR
5962 5 AUX MAST LWR VALVE DRIVER
CA705 5989 6 LOAD HANDLER PROPOR VALVE
4 BLK NEG 5963 7 PIVOT VALVE 2 DRIVER (PVP)
3 WHT CH A 2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
ECR4 5966
2 BLU CH B 9 EXT FKS PROPOR VALVE 1 DR
1 RED +5 5965 10 EXT FKS PROPOR VALVE 2 DR
2976 11 +BV & SUPP TO PVAR VALVE
2977 12 +BV & SUPP TO VALVES
Fig. 327 (27310)
CA703 (BLK)
Event Code 777 7 +BV INPUT
ACCESS 7 module traverse encoder (ECR4) count Platform
problem. CA701 CA105 Distribution
2974 2 WHT 2 Panel
The traction is decreased (in limp mode) and the trav-
erse does not operate. 5965
Step 1: The auxiliary raise or lower and pivot. PVF2
2982
5966 2981
• If: The traverse left occurs and Event Code 777 is PVF1
recorded. 5964
– Then examine the wire from CA702-3 to PVT2 for PVP1
2980
a short circuit to the truck frame. 5963 2983
PVP2
• If: The wires = good. 29106
– Then examine the PVT, CBV1, CBV2, and look 5989
PVLH
for contamination. 2979
5960
• If: The traverse right occurs and Event Code 777 is PVT2
recorded. 5959
PVAL 2978
– Then examine the wire from CA702-4 to PVT1 for 2984
a short circuit to the truck frame.
• If: The wires = good. CA708 SVAL
– Then examine the PVT, CBV1, CBV2, and look 3 RED
5962 4 GRN
for contamination.
Fig. 328 (27305)

Event Code 778

ACCESS 7 module traverse encoder (ECR4) reset
switch (TVRS) did not change condition.
Step 1: Calibrate the ECR4.
• If: The event code does not continue.
– Then the truck can be operated.
• If: The event code continues.
– Then examine the wire from TVRS to CA704-5
and the wire from TVRS to CA704-6.
• If: The wires are good and the event code contin-
ues.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700

– Then replace TVRS. – Then correct the wires and calibrate the traverse
Step 2: Examine the wire from ECR4 to CA705-1 and encoder.
the wire from CA705-1 to CA704-4. The wire from • If: The wires = good.
ECR4 to CA705-2 and the wire from CA705-2 to – Then examine the wire from PVT2 to CA702-3
CA704-10. The wire from ECR4 to CA705-3 and the and the wire from PVT1 to CA702-4.
wire from CA705-3 to CA704-11. The wire from ECR4
• If: The wires are not on the correct pin.
to CA705-4 and the wire from CA705-4 to CA704-12.
– Then correct the wires and calibrate the traverse
• If: The event code continues.
encoder.
– Then replace ACCESS 7.
• If: The wires = good.
– Then continue to Step 2.
Step 2: Measure the voltage between the PVT1 termi-
ACCESS 7 nal with the 5961 wire and -BV. Turn the truck ON and
TVRS
look at the indication.
CA704 (GRY)
• If: The voltage = +BV.
716 4 TRAV POS ENCODER +5V
RED 5 TRAV RESET SWITCH INPUT – Then continue to Step 3.
BLK 6 BATT NEG • If: The voltage = 0 V.
050 10 TRAV POS ENCODER CH A
051 11 TRAV POS ENCODER CH B – Then examine the wire from CA702-4 to the
571 12 TRAV POS ENCODER BATT NEG PVT1 valve for a short circuit. Repair or replace
the wire.
CA705
BLK NEG Step 3: Measure the voltage between the PVT2 termi-
4
3 WHT CH A nal with the 5960 wire and -BV. Turn the truck ON and
ECR4 look at the indication.
2 BLU CH B
1 RED +5
• If: The voltage = +BV and the event code continues.

Fig. 329 (27311)

– Then replace the ECR4 and calibrate ECR4.
• If: The voltage = 0 V.
Event Code 779 – Then examine the wire from CA702-3 to PVT2 for
ACCESS 7 module traverse encoder (ECR4) count a short circuit. Repair or replace the wire.
speed is out of range. • If: The event code continues.
The traction is decreased (in limp mode) and the trav- – Then replace ACCESS 7 and calibrate ECR4.
erse does not operate.
Step 1: Examine the wire from PVT2 to CA702-3 and
the wire from PVT1 to CA702-4. ACCESS 7
• If: The wires = good. CA704 (GRY)
– Then replace ECR4. 716 4 TRAV POS ENCODER +5V
050 10 TRAV POS ENCODER CH A
• If: The event code continues. 051 11 TRAV POS ENCODER CH B
– Then replace ACCESS 7. 571 12 TRAV POS ENCODER BATT NEG
CA705
Event Code 780 4 BLK NEG
3 WHT CH A ECR4
ACCESS 7 module traverse encoder (ECR4) count 2 BLU CH B
direction is incorrect. 1 RED +5
The traction is decreased (in limp mode) and the trav-
erse does not operate. Fig. 330 (27310)
Step 1: Examine the wire from ECR4 to CA705-2and
the wire from CA705-2 to CA704-10. The wire from
ECR4 to CA705-3 and the wire from CA705-3 to
CA704-11.
• If: The wires are not on the correct pin.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

• If: The cable = damaged.

– Then repair or replace the cable.
ACCESS 7 • If: The cable = good.
PVAR CA702 (GRAY) – Then continue to Step 2.
5958 1 AUX RAISE PROPOR VALVE DR
5959 Step 2: Measure the voltage between the PVAL termi-
2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR nal with wires 2979 and 2978 to -BV. Turn the truck ON
5961 4 TRAVERSE PROPOR VALVE 1 DR and look at the indication.
5962 5 AUX MAST LWR VALVE DRIVER • If: The voltage = +BV.
5989 6 LOAD HANDLER PROPOR VALVE
5963 7 PIVOT VALVE 2 DRIVER (PVP) – Then examine the PVAL for contamination.
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP)
5966 • If: The PVAL has contamination.
9 EXT FKS PROPOR VALVE 1 DR
5965 10 EXT FKS PROPOR VALVE 2 DR – Then clean the PVAL.
2976 11 +BV & SUPP TO PVAR VALVE
2977 12 +BV & SUPP TO VALVES • If: The PVAL does not have contamination.
CA703 (BLK) – Then calibrate the PVAL.
7 +BV INPUT • If: The event code continues.
– Then continue to Step 3.
Platform
CA701 CA105 Distribution • If: The voltage = 0 V.
2974 2 WHT 2 Panel – Then examine the wires 2979, 2978 for a short
circuit. Repair or replace the wire
5965
PVF2 Step 3: Look at the auxiliary mast height.
2982
5966 2981 • If: The auxiliary mast is not at maximum height.
PVF1
5964 – Then raise the mast to clear problem.
PVP1
2980 • If: The auxiliary mast is at maximum height.
5963 2983 – Then the mast must be lowered by the override
PVP2
29106 function in the Utilities menu.
5989
PVLH 2979
5960
PVT2
5959
PVAL 2978
2984

CA708 SVAL
3 RED
5962 4 GRN

Fig. 331 (27305)

Event Code 781

ACCESS 7 module auxiliary lower velocity fuse
trip.
The traction is decreased (in limp mode) and the auxil-
iary lower does not operate.
Step 1: Examine the hydraulic lines and fittings.
• If: The lines and fittings = damaged.
– Then repair or replace the lines or fittings.
• If: The lines and fittings = good.
– Then examine the ECR3 cable.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700

CA704-11. The wire from ECR4 to CA705-4 and

the wire from CA705-4 to CA704-12.
ACCESS 7 • If: The event code continues.
PVAR CA702 (GRAY) – Then replace and calibrate ECR4.
5958 1 AUX RAISE PROPOR VALVE DR • If: The event code continues.
5959 2 AUX LOWER PROPOR VALVE DR
PVT1 5960 3 TRAVERSE PROPOR VALVE 2 DR – Then replace ACCESS 7 and calibrate ECR4.
5961 4 TRAVERSE PROPOR VALVE 1 DR
5962 5 AUX MAST LWR VALVE DRIVER
5989 6 LOAD HANDLER PROPOR VALVE
5963 7 PIVOT VALVE 2 DRIVER (PVP) ACCESS 7
2984 5964 8 PIVOT VALVE 1 DRIVER (PVP) CA704 (GRY)
5966 9 EXT FKS PROPOR VALVE 1 DR 716
5965 4 TRAV POS ENCODER +5V
10 EXT FKS PROPOR VALVE 2 DR 050 10 TRAV POS ENCODER CH A
2976 11 +BV & SUPP TO PVAR VALVE
2977 051 11 TRAV POS ENCODER CH B
12 +BV & SUPP TO VALVES 571 12 TRAV POS ENCODER BATT NEG
CA703 (BLK)
7 +BV INPUT CA705
4 BLK NEG
Platform 3 WHT CH A ECR4
CA701 CA105 Distribution 2 BLU CH B
2974 2 WHT 2 1 RED +5
Panel
5965 Fig. 333 (27310)
PVF2
2982
5966 2981
PVF1
5964 ACCESS 7
PVP1
2980 CA708 CA703 (BLK)
5963 2983 6 048 4 AUX HGT ENCODER CH B
PVP2 7 049 5 AUX HGT ENCODER CH A
29106
5 715 6 AUX HGT ENCODER +5V
5989 8 565 9 AUX HGT ENCODER BATT NEG
PVLH 2979
5960
PVT2 CA710
5959 ORG 1 RED +5
PVAL 2978 BLU 2 GRN CH B ECR3
2984 BRN 3 WHT CH A
YEL 4 BLK NEG
CA708 SVAL
3 RED Fig. 334 (27309)
5962 4 GRN
Event Code 783
Fig. 332 (27305)
ACCESS 7 module auxiliary height encoder (ECR3)
Event Code 782 does not count.
ACCESS 7 module traverse encoder (ECR4) cali- The traction is decreased (in limp mode) and the auxil-
bration is out of range. iary lower does not operate.
The traction is decreased (in limp mode). Note: The event code will record if the load is to much
and will not let an auxiliary raise movement.
Step 1: Calibrate ECR4.
Step 1: Turn the truck OFF then ON.
• If: The event code continues.
• If: The Event Code 751 is recorded.
– Then examine the wire from ECR4 to CA705-1
and the wire from CA705-1 to CA704-4. The wire – Then examine the PVLH circuit, refer to Event
from ECR4 to CA705-2 and the wire from Code 751 for repair procedure.
CA705-2 to CA704-10. The wire from ECR4 to • If: The Event Code 751 is not recorded.
CA705-3 and the wire from CA705-3 to – Then try to raise and lower the auxiliary forks.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 700

• If: The forks do not move.

– Then examine the PVAR, PVLH, SVAL, RV1, LS
valves operation. HGTRS2 CA707
• If: PVAR, PVLH, SVAL, RV1, LS operation is good. 1 RED A
3 ACCESS 7
– Then examine the PVAR, PVLH, SVAL, RV1, LS 5967
TB709 CA703 (BLK)
valves for contamination.
CA708 2 AUX HGT RESET SW INPUT
• If: The forks move. 6 048 4 AUX HGT ENCODER CH B
– Then examine the wire from ECR3 to CA710-1 7 049 5 AUX HGT ENCODER CH A
and the wire from CA710-1 to CA708-5. The wire 5 715 6 AUX HGT ENCODER +5V
8 565 9 AUX HGT ENCODER BATT NEG
from CA708-5 to CA703-6 and the wire from
ECR3 to CA710-2. The wire from CA710-2 to
CA708-6 and the wire from CA708-6 to CA703-4. CA710
The wire from ECR3 to CA710-3 and the wire ORG 1 RED +5
BLU 2 GRN CH B
from CA710-3 to CA708-7. The wire from to 3
ECR3
BRN WHT CH A
CA703-5 and the wire from ECR3 to CA710-4. YEL 4 BLK NEG
The wire from CA710-4 to CA708-8 and the wire
from CA708-8 to CA703-9. Fig. 335 (27312)
• If: The event code continues.
– Then replace and calibrate ECR3.
Event Code 785
• If: The event code continues. ACCESS 7 module auxiliary fork height encoder
– Then replace ACCESS 7. (ECR3) counts are out of range.
The traction is decreased (in limp mode) and the auxil-
Event Code 784 iary lower does not operate.
Step 1: Go to the FEATURES menu F30 and look at
ACCESS 7 module auxiliary height reset did not
the auxiliary mast height
toggle.
• If: The correct auxiliary height is set and event code
The traction is decreased (in limp mode).
continues.
Step 1: Examine the wire from ECR3 to CA710-1 and
– Then lower the auxiliary forks to a minimum
the wire from CA710-1 to CA708-5. The wire from
height, then raise the fork height to 305 mm
CA708-5 to CA703-6 and the wire from ECR3 to
(12 in).
CA710-2. The wire from CA710-2 to CA708-6 and the
wire from CA708-6 to CA703-4. The wire from ECR3 to • If: The event code does not continue.
CA710-3 and the wire CA710-3 to CA708-7. The wire – Then the truck can be put into operation.
from CA708-7 to CA703-5 and the wire from ECR3 to • If: The event code continues.
CA710-4. The wire from CA710-4 to CA708-8 and the
– Then examine the wire from ECR3 to CA710-1
wire from CA708-8 to CA703-9.
and the wire from CA710-1 to CA708-5. The wire
• If: The ECR3 wires = good. from CA708-5 to CA703-6 and the wire from
– Then examine the HGTRS2 wire from TB709-1 ECR3 to CA710-2. The wire from CA710-2 to
to CA707-A and the wire from CA707-A to CA708-6 and the wire from CA708-6 to CA703-4.
CA703-2. The wire from ECR3 to CA710-3 and the wire
• If: The wires are good and the event code contin- from CA710-3 to CA708-7. The wire from CA708-
ues. 7 to CA703-5 and the wire from ECR3 to
CA710-4. The wire from CA710-4 to CA708-8
– Then replace the HGTRS2.
and the wire from CA708-8 to CA703-9.
• If: The wires are good and the event code contin-
ues.
– Then replace and calibrate ECR3.
• If: The event code continues.
– Then replace ACCESS 7.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 700

ACCESS 7
CA708 CA703 (BLK)
6 048 4 AUX HGT ENCODER CH B
7 049 5 AUX HGT ENCODER CH A
5 715 6 AUX HGT ENCODER +5V
8 565 9 AUX HGT ENCODER BATT NEG

CA710
ORG 1 RED +5
BLU 2 GRN CH B
BRN ECR3
3 WHT CH A
YEL 4 BLK NEG

Fig. 336 (27309)

Event Codes 790 - 799

ACCESS 7 module internal problem.
The procedures below apply to Event Codes 790 - 799.
The traction is decreased (in limp mode), the auxiliary
raise or lower, traverse, pivot, extend, and retract do
not operate.
Step 1: Install software into ACCESS 7.
• If: The event code continues.
– Then replace ACCESS 7.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

Event Code Group 800 • If: The resistance = ∞ Ω.

– Then there are two 60 Ω resistors. One in the
Event Code 800 wire harness near CA703 and one is internal to
ACCESS 5. Measure the resistance between
ACCESS 5 and ACCESS 8 module CAN time out. ACCESS 7 CA703-1, CA703-12
Step 1: Turn the truck ON and look at the status of • If: The resistance = 0 Ω.
ACCESS 5 LED’s. – Then the resistor in the wire harness is bad. Re-
• If: The ACCESS 5 LED’s = ON. place the resistor or the wire harness.
– Then continue to Step 2.
• If: The ACCESS 5 LED’s = OFF.
– Then measure for +BV between CA403-1 and ACCESS 7
ACM
CA403-10 on ACCESS 5.
RES3 CA703 (BLK)
• If: The voltage = +BV. 059 1 CAN_H
– Then replace ACCESS 5. 058 12 CAN_L
• If: The voltage = 0 V.
– Then examine FU8 and the wire from CA403-1 to Fig. 337 (27251)
CA406 -B and the wire from CA403-10 to
CA206-9.
Power Unit
• If: The wire connections and FU8 are good. Distribution
– Then examine the wires between ACCESS 8 Panel
CA504-3 and CA504-4 and the platform distribu- FU8
4 ACCESS 5
tion panel, CA106-3 and CA106-10. Repair or re- CA201
CA204
place wires as is necessary CA402
Step 2: The event code continues then turn the truck 8 003 4 CAN_H
TP17 2
OFF. Measure the resistance between wire CA402-4 004 5 CAN_L
CAN_H and the wire CA402-5 CAN_L. The resistance CA403
CA206 9
must = 60 Ω. 505 1 L-COMM INPUT
• If: The resistance = 0 Ω. NEG BUS 2903 10 +BV INPUT
– Then a short circuit problem between the CAN_H A1 B+ A2 B-
and CAN_L. Disconnect CA402 from ACCESS 5 CA406
and measure the resistance at module pins
CA402-3 and CA402-4.
• If: The resistance = 0 Ω.
– Then replace ACCESS 8. Fig. 338 (27313)

Event Code 801

ACCESS 5 and ACCESS 8 module CAN time out.
Step 1: Turn the truck ON and look at the status of
ACCESS 5 LED’s.
• If: The ACCESS 5 LED’s = ON.
– Then continue to Step 2.
• If: The ACCESS 5 LED’s = OFF.
– Then measure for +BV between CA403-1 and
CA403-10 on ACCESS 5.
• If: The voltage = +BV.
– Then replace ACCESS 5.
• If: The voltage = 0 V.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

– Then examine the wires connected to CA403-1

and CA403-10. The repair or replace as is neces-
sary.
• If: The wire connections = good.
– Then examine the wires between ACCESS 8,
CA504-3 and CA504-4 and the platform distribu-
tion panel, CA106-3 and CA106-10. Then repair
or replace as is necessary.
Step 2: The event code continues, turn the truck OFF.
Measure the resistance between CA402-4 CAN_H and
CA402-5 CAN_L. The resistance must = 60 Ω.
• If: The resistance = 0 Ω.
– Then replace ACCESS 5.
• If: The resistance = ∞ Ω.
– Then disconnect CA504 from ACCESS 8 and
measure the resistance between module pins
VA504-3 and CA504-4.
• If: The resistance = 0 Ω.
– Then replace ACCESS 8.
• If: The resistance = ∞ Ω.
– Then there are two 60 Ω resistors. One is in the
wire harness near CA703 and one is internal to
ACCESS 5. Measure the resistance between
ACCESS 7 CA703-1, CA703-12.
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness.
ACCESS 6
GCM
CA601
2905 1 +BVAK
507 2 BATT COMM
011 4 CAN_H
012 5 CAN_L
Power Unit Distribution Panel
CA201
012 5
011 11
CA206 11
2905
CA406
NEG BUS
507
Fig. 339 (27286)
ACCESS 7
ACM
RES3 CA703 (BLK)
059 1 CAN_H
058 12 CAN_L
Fig. 340 (27251)
Event Code 802
ACCESS 1 and ACCESS 8 module CAN time out.
Step 1: Turn the truck ON and look at the status of
ACCESS 1 LED’s.
• If: The ACCESS 1 LED’s = ON.
– Then continue to Step 2.
• If: The ACCESS 1 LED’s = OFF.
– Then measure for +BV between CA304-1 and
CA304-2 on ACCESS 1.
• If: The voltage = +BV.
– Then examine the connection.
• If: The voltage = 0 V.
– Then examine FU7, FU18 and the wire from
CA304-1 to CA103-12 and the wire from
CA304-2 to CA104-6. Repair or replace the wires
or fuses.
• If: The wires, FU7, and FU18 = good.
– Then examine the wire between ACCESS 8
CA504-3 and CA504-4 and the platform distribu-
tion panel CA106-3 and CA106-10. Repair or re-
place the wires as is necessary.
Step 2: The event code continues then turn the truck
OFF. Measure the resistance between wire CA304-4
CAN_H and the wire CA304-5 CAN_L. The resistance
must = 60 Ω.
• If: The resistance = 0 Ω.
– Then a short circuit problem between CAN_H
and CAN_L. Turn the truck OFF and disconnect
CA304 from ACCESS 1. Measure the resistance
between module pins CA304-4 and CA304-5.
• If: The resistance = 0 Ω.
– Then replace ACCESS 1.
• If: The resistance is > 60 Ω.
– Then disconnect CA504 from ACCESS 8. Meas-
ure the resistance between module pins
CA504-3 and CA504-4.
• If: The resistance = 0 Ω.
– Then replace ACCESS 8.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The resistance = 120 Ω or more.

– Then there are two 60 Ω resistors that connect
CAN_H and CAN_L together. One is in the wire ACCESS 7
harness near CA703 and one is internal to CA703 (BLK)
ACCESS 5. Measure the resistance between CA701 059 1 CAN H
connector CA703-1 and CA703-12 on BRN 7 046 058 12 CAN L
ACCESS 7. YEL 8 047
• If: The resistance = 0 Ω.
RES3
– Then disconnect CA402 from ACCESS 5. Meas-
ure the resistance between CA402-4 and CA402-
5. The resistance must = 120 Ω. CA106 CA103
• If: The resistance = 0 Ω 2 12
6 TP11
– Then replace ACCESS 5. 7 FU18 CA104
8 6
• If: The resistance = 120 Ω.
– Then the resistor in the wire harness is bad. Re- 1 2 3 5 6 CA107
place the resistor or the wire harness.

WHT

ORG
RED
BLK

BLU
CA406
1 2 3 5 6 CA413
527

2920
2923
528
529
5 6 CA205
NEG
BUS
TP16
CA204
4
FU7
Power Unit
Distribution Panel

ACCESS 1
CA304 ALM1
2946 1 +BV (KYS)
512 2 BATT NEG
027 4 CAN_H
022 5 CAN_L

Fig. 341 (27314)

Event Code 803

ACCESS 4 and ACCESS 8 module CAN time out.
Step 1: Turn the truck ON and look at the status of
ACCESS 4 LED’s.
• If: The ACCESS 4 LED’s = ON.
– Then continue to Step 2.
• If: The ACCESS 4 LED’s = OFF.
– Then measure for +BV between CA314-1 and
CA314-2.
• If: The voltage = +BV.
– Then replace ACCESS 4.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The voltage = 0 V. • If: The resistance = 0 Ω.

– Then examine the FU7, FU19, and the wire from – Then disconnect CA402 from ACCESS 5. Meas-
CA314-1 to CA103-13 and the wire from ure the resistance between CA402-4, CA402-5.
CA314-2 to CA101-1. The repair or replace the The resistance must = 120 Ω.
wires or fuses as is necessary. • If: The resistance = 0 Ω.
• If: The wires, FU7, FU18 = good. – Then replace ACCESS 5.
– Then examine the wires between ACCESS 8 • If: The resistance = 120 Ω.
CA504-3, CA504-4, and the platform distribution
– Then the resistor in the wire harness is bad. Re-
panel CA106-3, CA106-10. The repair or replace
place the resistor or the wire harness.
the wires as is necessary.
Step 2: The event code continues then turn the truck
OFF. Measure the resistance between the wire on
CA314-3 CAN_H and the wire on CA314-4 CAN_L.
The resistance must = 60 Ω.
CA107 FU19 CA101 ACCESS4
• If: The resistance = 0 Ω. 3 1
– Then a short circuit problem between CAN_H CA103 CA314 (BRN)
and CAN_L. Disconnect CA314 from ACCESS 4 TP9 13 2950 1 +BV IN
and measure the resistance between module 518 2 BATT COMM IN
pins CA314-3, CA314-4.
• If: The resistance = 0 Ω. Fig. 342 (27315)
– Then replace ACCESS 4.
• If: The resistance > 60 Ω.
ACCESS 7
– Then disconnect CA504 from ACCESS 8 and ACM
measure the resistance between module pins CA703 (BLK)
RES3
CA504-3, CA504-4. 059 1 CAN_H
• If: The resistance = 0 Ω. 058 12 CAN_L
– Then replace ACCESS 8.
Fig. 343 (27251)
• If: The resistance = 120 Ω or more.
– Then there are two 60 Ω resistors that connect Event Code 804
CAN_H and CAN_L together. One is in the wire
harness near CA703 and one is internal to ACCESS 7 and ACCESS 8 module CAN time out.
ACCESS 5. Measure the resistance between Step 1: Turn the truck ON and look at the status of
connector CA703-1, CA703-12 on ACCESS 7. ACCESS 7 LED’s.
• If: The ACCESS 7 LED’s = ON.
– Then continue to Step 2.
• If: The ACCESS 7 LED’s = OFF.
– Then measure for +BV between CA703-7 and
CA703-8 on ACCESS 7.
• If: The voltage = +BV.
– Then replace ACCESS 7.
• If: The voltage = 0 V.
– Then examine the FU7, FU17 or the wire from
CA701-2 to CA703-7 and the wire from CA701-1
to CA703-8. Then repair or replace the wires or
fuses as is necessary.
Step 2: The event code continues then turn the truck
OFF. Measure the resistance between the wire on

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

CA703-1 CAN_H and the wire on CA703-12 CAN_L. – Then measure for +BV between CA304-1 and
The resistance = 60 Ω. CA304-2.
• If: The resistance = 0 Ω. • If: The voltage = +BV.
– Then a short circuit problem between CAN_H – Then replace ACCESS 1.
and CAN_L. Disconnect CA703 from ACCESS 7. • If: The voltage = 0 V.
Measure the resistance between module pins,
– Then examine the wire from CA304-1 to
CA703-1, CA703-4, and CA703-12.
CA103-12 and the wire from CA304-2 to
• If: The resistance = 0 Ω. CA104-6. Fuses FU7 and FU18. The repair or re-
– Then replace ACCESS 7. place the wires or fuses as is necessary.
• If: The resistance is > 60 Ω. • If: The wires, connections, and fuses = good.
– Then there are two 60 Ω resistors that connect – Then examine the wires between ACCESS 8
CAN_H and CAN_L together. One is in the wire CA504-3 and CA504-4 and the platform distribu-
harness near CA703 and one is internal to tion panel CA106-3 and CA106-10. Then repair
ACCESS 5. Measure the resistance between or replace the wires as is necessary.
connector CA703-1 and CA703-12 on Step 2: The event code continues then turn the truck
ACCESS 7. OFF. Measure the resistance between CAN_H,
• If: The resistance = 0 Ω. CA304-4 and CAN_L, CA304-5. The resistance must =
– Then disconnect CA402 from ACCESS 5. Meas- 60 Ω.
ure the resistance between CA402-4 and CA402- • If: The resistance = 0 Ω.
5. The resistance must = 120 Ω. – Then a short circuit problem between CAN_H
• If: The resistance = 0 Ω. and CAN_L. Disconnect CA304 from ACCESS 1.
– Then replace ACCESS 5. Measure the resistance between module pins
CA304-4 and CA304-5.
• If: The resistance = 120 Ω.
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness. – Then replace ACCESS 1.
• If: The resistance = ∞ Ω.
– Then there are two 60 Ω resistors that connect
Platform CAN_H and CAN_L together. One is in the wire
Distribution ACCESS7 harness near CA703 and one is internal to
Panel ACM ACCESS 5. Measure the resistance between
FU17 CA105 CA703 (BLK) connector CA703-1 and CA703-12 on
1 BLK
TP10 2 059 1 CAN_H ACCESS 7.
1 2974 7 +BV INPUT
CA106 WHT 2
• If: The resistance = 0 Ω.
569 8 BATT NEG IN
1
6 BRN 7 046 058 12 CAN_L – Then disconnect CA402 from ACCESS 5. Meas-
CA107
7 YEL 8 047 ure the resistance between CA402-4 and CA402-
CA701 5. The resistance must = 120 Ω.
• If: The resistance = 0 Ω.
RES3
– Then replace ACCESS 5.
Fig. 344 (27255)

Event Code 805

ACCESS 1 and ACCESS 8 module CAN time out.
Step 1: Turn the truck ON and look at the status of
ACCESS 1 LED’s.
• If: The ACCESS 1 LED’s = ON.
– Then continue to step 2
• If: The ACCESS 1 LED’s = OFF.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The resistance = 120 Ω. – Then examine FU7, FU19, and the wire from
– Then the resistor in the wire harness is bad. Re- CA314-1 to CA103-13. The wire from CA314-2 to
place the resistor or the wire harness. CA101-1. Then repair or replace the wires or
fuses as is necessary.
• If: The wires and fuses = good.
ACCESS 7 – Then examine the wires between ACCESS 8
CA504-3 and CA504-4 and the platform distribu-
CA703 (BLK)
CA701 tion panel CA106-3 and CA106-10. Then repair
059 1 CAN_H
BRN 7 046 058 12 CAN_L or replace the wires as is necessary.
YEL 8 047 Step 2: The event code continues then turn the truck
OFF. Measure the resistance between the wire on
RES3
CA314-3 CAN_H and the wire on CA314-4 CAN_L.
Platform Distribution The resistance must = 60 Ω.
Panel
CA106 • If: The resistance = 0 Ω.
CA103
022 2 12 2946 – Then a short circuit problem between CAN_H
036 3 and CAN_L. Disconnect CA314 from the
BRN 6 CA104
ACCESS 4 module. Measure the resistance be-
YEL 7 6 512
027 8 tween module pins, CA314-3 and CA314-4.
037 10 • If: The resistance = 0 Ω.
– Then replace ACCESS 4.
ACCESS 8
CA504 (BRN) • If: The resistance > 60 Ω.
8 BRN 8 057 3 CAN H – Then disconnect CA504 from ACCESS 8. Meas-
7 YEL 7 056 4 CAN L ure the resistance between module pins
CA504-3 and CA504-4.
• If: The resistance = 0 Ω.
– Then replace ACCESS 8.
ACCESS 1
ALM1 • If: The resistance = 120 Ω or more.
CA304
2946 1 +BV (KYS) – Then there are two 60 Ω resistors that connect
512 2 BATT NEG CAN_H and CAN_L together. One is in the wire
027 4 CAN H harness near CA703 and one is internal to
022 5 CAN L ACCESS 5. Measure the resistance between
connector CA703-1 and CA703-12 on
ACCESS 7.
Fig. 345 (27316)

Event Code 806

ACCESS 4 and ACCESS 8 module CAN time out.
Step 1: Turn the truck ON and look at the status of
ACCESS 4 LED’s.
• If: The ACCESS 4 LED’s = ON.
– Then continue to Step 2.
• If: The ACCESS 4 LED’s = OFF.
– Then measure for +BV between CA314-1 and
CA314-2.
• If: The voltage = +BV.
– Then replace ACCESS 4.
• If: The voltage = 0 V.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The resistance = 0 Ω. • If: The voltage = +BV.

– Then disconnect CA402 from ACCESS 5. Meas- – Then replace ACCESS 5.
ure the resistance between CA402-4 and CA402- • If: The voltage = 0 V.
5. The resistance = 120 Ω.
– Then examine CA403-1 and CA403-10 connec-
• If: The resistance = 0 Ω. tions and wires. Then repair or replace as is nec-
– Then replace ACCESS 5. essary.
• If: The resistance = 120 Ω. • If: The wires and connections = good.
– Then the resistor in the wire harness is bad. Re- – Then examine the wires between ACCESS 8
place the resistor or the wire harness. CA504-3 and CA504-4 and platform distribution
panel CA106-3 and CA106-10. Then repair or re-
place as is necessary.
ACCESS 7 Step 2: The event code continues then turn the truck
CA703 (BLK) OFF. Measure the resistance between the wire on
CA701 CA402-4 CAN_H and the wire on CA402-5 CAN_L.
059 1 CAN_H
BRN 7 046 058 12 CAN_L The resistance must = 60 Ω.
YEL 8 047 • If: The resistance = 0 Ω.
RES3 – Then a short circuit problem between CAN_H
and CAN_L. Disconnect CA402 from ACCESS 5.
Measure the resistance between the module pins
CA106 CA103 CA402-3 and CA402-4.
028 1 12 2946 • If: The resistance = 0 Ω.
036 3
BRN 6 CA104 – Then replace ACCESS 5.
YEL 7 6 512 • If: The resistance > 60 Ω. Connect CA402 to
029 9
037 10 ACCESS 5.
– Then disconnect CA504 from ACCESS 8. Meas-
ACCESS 8 ure the resistance between the module pins,
CA504 (BRN) CA504-3 and CA504-4.
8 BRN 8 057 3 CAN_H • If: The resistance = 0 Ω.
7 YEL 7 056 4 CAN_L
– Then replace ACCESS 8.
• If: The resistance = ∞ Ω.
– Then there are two 60 Ω resistors. One is in the
ACCESS 4
wire harness near CA703 and one is internal to
CA314 (BRN)
ACCESS 5. Measure the resistance between
2950 1 +BV IN
518 2 BATT COMM IN CA703-1 and CA703-12 on ACCESS 7.
029 3 CAN_H • If: The resistance = 0 Ω.
028 4 CAN_L
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness.
Fig. 346 (27317)

Event Code 807

ACCESS 5 and ACCESS 8 module CAN time out.
Step 1: Turn the truck ON and look at the status of
ACCESS 5 LED’s.
• If: The ACCESS 5 LED’s = ON.
– Then continue to step 2.
• If: The ACCESS 5 LED’s = OFF.
– Then measure for +BV between CA403-1 and
CA403-10 on ACCESS 5.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

– Then examine FU7, FU18, wires and the condi-

tion of the battery. The wire CA504-1 to CA318-6
Power Unit and the wire from CA504-2 to CA505-1.
Distribution ACCESS 5 • If: The voltage = 44 V–52 V (TSP 6500) or 68–84 V
SCM
Panel (TSP 7000).
CA201 CA402 – Then replace ACCESS 8.
8 003 4 CAN_H
CA206 2 004 5 CAN_L
9
CA403 ACCESS8
2903 10 +BV INPUT OCM
A1 B+ A2 B- CA318 CA504 (BRN)
6 2995 1 +BV IN
Fig. 347 (27272) 1 520 2 BATT COMM IN
CA505
Event Code 816
ACCESS 8 module internal problem. Fig. 348 (27256)

The travel, steering, primary raise or lower do not oper-
ate.
Step 1: Replace ACCESS 8.
Event Code 821
ACCESS 8 module 5 V power supply is out of toler-
ance.
The traction, primary raise or lower do not operate, hy-
draulic functions are decreased (in limp mode).
Step 1: Measure the voltage between CA504-1 and
CA504-2. Turn the truck ON and look at the voltage
indication.
• If: The voltage ≠ 44–52 V (TSP 6500) or 68–84 V
(TSP 7000).
– Then examine FU7, FU18, wires, and the condi-
tion of the battery. The wire from CA504-1 to
CA318-6 and the wire from CA504-2 to CA505-1.
• If: The voltage = 44–52 V (TSP 6500) or 68–84 V
(TSP 7000).
– Then replace ACCESS 8.
Event Code 822
ACCESS 8 module 15 V power supply is out of tol-
erance.
The traction, primary raise, lower do not operate, hy-
draulic functions are decreased (in limp mode).
Step 1: Measure the voltage between CA504-1 and
CA504-2. Turn the truck ON and look at the voltage
indication.
• If: The voltage ≠ 44–52 V (TSP 6500) or 68–84 V
(TSP 7000).
Event Code 823
ACCESS 8 module steer encoder ECR2 power sup-
ply is out of tolerance.
The traction, primary raise do not operate and hydrau-
lic functions are decreased (in limp mode).
Step 1: Measure the voltage from CA503-5 to
CA503-6. Turn the truck ON and look at the voltage
indication.
• If: The voltage ≠ 4.75–5.5 V.
– Then turn the truck OFF and disconnect CA508
in the left armrest (CA508 connects ECR1, ECR2
to seat tube harness). Measure the voltage from
CA503-5 to CA503-6. Turn the truck ON and look
at the voltage indication.
• If: The voltage = 4.75–5.5 V.
– Then a short circuit problem in the wires to ECR2
or internal to ECR2. Examine the wire from ECR2
to CA508-5 and the wire from CA508-5 to
CA503-7. The wire from ECR2 to CA508-6 and
the wire from CA508-6 to CA503-6. The wire from
ECR2 to CA508-7 and the wire from CA508-7 to
CA503-8. The wire from ECR2 to CA508-8 and
the wire CA508-8 to CA503-5.
• If: The wires are good and the event code contin-
ues.
– Then replace ECR2.
• If: The voltage ≠ 4.75–5.5 V.
– Then turn the truck OFF and the remove wire
from CA503-5. Turn the truck ON and measure
the voltage on CA503-5.
• If: The voltage = 4.75–5.5 V.
– Then a problem is in the seat tube harness be-
tween CA508 and CA503.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The voltage ≠ 4.75–5.5 V.

– Then replace ACCESS 8.
FS

GRN
WHT
RED
ACCESS 8

BLU
BLK
ACCES 8
CA503 (GRN) CA501 (GRAY)
710 5 STEER CMD ECR +5 (2) VIO 7 +5V TO FS FS & RS
521 6 STEER CMD ECR COMM (2) Optical
Switch GRN 8 FS & RS COMM
038 7 STEER CMD CH A (2) 9 REV SW IN
8 STEER CMD CH B (2) WHT
039 Board BLK 10 FWD SW IN
711 9 +5V TO STEER ECR (1)
542 10 BATT COMM TO STEER ECR (1)

WHT
GRN
RED

BLU
BLK
030 11 STEER CMD CH A (1)
031 12 STEER CMD CH B (1)

RS
CA508 ECR1
030 1 WHT CH A Fig. 350 (27319)
542 2 BLK BATT NEG
031 3 BLU CH B Event Code 825
711 4 RED +5V
038 5 WHT ACCESS 8 module steer encoder ECR1 power sup-
521 6 BLK ply is out of tolerance.
039 7 BLU ECR2
710 8 RED Full traction and primary raise do not operate, hydrau-
CH A
BATT NEG lics functions are decreased (in limp mode).
CH B Step 1: Measure the voltage from CA503-9 to
+5V CA503-10. Turn the truck ON and look at the voltage
indication.
Fig. 349 (27318) • If: The voltage ≠ 4.75–5.5 V.
Event Code 824 – Then turn the truck OFF and disconnect CA508
in the left armrest (CA508 connects ECR1, ECR2
ACCESS 8 module optical switch board FS/RS to the seat tube harness). Measure the voltage
power supply is out of tolerance. from CA503-9 and CA503-10. Turn the truck ON
Full traction and primary raise do not operate, hydrau- and look at the voltage indication.
lics functions are decreased (in limp mode). • If: The voltage = 4.75–5.5 V.
Step 1: Measure the voltage from CA501-7 (optical – Then a short circuit problem in the wires to ECR1
switch board 5 V) to CA501-8. Turn the truck ON and or internal to ECR1. Examine the wire from ECR1
look at the voltage indication. to CA508-1 and the wire from CA508-1 to
• If: The voltage = 4.75–5.5 V. CA503-11. The wire from ECR1 to CA508-2 and
the wire from CA508-2 to CA503-10. The wire
– Then examine the wire from CA501-7 to the opti-
from ECR1 to CA508-3 and the wire from
cal board and the wire from CA501-8 to the opti-
CA508-3 to CA503-12. The wire from ECR1 to
cal board.
CA508-4 and the wire from CA508-4 to CA503-9.
• If: The voltage ≠ 4.75–5.5 V.
• If: The wires are good and the event code contin-
– Then turn the truck OFF and disconnect the wire ues.
from CA501-7. Turn the truck ON and measure
– Then replace ECR1.
the voltage between CA501-7 and CA501-8.
• If: The voltage ≠ 4.75–5.5 V.
• If: The voltage = 4.75–5.5 V.
– Then turn the truck OFF and remove the wire
– Then a short circuit problem in the optical board.
from CA503-9. Measure the voltage on CA503-9.
Replace the optical board.
• If: The voltage = 4.75–5.5 V.
• If: The voltage ≠ 4.75–5.5 V.
– Then the problem is in the seat tube harness be-
– Then replace ACCESS 8.
tween CA508 and CA503.

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• If: The voltage ≠ 4.75–5.5 V. • If: The voltage = 3.4–4.3 V.

– Then replace ACCESS 8. – Then the control handle is in the full reverse po-
sition.
• If: The correct POT1 voltage is measured and the
ACCESS 8 event code continues.
CA503 (GRN) – Then replace and calibrate POT1.
710 5 STEER CMD ECR +5 (2) • If: The voltage ≠ 0.7 V.
521 6 STEER CMD ECR COMM (2)
038 7 STEER CMD CH A (2) – Then examine the wire from POT1-3 to CA502-1
039 8 STEER CMD CH B (2) and the wire from POT1-2 to CA502-2. The wire
711 9 +5V TO STEER ECR (1) from POT1-1 to CA502-3.
542 10 BATT COMM TO STEER ECR (1)
030 11 STEER CMD CH A (1) • If: The wires are good and the event code contin-
031 12 STEER CMD CH B (1) ues.
– Then replace and calibrate POT1.
CA508 ECR1
030 1 WHT CH A
Event Code 837
542 2 BLK BATT NEG ACCESS 8 module traction potentiometer POT2 is
031 3 BLU CH B
711 4 RED +5V
out of electrical limits.
038 5 WHT Primary raise, lower and full traction does not operate.
521 6 BLK
039 7 BLU ECR2 Note: The event code is recorded when POT2 voltage
710 8 RED at CA502-11 is above or below the electrical limit.
CH A
BATT NEG Step 1: Turn the truck ON while you push the up arrow
CH B button. Go to POT2 A2.3.3 in the ANALYZER menu
+5V and look at the indication.
• If: The voltage = 5 V or more.
Fig. 351 (27318) – Then examine the wire from POT2-1 to
Event Code 836 CA502-10 WHT and the wire from POT2-2 to
CA502-11. The wire from POT2-3 to CA502-12.
ACCESS 8 module traction potentiometer POT1 is • If: The wires are good and the event code contin-
out of electrical limits. ues.
The traction does not operate. – Then replace and calibrate POT2.
Note: The event code is recorded when POT1 voltage • If: The voltage = 2.1–2.9 V.
at CA502-2 is above or below the electrical limit.
– Then the control handle is in the center position.
Step 1: Turn the truck ON while you push the up arrow
• If: The voltage = 0.7–1.5 V.
button. Go to POT1 A2.3.2 in the ANALYZER menu
and look at the indication. – Then the control handle is in the full primary raise
position.
• If: The voltage = 5 V or more.
• If: The voltage = 3.4–4.3 V.
– Then examine the wire from POT1-3 to CA502-1
and the wire from POT1-2 to CA502-2. The wire – Then the control handle is in the full primary lower
from POT1-1 to CA502-3. position.
• If: The wires are good and the event code contin- • If: The correct POT2 voltage is measured and the
ues. event code continues.
– Then replace and calibrate POT1. – Then replace and calibrate POT2.
• If: The voltage = 2.1–2.9 V. • If: The voltage ≠ 0.7 V.
– Then the control handle is in the center position. – Then examine the wire from POT2-1 to
CA502-10 and the wire from POT2-2 to
• If: The voltage = 0.7–1.5 V.
CA502-11. The wire from POT2-3 to CA502-12.
– Then the control handle is in the full forward po-
• If: The wires are good and the event code contin-
sition.
ues.

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– Then replace and calibrate POT2.

Event Code 838 ACCESS 8

ACCESS 8 module POT3 auxiliary raise, lower po- CA502 (BLK)
tentiometer is out of electrical limits. 3 RED 1 TRACT POT +
POT1 2 WHT 2 TRACT CMD IN
The auxiliary raise or lower do not operate. 1 BLK 3 TRACT POT -
Note: The event code is recorded when POT3 voltage 1 RED 4 TRAV POT +
at CA504-8 is above or below the electrical limit. POT4 2 WHT 5 TRAV CMD IN
3 BLK 6 TRAV POT -
Step 1: Turn the truck ON while you push the up arrow 1 RED 10 MAIN R/L POT +
button. Go to POT3 A2.3.4 in the ANALYZER menu POT2 2 WHT 11 MAIN R/L CMD IN
and look at the indication. 3 BLK 12 MAIN R/L POT -
• If: The voltage = 5 V or more. CA507 CA504 (BRN)
– Then examine the wire from POT3-1 to CA507-5 1 RED 5 713 7 AUX R/L POT +
and the wire from CA507-5 to CA504-7. The wire POT3 2 WHT 6 105 8 AUX R/L CMD IN
from POT3-2 to CA507-6 and the wire from 3 BLK 7 544 9 AUX R/L POT -
CA507-6 to CA504-8. The wire from POT3-3 to
CA507-7 and the wire from CA507-7 to CA504-9. Fig. 352 (27320)
• If: The wires are good and the event code contin- Event Code 839
ues.
– Then replace and calibrate POT3. ACCESS 8 module POT4 traverse potentiometer
out of electrical limits.
• If: The voltage = 2.1–2.9 V.
The traverse, fork extend or retract do not operate.
– Then the control handle is in the center position.
Note: The event code is recorded when POT4 voltage
• If: The voltage = 0.7–1.5 V.
at CA502-5 is above or below the electrical limit.
– Then the control handle is in the full auxiliary
Step 1: Turn the truck ON while you push the up arrow
raise position.
button. Go to POT4 A2.3.5 in the ANALYZER menu
• If: The voltage = 3.4–4.3 V. and look at the indication.
– Then the control handle is in the full auxiliary • If: The voltage = 5 V or more.
lower position.
– Then examine the wire from POT4-1 to CA502-4
• If: The correct POT3 voltage is measured and the and the wire from POT4-2 to CA502-5. The wire
event code continues. from POT4-3 to CA502-6.
– Then replace and calibrate POT3. • If: The voltage ≠ 0.7 V.
• If: The voltage ≠ 0.7 V. – Then examine the wire from POT4 to CA502-4
– Then examine the wire from POT3-1 to CA507-5 and the wire from POT4-2 to CA502-5. The wire
and the wire from CA507-5 to CA504-7. The wire from POT4 to CA502-6.
from POT3-2 to CA507-6 and the wire from • If: The voltage = 2.1–2.9 V.
CA507-6 to CA504-8. The wire from POT3-3 to
– Then the control handle is in the center position.
CA507-7 and the wire from CA507-7 to CA504-9.
• If: The voltage = 0.7–1.5 V.
• If: The wires are good and the event code contin-
ues. – Then the control handle is in the full traverse left
position.
– Then replace and calibrate POT3.
• If: The voltage = 3.4–4.3 V.
– Then the control handle is in the full traverse right
position.
• If: The POT4 wires and voltage is good and the
event code continues.
– Then replace and calibrate POT4.

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vice to diode check. Connect to CA506-1 (+) and

CA501-6 (-).
ACCESS 8 • If: The voltage = 1.1 V.
CA502 (BLK) – Then the HPSR circuit is good. To measure the
3 RED 1 TRACT POT + HPSL circuit. Set test device to diode check.
POT1 2 WHT 2 TRACT CMD IN Connect to CA504-10 (+) and CA506-1 (-).
1 BLK 3 TRACT POT -
1 RED 4 TRAV POT + • If: The voltage = 0 V.
POT4 2 WHT 5 TRAV CMD IN – Then replace HPSR.
3 BLK 6 TRAV POT -
1 RED 10 MAIN R/L POT + • If: The voltage = 1.1 V.
POT2 2 WHT 11 MAIN R/L CMD IN – Then HPSL circuit = good.
3 BLK 12 MAIN R/L POT -
• If: The voltage = 0 V.
CA507 CA504 (BRN) – Then replace HPSL
1 RED 5 713 7 AUX R/L POT + • If: The voltage = 1.1 V and the event code contin-
POT3 2 WHT 6 105 8 AUX R/L CMD IN
3 BLK 7 544 9 AUX R/L POT - ues.
– Then replace ACCESS 8.
Fig. 353 (27320)

Event Code 840 ACCESS 8

ACCESS 8 module hand presence switch HPSL HPSR CA501 (GRAY)
(left hand presence switch) or HPSR (right hand VIO 3 RIGHT OPTICAL EMITTER
presence switch) photodiode open. BLK 4 RIGHT OPTICAL COLLECTOR
GRN 6 LED OPTIC -
The traction is decreased (in limp mode). Primary and
auxiliary raise or lower, traverse, fork extend or retract, CA504 (BRN)
and pivot do not operate. 2965 5 LEFT OPTICAL COLLECTOR
2966 6 LEFT OPTICAL EMITTER
Note: The wires for HPSL and HPSR are in series. The 2964 10 LED OPTIC +
tests are done with the truck OFF and the connectors
disconnected for access to the terminals. To get an ac-
curate indication the test leads must be on the connec- CA507
HPSL
tor as given in each step. 2966 1 VIO
Step 1: Measure for continuity and the correct diode 2965 2 BLK
2964 3 ORG
installation of the two photodiodes. Set the test device ORG 1 5945 4
to diode check. Connect to CA504-10 (+) and to CA506
CA504-6 (-). The test device will show the two diodes GRN
forward biased by an indication near 2.3 V.
Fig. 354 (27321)
• If: The voltage = 2.3 V.
– Then HPSL and HPSR are wired correctly. Event Code 841
• If: The voltage = 2.3 V and the event code contin- ACCESS 8 module traction potentiometer (POT1)
ues. does not agree with the forward switch (FS).
– Then examine the wire from CA504-6 to The traction function is decreased (in limp mode).
CA507-1 and the wire from CA507-1 to HPSL.
The wire from CA504-6 to CA507-3 and the wire Note: Handle calibration is not correct.
from CA507-3 to HPSL. Step 1: Turn the truck ON while you push the up arrow
• If: The wires are good and the event code contin- button. Go to POT1 A2.3.2, FS A2.3.7 in the ANA-
ues. LYZER menu. Look the indication on the display. FS
POT1 operation: the input status of the FS switch with
– Then replace ACCESS 8. the right multi-task handle in neutral will be open as
• If: The voltage = 0 V. shown on the display A2.3.7. The POT1 value on the
– Then an open circuit or the wires not on the cor- display A2.3.2 will be between 2.1–2.9 V. Move the
rect pin in the photodiode circuit. Set the test de- right multi -task handle to the full forward position will

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close the FS switch A2.3.7. The POT1 value A2.3.2 will
be between 0.7–1.5 V.
• If: The operation is not correct.
– Then examine the wires on FS (yellow sleeving)
nearest the handle grip. F is on the actuator that
goes between the optic sensors.
• If: Indications are not as shown.
– Then examine FS.
• If: FS = bad.
– Then replace FS.
• If: POT1 is not in limits.
– Then calibrate POT1.
• If: Calibration did not repair the problem.
– Then replace POT1.
Event Code 842
ACCESS 8 module traction potentiometer (POT1)
does not agree with reverse switch (RS).
The traction function is decreased (in limp mode).
Note: Handle calibration is not correct.
Step 1: Turn the truck ON while you push the up arrow
button. Go to POT1 A2.3.2, RS A2.3.8 in the ANA-
LYZER menu. Look the indication on the display. RS
POT1 operation: the input status of the RS switch with
the right multi-task handle in neutral will be open as
Event Code 843
ACCESS 8 module forward switch (FS) and reverse
switch (RS) shows the two are closed at the same
time.
The traction is decreased (in limp mode).
Step 1: Turn the truck ON while you push the up arrow
button. Go to FS A2.3.7, RS A2.3.8 in the ANALYZER
menu. Look the indication at the status of FS with right
multi-task handle in the neutral position.
• If: Use the switch that = closed. (FS or RS)
– Then continue to Step 2.
• If: The two switches are closed then select one.
– Then continue to Step 2.
Step 2: Examine the optical switch function. Turn the
truck OFF and disconnect the wire from CA501-10 for
the FS test or the wire from CA501-9 for the RS test.
• If: The FS or RS switch display changes to open.
– Then replace the FS or RS and calibrate.
• If: The FS or RS switch = closed.
– Then replace ACCESS 8.
FS
GRN
WHT
RED

BLU
BLK

shown on the display A2.3.8. The POT1 value on dis- ACCES 8

play A2.3.2 will be between 2.1 V–2.9 V. Move the right CA501 (GRAY)
multi-task handle to the full forward position will close Optical VIO 7 +5V TO FS FS & RS
the RS switch A2.3.8. The POT1 value A2.3.2 will be Switch GRN 8 FS & RS COMM
WHT 9 REV SW IN
between 0.7–1.5 V. Board BLK 10 FWD SW IN
• If: The operation is not correct.
WHT
GRN
RED

BLU
BLK

– Then examine the wires on RS (black sleeving)

nearest the casting. R is on the actuator that goes
between the optic sensors.
RS
• If: Indications are not as shown.
– Then examine RS. Fig. 355 (27319)
• If: RS = bad.
Event Code 844
– Then replace RS.
• If: POT1 is not within limit. ACCESS 8 module cold condition heater driver
current to high.
– Then calibrate POT1.
Note: The event code is recorded if to much current
• If: Calibration did not repair the problem.
flows through the module driver at CA502-7.
– Then replace POT1.
Step 1: Turn the truck OFF and disconnect the wire
from CA502-7 on ACCESS 8 and isolate the wire. At
ACCESS 4 CA314-5 put a jumper across TS3 and turn
the truck ON.
• If: Event Code 844 is recorded.

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– Then replace ACCESS 8. Event Code 846

• If: Event code does not continue.
ACCESS 8 module right hand presence switch
– Then a short circuit problem in the wires. Turn the
(HPSR) open receiver.
truck OFF and connect wire into CA502-7 and
continue to Step 2. The traction is decreased (in limp mode), primary raise,
auxiliary raise or lower and pivot do not operate.
Step 2: Disconnect CA510, CA511 that go to the EDS
switch heater. Measure the resistance across the two Step 1: Examine the wires from HPSRL receiver to
connectors. The resistance > 50 Ω. ACCESS 8. The wire from HPSR to CA501-3 and the
wire from HPSR to CA501-4.
• If: The resistance < 50 Ω.
• If: The wires = good.
– Then replace the heater.
– Then turn the truck OFF and disconnect CA501
from ACCESS 8. Measure the resistance be-
tween the wire CA501-4 and the wire CA501-3.
ACCESS 8
• If: The resistance = 220 K Ω or less.
CA510 CA502 (BLK)
– Then the HPSR receiver is good.
5985 7 C/C DRIVER (LOW SIDE)
CA511 29105 8 C/C DRIVER (+V TO HTRS) • If: The resistance > 220 K Ω.
– Then replace HPSR.
• If: The event code continues.
RES7 ACCESS 4 – Then replace ACCESS 8.
HGTRS1 CA311 (GRY)
BLK 5920 5 HEIGHT RESET SW IN
ACCESS 8
CA314 (BRN)
HPSR CA501 (GRAY)
BLK 590 5998 5 C/C THERMOSTAT INPUT
VIO 3 RIGHT OPTICAL EMITTER
CA308 BLK 4 RIGHT OPTICAL COLLECTOR
TS3 GRN 6 LED OPTIC -
CA504 (BRN)
Fig. 356 (27322)
2965 5 LEFT OPTICAL COLLECTOR
Event Code 845 2966 6 LEFT OPTICAL EMITTER
2964 10 LED OPTIC +
ACCESS 8 module left hand presence switch
(HPSL) open receiver.
CA507 HPSL
The traverse and fork extend or retract do not operate.
2966 1 VIO
Step 1: Examine the wires from HPSL receiver to 2965 2 BLK
ACCESS 8. The wire from HPSL to CA507-1 and the 2964 3 ORG
wire from CA507-1 to CA504-6. The wire from HPSL to ORG 1 5945 4
CA507-2 and the wire from CA507-2 to CA504-5. CA506
GRN
• If: The wires = good.
– Then turn the truck OFF and disconnect CA504 Fig. 357 (27321)
from ACCESS 8. Measure the resistance be- Event Code 847
tween the wire CA504-6 and the wire CA504-5.
• If: The resistance = 220 K Ω or less. ACCESS 8 module steer tiller encoders (ECR1 and
ECR2) turn rate event.
– Then the HPSL receiver = good.
The truck will brake to a stop and the ED opens.
• If: The resistance > 220 K Ω.
Full traction does not operate.
– Then replace HPSL.
Note: The event code is recorded if the turn rate be-
• If: The event code continues.
tween ECR1 and ECR2 is not equal. This could be-
– Then replace ACCESS 8. cause of a loss of power or channel A or B of one or two
of the encoders.

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Step 1: Turn the truck ON while you push the up arrow
button. Go to ECR1 A2.3.1 in the ANALYZER menu.
Look the indication on the display.
• If: ECR1 count = correct.
– Then continue to Step 2.
• If: ECR1 does not count or has an irregular count.
– Then continue to Step 3.
Step 2: Go to ECR2 A2.3.1 in the ANALYZER menu.
Look at the indication on the display.
• If: ECR2 count = correct.
– Then examine the wire from ECR2 to CA508-5
and the wire from CA508-5 to CA503-7. The wire
from ECR2 to CA508-6 and the wire from
CA508-6 to CA503-6. The wire from ECR2 to
CA508-7 and the wire from CA508-7 to CA503-8.
The wire from ECR2 to CA508-8 and the wire
from CA508-8 to CA503-5.
• If: ECR2 count is not correct.
– Then continue to Step 3.
Step 3: Turn the truck OFF and examine the steer tiller
if it has moved between ECR1 or ECR2 and the steer
tiller. For damaged or broken wires from ECR1 or
ECR2 to the seat tube wire harness CA508.
• If: The wires or ECR1 or ECR2 has moved or the
steer tiller is damaged.
– Then repair or replace as is necessary.
• If: ECR1 or ECR2 has not moved or damaged
wires.
– Then examine all of the wires from CA508-1
through -8 to CA503-5 through -12.
• If: The wires are good and the event code contin-
ues.
– Then continue to Step 4.
Step 4: For ECR1 turn the truck OFF and disconnect
CA508. Turn the truck ON and measure the voltage
from CA508-4 to CA508-2. Look for 4.75–5 V.
• If: The voltage = 4.75–5.5 V.
– Then turn the truck OFF and connect CA508.
Turn the truck ON and measure for 4.75–5.5 V
between CA508-4 and CA508-5.
• If: The voltage ≠ 4.75–5.5 V.
– Then turn the truck OFF and disconnect CA503.
Turn the truck ON and measure for 5 V between
pins CA503-9 and CA503-10.
• If: The voltage = 4.75–5.5 V.
– Then replace ECR1.
• If: The voltage ≠ 4.75–5.5 V
– Then replace ACCESS 8.
Crown 2012 PF25715-120 TSP 7000 SERIES
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EVENT CODE GROUP 800
• If: The event code continues.
– Then continue to Step 5.
Step 5: For ECR2 turn the truck OFF and disconnect
CA508. Turn the truck ON and measure the voltage
from CA508-8 to CA508-6. Look for 4.75–5 V.
• If: The voltage = 4.75–5.5 V.
– Then turn the truck OFF and connect CA508.
Turn the truck ON and measure for 4.75–5.5V
between CA508-8 and CA508-6.
• If: The voltage ≠ 4.75–5.5 V.
– Then turn the truck OFF and disconnect CA503.
Turn the truck ON and measure for 5 V between
pins CA503-5 and CA503-6.
• If: The voltage = 4.75–5.5 V.
– Then replace ECR2.
• If: The voltage ≠ 4.75–5.5 V.
– Then replace ACCESS 8.
Step 6: To look at the ECR1 CH A counts. Measure the
voltage from CA503-11 (+) to CA503-10 (-). Turn the
steer tiller slowly.
• If: The voltage does not change between 0.5–4.5 V.
– Then replace ECR1.
• If: The voltage does change between 0.5–4.5 V.
– Then look at the ECR1 CH B counts. Measure
the voltage from CA503-12 (+) to CA503-10 (-).
Turn the steer tiller slowly.
• If: The voltage does not change between 0.5–4.5 V.
– Then replace ECR1.
• If: The voltage does change between 0.5–4.5 V.
– Then continue to Step 7.
Step 7: To look at the ECR2 CH A counts. Measure the
voltage from CA503-7 (+) to CA503-6 (-). Turn the
steer tiller slowly.
• If: The voltage does not change between 0.5–4.5 V.
– Then replace ECR2.
• If: The voltage does change between 0.5–4.5 V.
– Then look at the ECR2 CH B counts. Measure
the voltage from CA503-8 (+) to CA503-6 (-).
Turn the steer tiller slowly.
• If: Voltage does not change between 0.5–4.5 V.
– Then replace ECR2.
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– Then repair or replace as is necessary

• If: ECR2 count is not correct.
ACCESS 8 – Then continue to Step 3.
CA503 (GRN) Step 3: Turn the truck OFF and disconnect CA508.
710 5 STEER CMD ECR +5 (2) Turn the truck ON and measure the voltage from
521 6 STEER CMD ECR COMM (2)
038 7 STEER CMD CH A (2) CA508-4 (+) to CA508-2 (-) for ECR1. Turn the truck
039 8 STEER CMD CH B (2) ON.
711 9 +5V TO STEER ECR (1) • If: The voltage = 4.75–5.5 V.
542 10 BATT COMM TO STEER ECR (1)
030 11 STEER CMD CH A (1) – Then turn the truck OFF and connect CA508.
031 12 STEER CMD CH B (1) Measure for 4.75–5.5 V between CA508-4,
CA508-5. Turn the truck ON.
CA508 ECR1 • If: The voltage ≠ 4.75–5.5 V.
030 1 WHT CH A – Then turn the truck OFF and disconnect CA503
542 2 BLK BATT NEG from ACCESS 8. Turn the truck ON and measure
031 3 BLU CH B for 5 V between pins CA503-9 and CA503-10.
711 4 RED +5V
038 5 WHT • If: The voltage = 4.75–5.5 V.
521 6 BLK – Then replace ECR1.
039 7 BLU ECR2
710 8 RED • If: The voltage ≠ 4.75–5.5 V.
CH A
BATT NEG – Then replace ACCESS 8.
CH B • If: The event code continues.
+5V
– Then continue to Step 4.
Step 4: Turn the truck OFF and disconnect CA508.
Fig. 358 (27318) Turn the truck ON and measure the voltage from
Event Code 848 CA508-8 (+) to CA508-6 (-) for ECR2.
• If: The voltage = 4.75 - 5.5 V.
ACCESS 8 module ECR1 and ECR2 (steer tiller en-
– Then turn the truck OFF and connect CA508.
coders) direction of rotation problem.
Turn the truck ON and measure for 4.75–5.5 V
The traction and steering do not operate. between CA508-8 and CA508-6.
Note: The event code is recorded if the direction of the • If: The voltage ≠ 4.75–5.5 V.
count between ECR1 and ECR2 is not the same. This
– Then turn the truck OFF and disconnect CA503
could be because of no power or channel A or B of one
from ACCESS 8. Turn the truck ON and measure
or two of the encoders.
for 5 V between pins CA503-5 and CA503-6.
Step 1: Turn the truck ON while you push the up arrow
• If: The voltage = 4.75–5.5 V.
button. Go to ECR1 A2.3.1 in the ANALYZER menu.
Look at the indication on the display. – Then replace ECR2.
• If: ECR1 count = correct. • If: The voltage ≠ 4.75–5.5 V.
– Then continue to Step 2. – Then replace ACCESS 8.
• If: ECR1 count is not correct. Step 5: To examine the ECR1 CH A counts. Measure
the voltage between CA503-11(+) and CA503-10 (-).
– Then continue to Step 3.
Turn the steer tiller slowly.
Step 2: Go to ECR2 A2.3.1 in the ANALYZER menu.
• If: The voltage does not change between 0.5–4.5 V.
Look at the indication on the display.
– Then replace ECR1.
• If: ECR2 count = correct.
• If: The voltage does change between 0.5–4.5 V.
– Then problem could be because of the wires or
movement between ECR1 and ECR2. Look for – Then examine the ECR1 CH B counts. Measure
movement and all the wires from CA508-1 the voltage between CA503-12 (+) and the
through CA508-8 to CA503-5 through CA503-12. CA503-10 (-). Turn the steer tiller slowly.
• If: There is movement or wire problems. • If: The voltage does not change between 0.5–4.5 V.
– Then replace ECR1.

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• If: The voltage does change between 0.5–4.5 V. Step 1: Turn the truck ON while you push the up arrow
– Then continue to Step 6. button. Go to ECR1 A2.3.1 in the ANALYZER menu
and look at the indication.
Step 6: To examine the ECR2 CH A counts. Measure
the voltage between CA503-7 (+) and CA503-6 (-). • If: ECR1 count is not correct.
Turn the steer tiller slowly. – Then continue to Step 2.
• If: The voltage does not change between 0.5–4.5 V. • If: ECR1count is not correct.
– Then replace ECR2. – Then continue to Step 3.
• If: The voltage does change between 0.5–4.5 V. Step 2: Go to ECR2 A2.3.1 in the ANALYZER menu
– Then examine the ECR2 CH B counts. Measure and look at the indication.
the voltage between CA503-8 (+) and CA503-6 • If: ECR2 count is not correct.
(-). Turn the steer tiller slowly. – Then problem could be because of the wires or
• If: The voltage does not change between 0.5–4.5 V. movement between ECR1 and ECR2. Examine
– Then replace ECR2. for movement and all the wires from CA508-1
through -8 to CA503-5 through -12.
• If: Movement or wire problems.
ACCESS 8 – Then repair or replace as is necessary.
CA503 (GRN) • If: ECR2 count is not correct.
710 5 STEER CMD ECR +5 (2) – Then continue to Step 3.
521 6 STEER CMD ECR COMM (2)
038 7 STEER CMD CH A (2) Step 3: Turn the truck OFF and disconnect CA508.
039 8 STEER CMD CH B (2) Measure the voltage between CA508-4 (+) and
711 9 +5V TO STEER ECR (1) CA508-2 (-) for ECR1. Turn the truck ON.
542 10 BATT COMM TO STEER ECR (1)
030 11 STEER CMD CH A (1) • If: The voltage = 4.75–5.5 V.
031 12 STEER CMD CH B (1) – Then turn the truck OFF and connect CA508.
Turn the truck ON and measure for 4.75–5.5 V
CA508 ECR1 between CA508-4 and CA508-5.
030 1 WHT CH A • If: The voltage ≠ 4.75–5.5 V.
542 2 BLK BATT NEG – Then turn the truck OFF and disconnect CA503
031 3 BLU CH B
from ACCESS 8. Turn the truck ON and measure
711 4 RED +5V
038 5 WHT for 5 V between pins CA503-9 and CA503-10.
521 6 BLK • If: The voltage = 4.75–5.5 V.
039 7 BLU ECR2
710 8 RED – Then replace ECR1.
CH A
BATT NEG • If: The voltage ≠ 4.75–5.5 V.
CH B – Then replace ACCESS 8.
+5V
• If: The event code continues.
– Then continue to Step 4.
Fig. 359 (27318)
Step 4: Turn the truck OFF and disconnect CA508.
Event Code 849 Measure the voltage between CA508-8 (+) and
CA508-6 (-) for ECR2. Turn the truck ON.
ACCESS 8 module steer tiller encoders (ECR1 and
• If: The voltage = 4.75–5.5 V.
ECR2) direction of rotation event.
– Then connect CA508 and check for 4.75–5.5 V
The truck will brake to a stop and the ED opens.
between CA508-8 and CA508-6.
The traction and steering do not operate.
• If: The voltage ≠ 4.75–5.5 V.
Note: The event code is recorded if the direction of the
– Then turn the truck OFF and disconnect CA503
count between ECR1 and ECR2 is not equal. This
from ACCESS 8. Turn the truck ON and measure
could be because of no power or channel A or B of one
for 5 V between pins CA503-5 and CA503-6.
of the encoders.
• If: The voltage = 4.75–5.5 V.
– Then replace ECR2.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The voltage ≠ 4.75–5.5 V.

– Then replace ACCESS 8.
Step 5: To examine the ECR1 CH A counts. Measure ACCESS 8
the voltage between CA503-11 (+) and CA503-10 (-). CA503 (GRN)
Turn the steer tiller slowly. 710 5 STEER CMD ECR +5 (2)
521 6 STEER CMD ECR COMM (2)
• If: The voltage does not change between 0.5–4.5 V. 038 7 STEER CMD CH A (2)
– Then replace ECR1. 039 8 STEER CMD CH B (2)
711 9 +5V TO STEER ECR (1)
• If: The voltage does change between 0.5–4.5 V. 542 10 BATT COMM TO STEER ECR (1)
– Then examine the ECR1 CH B counts. Measure 030 11 STEER CMD CH A (1)
the voltage between CA503-12 (+) and 031 12 STEER CMD CH B (1)
CA503-10 (-). Turn the steer tiller slowly.
• If: The voltage does not change between 0.5–4.5 V. CA508 ECR1
– Then replace ECR1. 030 1 WHT CH A
542 2 BLK BATT NEG
• If: Voltage does change between 0.5–4.5 V. 031 3 BLU CH B
– Then continue to Step 6. 711 4 RED +5V
038 5 WHT
Step 6:To examine the ECR2 CH A counts. Measure 521 6 BLK
the voltage between CA503-7 (+) and CA503-6 (-). 039 7 BLU ECR2
Turn the steer tiller slowly. 710 8 RED
CH A
• If: The voltage does not change between 0.5–4.5 V. BATT NEG
CH B
– Then replace ECR2. +5V
• If: The voltage does change between 0.5–4.5 V.
– Then examine the ECR2 CH B counts. Measure
Fig. 360 (27318)
the voltage between CA503-8 (+) and CA503-6
(-). Turn the steer tiller slowly. Event Codes 850 - 852
• If: The voltage does not change between 0.5–4.5 V.
ACCESS 5 or ACCESS 8 module CAN receiving
– Then replace ECR2. problem.
The procedures below apply to Event Codes 850 - 852.
No truck functions operate.
Event Code 850: ACCESS 5 receiving data packets
too fast.
Event Code 851: ACCESS 5 receiving short data pack-
ets.
Event Code 852: ACCESS 5 receiving long data pack-
ets.
Step 1: Make sure the correct modules are installed on
the truck.
• If: New modules were installed on the truck.
– Then make sure they are correctly installed and
connected and have the correct software in-
stalled.
Step 2: Turn the truck OFF and measure the resist-
ance of the CAN lines. There are two CAN termination
resistors, one internal to ACCESS 5 and one in the
wire harness near CA703. The resistance at TP4 and
TP5 on the power unit distribution panel must = 60 Ω.
• If: The resistance = 0 Ω.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

– Then keep the test device connected to TP4, TP5

and disconnect CA402 from ACCESS 5.
• If: The resistance = 0 Ω ACCESS 7
– Then the resistor in the wire harness is bad. Re- ACM
place the resistor or the wire harness. RES3 CA703 (BLK)
059 1 CAN_H
• If: The resistance = 120 Ω. 058 12 CAN_L
– Then the resistor in ACCESS 5 is bad. Replace
ACCESS 5.
Fig. 362 (27251)

Event Codes 856 - 859

ACCESS 7
ACM
RES3 CA703 (BLK)
059 1 CAN_H
058 12 CAN_L
Fig. 361 (27251)
Event Codes 853 - 855
ACCESS 6 and ACCESS 8 module CAN receiving
problem.
The procedures below apply to Event Codes 853 - 855.
Event Code 853: ACCESS 6 receiving data packets
too fast.
Event Code 854: ACCESS 6 receiving short data pack-
ets.
Event Code 855: ACCESS 6 receiving long data pack-
ets.
Step 1: Make sure the correct modules are installed on
the truck.
• If: New modules were installed on the truck.
– Then insure they are correctly installed and con-
nected and have the correct software installed.
Step 2: Turn the truck OFF and measure the resist-
ance of the CAN lines. There are two CAN termination
resistors one in the wire harness near CA703 and one
internal to ACCESS 5. The resistance at TP4 and TP5
on the power unit distribution panel must = 60 Ω.
• If: The resistance = 0 Ω.
– Then keep the test device connected to TP4, TP5
and disconnect CA402 from ACCESS 5.
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness.
• If: The resistance = 120 Ω.
– Then the resistor in ACCESS 5 is bad. Replace
ACCESS 5.
ACCESS 1 and ACCESS 8 module receiving prob-
lem.
The procedures below apply to Event Codes 856 - 859.
Event Code 856: ACCESS 1 receiving data packets
too fast.
Event Code 857: ACCESS 1 receiving short data pack-
ets.
Event Code 858: ACCESS 1 receiving long data pack-
ets.
Step 1: Make sure the correct modules are installed on
the truck.
• If: New modules have been installed on the truck.
– Then make sure they are correctly installed and
connected and have the correct software in-
stalled.
Step 2: Turn the truck OFF and measure the resist-
ance of the CAN lines. There are two CAN termination
resistors one in the wire harness near CA703 and one
internal to ACCESS 5. The resistance at TP4 and TP5
on the power unit distribution panel must = 60 Ω.
• If: The resistance = 0 Ω.
– Then keep the test device connected to TP4, TP5
and disconnect CA402 from ACCESS 5.
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness.
• If: The resistance = 120 Ω.
– Then resistor in ACCESS 5 is bad. Replace
ACCESS 5.
ACCESS 7
ACM
RES3 CA703 (BLK)
059 1 CAN_H
058 12 CAN_L
Fig. 363 (27251)

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800
Event Codes 860 - 863
ACCESS 4 and ACCESS 8 module CAN receiving
problem.
The procedures below apply to Event Codes 860 - 863.
Event Code 860: ACCESS 4 receiving data packets
too fast.
Event Code 861: ACCESS 4 receiving short data pack-
ets.
Event Code 862: ACCESS 4 receiving longdata pack-
ets.
Event Code 863: ACCESS 4 receiving duplicate ID.
Step 1: Make sure the correct modules are installed on
the truck.
• If: New modules have been installed on the truck.
– Then make sure they are correctly installed and
connected and have the correct software in-
stalled.
Step 2: Turn the truck OFF and measure the resist-
ance of the CAN lines. There are two CAN termination
resistors one in the wire harness near CA703 and one
internal to ACCESS 5. The resistance at TP4 and TP5
on the power unit distribution panel must = 60 Ω.
• If: The resistance = 0 Ω.
– Then keep the test device connected to TP4, TP5
and disconnect CA402 from ACCESS 5.
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness.
• If: The resistance = 120 Ω.
– Then resistor in ACCESS 5 is bad. Replace
ACCESS 5.
ACCESS 7
ACM
CA703 (BLK)
RES3
059 1 CAN_H
058 12 CAN_L
Fig. 364 (27251)
Event Codes 864 - 867
ACCESS 7 and ACCESS 8 module CAN receiving
problem.
The procedures below apply to Event Codes 864 - 867.
No action taken.
Event Code 864: ACCESS 7 receiving data packets
too fast.
M4.8-1970-159 TSP 7000 SERIES
486
Event Code 865: ACCESS 7 receiving short data pack-
ets.
Event Code 866: ACCESS 7 receiving long data pack-
ets.
Event Code 867: ACCESS 7 receiving duplicate ID.
Step 1: Make sure the correct modules are in place on
the truck.
• If: New modules have been installed on the truck.
– Then make sure they are correctly installed and
connected and have the correct software in-
stalled.
Step 2: Turn the truck OFF and measure the resist-
ance of the CAN lines. There are two CAN termination
resistors, one internal to ACCESS 5 and one in the
wire harness near CA703. The resistance at TP4 and
TP5 on the power unit distribution panel must = 60 Ω.
• If: The resistance = 0 Ω.
– Then keep the test device connected to TP4, TP5
and disconnect CA402 from ACCESS 5.
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
place the resistor or the wire harness.
• If: The resistance = 120 Ω.
– Then resistor in ACCESS 5 is bad. Replace
ACCESS 5.
ACCESS 7
ACM
RES3 CA703 (BLK)
059 1 CAN_H
12 CAN_L
058
Fig. 365 (27251)
Event Codes 868, 869
ACCESS 5 and ACCESS 8 module CAN event.
The procedures below apply to Event Codes 868, 869.
Event Code 868: ACCESS 5 passive event.
Event Code 869: ACCESS 5 event control event.
Step 1: Turn the truck ON and measure for +BV at
ACCESS 5 CA403-1 (-BV) and CA403-10 (+BV).
• If: The voltage is +BV and the event code contin-
ues.
– Then replace ACCESS 5.
• If: The voltage = 0 V.
– Then examine the wire from CA403-1 to the neg-
ative buss bar and CA403-10 to FU8.
Crown 2012 PF25715-125
 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

Step 2: The event code continues then turn the truck Event Code 871: ACCESS 6 event control problem.
OFF. Measure the resistance between ACCESS 8 Step 1: Turn the truck ON and measure for +BV at
CAN_H CA504-3 and CAN_L CA504-4. The resist- ACCESS 6, CA601-2 (-BV) and CA601-1 (+BV).
ance must = 60 Ω.
• If: The voltage = +BV and the event code continues.
• If: The resistance = 0 Ω.
– Then replace ACCESS 6.
– Then a short circuit between CAN_H and
• If: The voltage = 0 V.
CAN_L. Disconnect CA504 from ACCESS 8 and
measure the resistance between module pins – Then examine the wire from CA601-2 to the neg-
CA504-3 and CA504-4. ative buss bar and CA403-1 to FU8.
• If: The resistance = 0 Ω. Step 2: The event code continues then turn the truck
OFF. Measure the resistance between ACCESS 8
– Then replace ACCESS 8.
CAN_H CA504-3 and CAN_L CA504-4. The resist-
• If: The resistance = ∞ Ω. Connect CA504 to ance must = 60 Ω.
ACCESS 8.
• If: The resistance = 0 Ω.
– Then disconnect CA402 from ACCESS 5. Meas-
– Then a short circuit between CAN_H and
ure the resistance between module pins
CAN_L. Disconnect CA504 from ACCESS 8 and
CA402-4 and CA402-5.
measure the resistance between module pins
• If: The resistance = 0 Ω. CA504-3 and CA504-4.
– Then replace ACCESS 5. • If: The resistance = 0 Ω.
• If: The resistance = 120 Ω. – Then replace ACCESS 8.
– Then measure the resistance between CA402-4 • If: The resistance = ∞ Ω. Connect CA504 connec-
and CA402-5 on ACCESS 5 connector. tor.
• If: The resistance = 0 Ω. – Then disconnect CA601 from ACCESS 6 and
– Then the resistor in the wire harness is bad. Re- measure the resistance between module pins
place the resistor or the wire harness. CA601-4 and CA601-5.
• If: The resistance = 0 Ω.
– Then replace ACCESS 6.
Power Unit
• If: The resistance = ∞ Ω.
Distribution
Panel – Then there are two 60 Ω resistors. One is in the
FU8 wire harness near CA703 and one is internal to
4 ACCESS 5 ACCESS 5. Measure the resistance between
CA204 CA201
CA402 pins CA703-1 and CA703-12 on ACCESS 7.
8 003 4 CAN_H • If: The resistance = 0 Ω.
TP17 2 004 5 CAN_L – Then keep the test device connected to connec-
CA206 9 CA403 tor CA703 and disconnect CA402 from
505 1 L-COMM INPUT ACCESS 5.
NEG BUS 2903 10 +BV INPUT • If: The resistance = 0 Ω.
A1 B+ A2 B- – Then the resistor in the wire harness is bad. Re-
CA406 place the resistor or the wire harness.
• If: The resistance = 120 Ω.
– Then the resistor in ACCESS 5 is bad. Replace
ACCESS 5.
Fig. 366 (27313)

Event Codes 870, 871

ACCESS 6 and ACCESS 8 module CAN event.
The procedures below apply to Event Codes 870, 871.
Event Code 870: ACCESS 6 passive error.

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The resistance = 0 Ω.

– Then a short circuit between CAN_H and
ACCESS 6 CAN_L. Disconnect CA504 from ACCESS 8 and
GCM measure the resistance between module pins
CA601 CA504-3 and CA504-4.
2905 1 +BVAK
507 2 BATT COMM • If: The resistance = 0 Ω.
011 4 CAN_H – Then replace ACCESS 8.
012 5 CAN_L
• If: The resistance = ∞ Ω. Connect CA504 to
Power Unit Distribution Panel ACCESS 8.
CA201 – Then disconnect CA304 from ACCESS 1. Meas-
012 5 ure the resistance between module pins
011 11 CA304-4 and CA304-5.
CA206 11 • If: The resistance = 0 Ω.
2905 – Then replace ACCESS 1.
CA406 • If: The resistance = ∞ Ω.
– Then there are two 60 Ω resistors. One is in the
wire harness near ACCESS 5 and one internal to
NEG BUS ACCESS 5. Measure the resistance between
507 CA703-1 and CA703-12 on ACCESS 7.
• If: The resistance = 0 Ω.
Fig. 367 (27286)
– Then keep the test device connected to connec-
tor to CA703 and disconnect CA402 from
ACCESS 5.
ACCESS 7
ACM • If: The resistance = 0 Ω.
RES3 CA703 (BLK) – Then the resistor in the wire harness is bad. Re-
059 1 CAN_H place the resistor or the wire harness.
058 12 CAN_L

Fig. 368 (27251)

Event Codes 872 - 874

ACCESS 1 and ACCESS 8 module CAN event.
The procedures below apply to Event Codes 872 - 874.
Event Code 872: ACCESS 1 passive event.
Event Code 873: ACCESS 1 event control problem.
Event Code 874: ACCESS 1 CAN off line.
Step 1: Turn the truck ON and measure for +BV at
ACCESS 1 CA304-2 (-BV) and CA304-3 (+BV).
• If: The voltage = +BV and the event code continues.
– Then replace ACCESS 1.
• If: The voltage = 0 V.
– Then examine the wires between ACCESS 1
wire from CA304-2 to FU8 and CA403-1 to
CA104-3 on the platform distribution panel.
Step 2: The event code continues then turn the truck
OFF. Measure the resistance between CAN_H
CA504-3 and CAN_L CA504-4 on ACCESS 8. The re-
sistance must = 60 Ω.

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The resistance = 120 Ω. Event Codes 875 - 877

– Then resistor in ACCESS 5 is bad. Replace
ACCESS 5. ACCESS 4 and ACCESS 8 module CAN event.
The procedures below apply to Event Codes 875 - 877.
Event Code 875: ACCESS 4 passive event.
ACCESS 7 Event Code 876: ACCESS 4 event control problem.
ACM
Event Code 877: ACCESS 4 CAN off line.
RES3 CA703 (BLK)
059 1 CAN_H Step 1: Turn the truck ON and measure for +BV at
058 12 CAN_L ACCESS 4, CA314-2 (-BV) and CA314-1 (+BV)
• If: The voltage = +BV and the event code continues.
Fig. 369 (27251) – Then replace ACCESS 4.
• If: The voltage = 0 V.
– Then examine the wire CA314-1 and CA314-2 to
ACCESS 7
the platform distribution panel and FU7. Repair or
CA703 (BLK) replace as is necessary.
CA701 059 1 CAN H
BRN 7 046 058 12 CAN L Step 2: The event code continues then turn the truck
YEL 8 047 OFF. Measure the resistance between CAN_H
CA504-3 and CAN_L CA504-4 on ACCESS 8. The re-
RES3 sistance must = 60 Ω.
• If: The resistance = 0 Ω.
CA106 CA103 – Then a short circuit between CAN_H and
2 12 CAN_L. Disconnect CA504 from ACCESS 8.
6 TP11 Measure the resistance between CA504-3 and
7 FU18 CA104
6 CA504-4.
8
• If: The resistance = 0 Ω.
1 2 3 5 6 CA107 – Then replace ACCESS 8.
WHT

ORG
RED
BLK

BLU

• If: The resistance = ∞ Ω. The connect CA504.

CA406
1 2 3 5 6 CA413 – Then disconnect CA314 from ACCESS 4 and
527
2920
2923

528 Measure the resistance between module pins

529 CA314-3 and CA314-4.
5 6 CA205 • If: The resistance = 0 Ω.
NEG
BUS – Then replace ACCESS 4.
TP16
CA204 • If: The resistance = ∞ Ω.
4 – Then there are two 60 Ω resistors. One is in the
FU7 wire harness near CA703 and one is internal to
Power Unit
ACCESS 5. Measure the resistance between
Distribution Panel
CA703-1 and CA703-12 on ACCESS 7.
• If: The resistance = 0 Ω.
ACCESS 1 – Then keep the meter leads connected to CA703
CA304 and disconnect CA402 from ACCESS 5.
ALM1
2946 1 +BV (KYS) • If: The resistance = 0 Ω.
512 2 BATT NEG – Then the resistor in the wire harness is bad. Re-
027 4 CAN_H
022 5 CAN_L place the resistor or the wire harness.

Fig. 370 (27314)

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ELECTRICAL SYSTEM
EVENT CODE GROUP 800

• If: The resistance = 120 Ω. Event Codes 878, 880

– Then the resistor in ACCESS 5 is bad. Replace
ACCESS 5. ACCESS 7 and ACCESS 8 module CAN event.
The procedures below apply to Event Codes 878 - 880.
Event Code 878: ACCESS 7 passive event.
ACCESS 7 Event Code 879: ACCESS 7 event control problem.
ACM
Event Code 880: ACCESS 7 CAN off line.
RES3 CA703 (BLK)
059 1 CAN_H Step 1: Turn the truck ON and measure for +BV at
058 12 CAN_L ACCESS 7, CA703-8 (-BV) and CA703-7 (+BV).
• If: The voltage = +BV and the event code continues.
Fig. 371 (27251) – Then replace ACCESS 7.
• If: The voltage = 0 V.
– Then examine the wires between ACCESS 7
ACCESS 7
CA703-1 and CA703-8 to the platform distribu-
CA703 (BLK) tion panel.
CA701 059 1 CAN_H
BRN 7 046 058 12 CAN_L Step 2: The event code continues then turn the truck
YEL 8 047 OFF. Measure the resistance between CAN_H
CA504-3 and CAN_L CA504-4 on ACCESS 8. The re-
RES3 sistance must = 60 Ω.
• If: The resistance = 0 Ω.
CA103 – Then a short exists between CAN_H and CAN_L.
CA106 TP9 13 Disconnect CA504 from ACCESS 8 and check
6
7 FU19 CA101 the resistance between module pins, CA504-3
1 and CA504-4.
1 2 3 5 6 CA107 • If: The resistance = 0 Ω.
– Then replace ACCESS 8.
ORG
WHT
RED

BLU
BLK

• If: The resistance = ∞ Ω. Connect CA504.

CA406 – Then disconnect CA703 from ACCESS 7 and
1 2 3 5 6 CA413
527 measure the resistance between module pins,
2920
2923

528 CA703-1 and CA703-12.

529
• If: The resistance = 0 Ω.
5 6 CA205
NEG – Then replace ACCESS 7.
BUS TP16 • If: The resistance = ∞ Ω.
CA204 – Then there are two 60 Ω resistors. One is in the
4 wire harness near CA703 and one is internal to
FU7 ACCESS 5. Measure the resistance between
Power Unit CA703-1 and CA703-12 on ACCESS 7.
Distribution Panel
• If: The resistance = 0 Ω.
– Then keep the meter leads connected to CA703
ACCESS 4 and disconnect CA402 from ACCESS 5.
CA314 (BRN) • If: The resistance = 0 Ω.
2950 1 +BV IN – Then replace ACCESS 5.
518 2 BATT COMM IN
• If: The resistance = 0 Ω.
– Then the resistor in the wire harness is bad. Re-
Fig. 372 (27323) place the resistor or the wire harness.
• If: The resistance = 120 Ω.

M4.8-1970-164 TSP 7000 SERIES Crown 2012 PF25715-129

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 ELECTRICAL SYSTEM
EVENT CODE GROUP 800

– Then the resistor in ACCESS 5 is bad. Replace

ACCESS 5.

Platform
Distribution ACCESS7
Panel ACM
FU17 CA105 CA703 (BLK)
1 BLK
2 059 1 CAN_H
TP10
1 2974 7 +BV INPUT
CA106 WHT 2 569 8 BATT NEG IN
6 BRN 7 046 058 12 CAN_L
1
7 YEL 8 047
CA107
CA701

RES3

Fig. 373 (27255)

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491
Notes:

492
BRAKE SYSTEM
493
Notes:

494
 BRAKE SYSTEM
BRAKE

Brake
Stopping the Truck
Two sources stop the truck:
• A disc brake on the traction motor
• Regenerative braking through the traction motor.
When the operator applies the brake, ACCESS 5 ap-
plies the disc brakes and regenerative braking through
the traction motor. The truck uses the maximum possi-
ble regenerative braking to decrease wear on the disc
brake.
Stopping Distance Adjustment
2. Make sure the torque gap and air gap of the brake
are correct. Refer to Torque Gap Adjustment and
Air Gap Adjustment.
3. From ACCESS 1, scroll to Field Service Mode >
Performance > P6.1 Braking FF menu.
Note: If you increase the Performance Menu setting,
the stop distance decreases. If you decrease the set-
ting, the stop distance increases and drive tire slide de-
creases.
4. Travel in the forks first direction and examine the
stopping distance.
5. From ACCESS 1, scroll to Field Service Mode >
Performance > P6.2 Braking PUF menu.
6. Travel in the reverse direction and examine the
stopping distance.

WARNING Torque Gap Adjustment

A truck that does not stop correctly can cause in-
jury or death.
The distance for a truck to stop must let an operator do
a task safely.
 Examine the distance for the truck to stop through
out the warehouse or factory.
 Make sure that the braking features on the truck are
not significantly different from other equivalent
trucks used by the operator.
 Train the operator to decrease the travel speed or
to allow an increased distance to stop the truck.
Special Tools and Equipment:
• Feeler gauges
• Spanner wrench
Note: The torque gap is the distance between the mag-
net body (1) and the torque adjuster plate (2). Refer to
Figure 374. The torque gap is set at the factory and no
adjustment is necessary. But if you replace the brake
components, you must set the torque gap to factory
specifications. Because of the capacity load and truck
weight, the torque gap is different for each truck.

To examine the stopping distance

• Move the truck to a floor surface that is usual for the
truck.
• Fully lower the forks (no load).
• Travel in the forward and reverse directions.
The truck must stop in the shortest possible distance
without drive tire slide and with the load stable.
• Usually a truck stops in 2.5–3.0 m (8–10 ft) when
the truck travels forks first, with no load at the max-
imum, non-guided speed of 8.8 km/h (5.5 mph).
• To increase or decrease the stop distance or if the
drive tire slides, refer to To adjust the brake force.
To adjust the brake force
Note: For a truck that operates on a smooth, dry con-
crete floor, the usual setting for the Performance Brake
Menu (P6.1 and P6.2) is 6 or 7.
Fig. 374 (27201)
1. Use ACCESS 1 (display) and make sure that Fea-
tures Menu > F5 Truck Weight and F6 Max Load
are correct.

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BRAKE SYSTEM
BRAKE

To prepare the truck

1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put the chocks against the tires to prevent the
movement of the truck.
5. Disconnect the battery.
6. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
7. Remove the back, center door on the power unit.
8. Remove the cover (1) on top of the traction motor.
Refer to Figure 375.

Fig. 375 (27200)

Adjust the torque gap
1. The torque gap is calculated from the gross vehicle
weight of the truck. Refer to the Torque Gap Chart
for the correct gap of the truck.
Note: Refer to the capacity and data plate for the ca-
pacity load, truck weight and maximum battery weight.

Torque Gap Chart

Torque Gap Gross Vehicle Weight (capacity load, truck

weight and maximum battery weight)
mm in kg lb
0.00 0.00 more than 9934 more than 21900
0.5 0.02 9480 - 9933 20900 - 21899
1.0 0.04 9004 - 9479 19850 - 20899
1.5 0.06 8550 - 9003 18850 - 19849
2.0 0.08 8074 - 8549 17800 - 18849
2.5 0.10 7620 - 8073 16800 - 17799
3.0 0.12 7167 - 7619 15800 - 16799
3.6 0.14 less than 7167 less than 15800

M5.0-1970-002 TSP 7000 SERIES Crown 2012 PF25710-2

496
 BRAKE SYSTEM
BRAKE

2. To adjust the gap, use a spanner wrench and turn

the torque adjuster. Refer to Figure 376.

Fig. 376 (27202)

1 Spanner wrench
2 Feeler gauge

3. Install the traction motor cover.

4. Check truck and brake operation.

Crown 2012 PF25710-3 TSP 7000 SERIES M5.0-1970-003

497
BRAKE SYSTEM
BRAKE

Air Gap Adjustment • When the brake pads measure 2.8 mm, replace the
brake pads and rotor.
Special tools and equipment: Note: The air gap is the distance between the armature
• Feeler gauge and magnet body with the brake applied. Refer to
Figure 377. As the brake pads and rotor wear, the air
• Torque wrench
gap increases. An air gap that measures more than
Specifications 1.0 mm could cause the brake to not release correctly.
• Adjust the gap when the air gap measures 1.0 mm.

6
7 8
5

4 9

10

11
1

12

Fig. 377 (27198)

1 Torque adjuster plat 7 7/8 inch hex nut
2 Adjuster disk 8 Rotor
3 Magnet body 9 Brake pads
4 Air gap 10 Armature
5 1-1/8 inch hex nut 11 Torque adjuster gap
6 Motor shaft 12 Traction motor

To prepare the truck 6. Lockout/tagout the truck. Refer to SAFETY > Con-
1. Move the truck to a maintenance area with a level trol of Hazardous Energy > Lockout/Tagout.
floor. 7. Remove the back, center door on the power unit.
2. Fully lower the forks. 8. Remove the cover (1) on top of the traction motor.
3. Turn the truck OFF. Refer to Figure 375.
4. Put chocks against the tires to prevent the move- 9. Use low pressure air to remove contamination be-
ment of the truck. tween the armature and magnet body.
5. Disconnect the battery.

M5.0-1970-004 TSP 7000 SERIES Crown 2012 PF25710-4

498

Adjust the air gap
1. Remove the retaining ring (1) and washer (1) from
the motor shaft. Refer to Figure 378.
2. Use a 7/8 inch wrench to loosen the top nut (2).
3. Use a 1 1/8 inch wrench and feeler gauge (3). Turn
the bottom nut (4) down until the air gap is 0.25–
0.38 mm where the magnet body (3) is nearest to
the armature (10).
Fig. 378 (27203)
Note: One full turn of the nut changes the gap 1.4 mm.
1/6 (60 degrees) of a turn changes the gap 0.235 mm.
4. Torque the 7/8 inch nut 122 Nm.
5. Check the truck and brake operation.
Rotor and Brake Pad Replacement
Special Tools and Equipment:
• 119343 Riveter base (1). Refer to Figure 379
• 114518 Riveter (2)
• Hydraulic press.
Crown 2012 PF25710-5 TSP 7000 SERIES
BRAKE SYSTEM
BRAKE
1
Fig. 379 (27199)
To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put chocks against the tires to prevent the move-
ment of the truck.
5. Disconnect the battery.
6. Lockout/Tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
7. Remove the back, center door on the power unit.
8. Remove the top cover from the traction motor.
To remove the rotor and brake pad assembly
1. Disconnect the brake connector, CA407.
2. Remove the retaining ring (16) and washer (15)
from the motor shaft. Refer to Figure 380.
3. Use a 7/8 inch wrench to remove the top nut (14).
4. Use a 1 1/8 inch wrench to remove the bottom nut
(13).
5. Remove the rotor (11) and brake pad assembly
(10).
Note: Examine all brake components. Replace compo-
nents that are worn or damaged.
Note: Use a hydraulic press with the 119343 riveter
base and 114518 riveter to replace the brake pads. The
hydraulic press supplies the necessary force to make
sure that the rivets hold the brake pads tightly on the
plate.
M5.0-1970-005
499
BRAKE SYSTEM
BRAKE

14
4

13
15
12
3

6
CA407

11

10
1

Fig. 380 (27197)

M5.0-1970-006 TSP 7000 SERIES Crown 2012 PF25710-6

500
 BRAKE SYSTEM
BRAKE

To Assemble the Brake 6. Install the cover on top of the traction motor.
7. Examine the brake operation and stop distance.
Special Tools and Equipment: Refer to Stopping Distance Adjustment.
• Feeler gauge
• Torque wrench
• Spanner wrench
• 063002-024 Multi-purpose grease
• 061004-026 Thread-locking adhesive (blue)
To assemble the magnet body
1. Fully assemble the torque adjuster plate (1) on the
motor. Refer to Figure 380.
2. Lightly apply 063002-024 multi-purpose grease to
the threads of the motor end cap above the torque
adjuster plate (1).
3. Put the adjuster disk (2) on the torque adjuster
plate (1).
4. Put the magnet body (3) on the motor. The coil
wires must be in the correct position as you see in
Figure 7.
5. Apply 061004-026 thread-locking adhesive (blue)
to the three M8 screws (5) that hold the magnet
body (3) to the motor. Assemble the screws (5) to
the motor.
To assemble the armatures, brake pad assembly
and rotor
1. Put the springs (4) in the magnet body (3). Refer to
Figure 380.
2. Put the armatures (7, 8) on the magnet body (3).
3. Lightly apply 063002-024 multi-purpose grease to
the bottom of the brake pad assembly (10). Make
sure that you don't get grease on the brake pads.
4. Put the brake pad assembly (10) on the armatures
(7, 8).
5. Assemble the spring (9) on the motor shaft.
6. Put the rotor (11) on the motor shaft.
7. Assemble the 1 1/8 inch nut (12) on the motor
shaft. Tighten the nut until the rotor (11) almost
touches the brake pads.
To adjust the brake
1. Set the torque adjuster gap. Refer to Torque Gap
Adjustment.
2. Set the air gap. Refer to Air Gap Adjustment.
3. Assemble the 7/8 inch nut (13) on the motor shaft.
4. Install the washer (14) and retaining ring (15) on
the motor shaft.
5. Connect CA407.

Crown 2012 PF25710-7 TSP 7000 SERIES M5.0-1970-007

501
BRAKE SYSTEM
BRAKE

Troubleshooting

Problem Possible Cause Correction

The air gap is more than 1.0 mm Adjust
The brake will not An open circuit or bad circuit Check the brake switches and circuits
release
Contamination keeps the armature from Use low pressure air to clean the brake
movement
The brake pads rub The air gap is less than 0.25 mm Adjust
the rotor
The mounting plate for the brake pads or rotor is Replace
damaged
Contamination keeps the armature from Use low pressure air to clean the brake
movement
The truck stop is The stop distance is incorrect Adjust
sudden
The mounting plate for the brake pads or rotor is Replace
damaged
The stop distance The stop distance is incorrect Adjust
is too long
The brake pads are loose or contaminated Replace
The brake makes a The brake pads are loose or contaminated Replace
noise when applied
The mounting plate for the brake pads or rotor is Replace
damaged
The brake applies For trucks with wire guidance, the guide wire has Correct the wire guidance event
without operator in- no power or the truck is off the guide wire
put
An open circuit or bad circuit Check the brake switches and circuits

M5.0-1970-008 TSP 7000 SERIES Crown 2012 PF25710-8

502
STEERING
503
Notes:

504
 STEERING
STEERING FEEDBACK

Steering Feedback
Steering Feedback Encoder (ECR6)
Replacement
Refer to Figure 381.
To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent the
movement of the truck.
5. Disconnect the battery.
6. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy.
7. Remove the power unit door.
To remove ECR6
1. Remove the cover (1).
2. Disconnect CA410 (21).
3. Loosen the set screw (18) in the gear shaft (17).
4. Remove the screws (6) and cleats (5).
5. Remove ECR6 (3).

Fig. 381 (21246-01)

Crown 2012 PF25712-1 TSP 7000 SERIES M6.0-1970-001

505
STEERING
STEERING FEEDBACK

To install ECR6
1. Install ECR6 (3) in the gear shaft (17).
2. Install the screws (6) and cleats (5).
3. Tighten the set screw (18) in the gear shaft (17).
Note: Make sure that you tighten the set screw on the
flat part of the encoder shaft.
4. Connect CA410 (21).
5. Install the cover (1).
CAUTION
If you do not calibrate the steering feedback en-
coder, the truck can steer incorrectly and cause in-
jury or equipment damage.
If you do not calibrate the encoder, the steering feed-
back encoder can input the incorrect steering angle to
ACCESS 5.
 Calibrate the steering feedback encoder (ECR6).
Refer to
ELECTRICAL>Access 1 2 3®>Calibration>C4
Steer Encoder.
6. Calibrate ECR6. Refer to
ELECTRICAL>Access 1 2 3®>Calibration>C4
Steer Encoder.
Steering Feedback Gears Replace-
ment
5. Remove ECR6 (3) and the retainer (4) as one as-
sembly.
To remove the gears
1. Record the location and quantity of the flatwashers
(10, 11, 13, 15) and the position of the bearings
(12).
2. Hold the gears in position and remove the retaining
ring (9), flatwashers (10, 11) and bearing (12).
3. Remove the gears.
4. Disassemble the bearing (12), flatwashers (13, 15)
and spring (16) from the gears.
Note: Examine all components. Replace the compo-
nents that are worn or damaged.
To assemble the gears
1. Put the flatwasher (15) and one bearing (12) on the
bottom gear shaft (17).
2. Put one end of the spring (16) into the small hole
on the bottom gear (17).
3. Install the top gear (14) on the bottom gear shaft
(17).
4. Put the end of the spring (16) in the small hole on
the top gear (14).
5. Install the flatwashers (13) and bearing (12) on the
gear shaft (17).
To install the gears
1. Install the top bearing (12) in the mounting plate
(22) of drive unit.

Refer to Figure 381.

To prepare the truck CAUTION
1. Move the truck to a maintenance area with a level
floor. Backlash from the steering feedback gears can
make the truck steer incorrectly and cause injury
2. Fully lower the forks. or equipment damage.
3. Turn the truck OFF. When you install the steering feedback gears, remove
4. Put chocks against the wheels to prevent the all gear backlash. Backlash from the steering feedback
movement of the truck. gears can cause the steering feedback encoder to in-
5. Disconnect the battery. put the incorrect steering angle to ACCESS 5. Also, an
event can occur.
6. Lockout/tagout the truck. Refer to SAFETY>Con-
trol of Hazardous Energy.  Make sure that you put tension on the spring (16) to
prevent gear backlash. See step 2 below.
7. Remove the power unit door.
To remove the steering feedback encoder (ECR6) 2. Turn the top gear (14) until the small outer slots on
1. Remove the cover (1). the two gears (14, 17) are aligned (approximately
2. Disconnect CA410 (21). four to six teeth).
3. Disconnect the spring (7) from the retainer (4). Note: This puts tension on the spring and prevents
backlash.
4. Loosen the set screw (18) in the gear shaft (17).

M6.0-1970-002 TSP 7000 SERIES Crown 2012 PF25712-2

506
 STEERING
STEERING FEEDBACK

3. From the bottom of the gears, put a 3 mm diameter

pin or drill bit in the slots.
Note: The pin or drill bit keeps the gears in position.
4. Install the washers (13) and bearing (12) on the
gear shaft (17).
5. Put the gear shaft (17) through the hole in the
mounting plate (22).
6. Turn the gears until the tapped hole in the gear
shaft (17) points to the back of the truck.
7. Adjust the steering feedback gears to correctly en-
gage the drive unit gears.
Note: After installation, the feedback gears must be in
the center or a small distance above the center of the
drive unit gears.
8. Install the correct number flatwashers (10, 11) to
keep the correct adjustment.
9. Install the retaining ring (9).
10. Remove the 3 mm diameter pin or drill bit from the
gears.
To install the steering feedback encoder (ECR6)
1. Install ECR6 (3) and the retainer (4).
2. Connect the spring (7) to the retainer (4).
3. Tighten the set screw (18) in the gear shaft (17).
Note: Make sure that you tighten the set screw on the
flat part of the encoder shaft.
4. Connect CA410 (21).
5. Install the cover (1).

CAUTION
If you do not calibrate the steering feedback en-
coder, the truck can steer incorrectly and cause in-
jury or equipment damage.
If you do not calibrate the encoder, the steering feed-
back encoder can input the incorrect steering angle to
ACCESS 5.
 Calibrate the steering feedback encoder (ECR6).
Refer to
ELECTRICAL>Access 1 2 3®>Calibration>C4
Steer Encoder.

6. Calibrate ECR6. Refer to

ELECTRICAL>Access 1 2 3®>Calibration>C4
Steer Encoder.

Crown 2012 PF25712-3 TSP 7000 SERIES M6.0-1970-003

507
STEERING
STEER MOTOR

Steer Motor
Replacing the Steer Motor Brushes
Specifications
• When the brushes measure 6.4 mm, replace them.
• Replace the brush springs and brushes at the same
time.
To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent the
movement of the truck.
5. Disconnect the battery.
6. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
7. Remove the rear, center door on the power unit.
To remove the steer motor brushes
1. Remove the brush cover (1) from the steer motor.
Refer to Figure 382.

Fig. 382 (27204)

2. Remove and discard the brushes (1) and springs.
Refer to Figure 383.

M6.0-1970-100 TSP 7000 SERIES Crown 2012 PF25713-1

508
 STEERING
STEER MOTOR

To remove the steer motor

1. Record the position of the motor terminals (1). Re-
fer to Figure 384.

Fig. 383 (27205)

3. Use low pressure air and remove all contamination
from the motor.
4. Examine the steer motor armature for:
• Wear
• Raised bars
• Burned bars.
To install the steer motor brushes
1. Install the brushes and springs.
2. Install the brush cover on the steer motor.
3. Install the power unit door. Fig. 384 (27206)
4. Examine the truck operation. 2. Disconnect the electrical cables (1) from the motor.
Steer Motor Replacement 3. Remove the four M8 locknuts (2).
4. Remove the steer motor (3) and gearbox (4) as-
To prepare the truck sembly.
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent the
movement of the truck.
5. Disconnect the battery.
6. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
7. Remove the rear, center door on the power unit.

Crown 2012 PF25713-2 TSP 7000 SERIES M6.0-1970-101

509
STEERING
STEER MOTOR
5. Remove the isolator (1) from the gearbox. Refer to
Figure 385.
2
4
1
3 ion (3) on the bottom of the gearbox. Refer to
Fig. 385 (27207)
6. Remove the four screws (2) that hold the steer mo-
tor to the gearbox.
Note: After you remove the motor, make sure that you
do not tilt the gearbox. If you do, the components could
fall out of the gearbox.
7. Remove the steer motor from the gearbox.
Note: Examine the gearbox components for wear and
damage. Make sure that the gearbox components are
lubricated. Use 063002-022 gear grease to lubricate
the components.
Examine the steer motor and gearbox assembly
studs
Examine the studs that hold the steer motor and gear-
box assembly to the mounting plate. If they are loose,
replace them. Trucks with a serial number 1A382745
or less have 50 mm long studs. Replace the 50 mm
studs, with 55 mm long studs and isolation bushings.
All replacement studs are 55 mm long. Refer to Drive
Unit Parts for the part numbers.
To install the studs and bushings
1. Clean the threads on the studs and in the mounting
plate.
2. Apply 061004-019 thread-locking adhesive (blue)
on the end of the stud that assembles to the mount-
ing plate.
M6.0-1970-102 TSP 7000 SERIES
510
3. Torque the studs to 33 Nm.
4. Install the isolation bushings (4) in the gearbox.
Refer to Figure 385.
To install the steer motor
1. Install the steer motor on the gearbox.
2. Align the screw holes for the steer motor with the
gearbox holes.
3. Clean the threads of the four screws that hold the
steer motor to the gearbox.
4. Apply 061004-026 thread-locking adhesive (red) to
the threads.
5. Install the screws. Torque the screws to 5.5 Nm.
6. Install the isolator (1) on the gearbox. Refer to
Figure 385.
To install the steer motor and gearbox
1. Apply 063002-022 gear grease to the steering pin-
Figure 385.
2. Apply 063002-022 gear grease to the gear below
the mounting plate that the steering pinion en-
gages.
3. Install the steer motor and gearbox assembly on
the mounting plate.
Note: Make sure that the motor terminals are in the
correct position.
4. Assemble the four M8 locknuts that hold the motor
and gearbox on the studs.
5. Trucks with a serial number 1A382745 or less
have grade 8.8, 50 mm long studs. Torque the
locknuts 23 Nm.
– Trucks with a serial number 1A382746 or more
have grade 10.9 55 mm long studs. Torque the
locknuts to 33 Nm.
6. Attach the electrical cables to the motor terminals.
Torque the terminal nuts to 4.5 Nm.
7. Install the door on the power unit.
8. Examine the truck operation.
Crown 2012 PF25713-3
 STEERING
STEERING GEARBOX

Steering Gearbox 2. Disconnect the electrical cables (1) from the motor.
3. Remove the four M8 locknuts (2).
Steering Gearbox Replacement 4. Remove the steer motor (3) and gearbox (4) as-
sembly.
To prepare the truck
5. Remove the isolator (1) from the gearbox. Refer to
1. Move the truck to a maintenance area with a level Figure 387.
floor.
2. Fully lower the forks.
3. Turn the truck OFF.
4. Put chocks against the wheels to prevent the 2
movement of the truck.
5. Disconnect the battery. 4
6. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.
7. Remove the rear, center door on the power unit.
To remove the steer motor and gearbox assembly
1. Record the position of the motor terminals (1). Re-
fer to Figure 386.
1

Fig. 387 (27207)

6. Remove the four screws (2) that hold the steer mo-
tor to the gearbox.
7. Remove the steer motor from the gearbox.

Fig. 386 (27206)

Crown 2012 PF25714-1 TSP 7000 SERIES M6.0-1970-200

511
STEERING
STEERING GEARBOX

To prepare the replacement steering gearbox for 2. Apply 061004-019 thread-locking adhesive (blue)
installation on the end of the stud that assembles to the mount-
1. Put the replacement steering gearbox (1) in an up ing plate.
position. Refer to Figure 388. 3. Torque the studs to 33 Nm.
4. Install the isolation bushings (4) in the gearbox.
Refer to Figure 387.
3 To install the steer motor and gearbox
4 1. Install the isolator (1) on the gearbox. Refer to
2
Figure 389.

1
2
Fig. 388 (27212)
Note: After you remove the shipping cover, do not tilt 4
the gearbox. If you do, the components could fall out of
the gearbox.
2. Remove the nuts (2) from the screws (3) that hold
the motor to the gearbox.
3. Remove the shipping cover (4) from the gearbox
(1).
Note: Make sure that the gearbox components are lu- 1
bricated. Use 063002-022 gear grease to lubricate the
components.
To assemble the steer motor to the steering gear- 3
box
1. Install the steer motor on the gearbox.
2. Align the screw holes for the steer motor with the
gearbox holes.
3. Clean the threads of the four screws that hold the Fig. 389 (27207)
steer motor to the gearbox.
2. Apply 063002-022 gear grease to the steering pin-
4. Apply 061004-026 thread-locking adhesive (red) to
ion (3) on the bottom of the gearbox.
the threads.
3. Apply 063002-022 gear grease to the gear below
5. Install the screws. Torque the screws to 5.5 Nm
the mounting plate that the steering pinion en-
(4 ft lb).
gages.
Examine the steer motor and gearbox assembly 4. Install the steer motor and gearbox assembly on
studs the mounting plate.
Examine the studs that hold the steer motor and gear- Note: Make sure that the motor terminals are in the
box assembly to the mounting plate. If they are loose, correct position.
replace them. Trucks with a serial number 1A382745
5. Assemble the four M8 locknuts that hold the motor
or less have 50 mm long studs. Replace the 50 mm
and gearbox on the studs.
studs, with 55 mm long studs and isolation bushings.
All replacement studs are 55 mm long. Refer to Drive
Unit Parts for the part numbers.
To install the studs and bushings
1. Clean the threads on the studs and in the mounting
plate.

M6.0-1970-201 TSP 7000 SERIES Crown 2012 PF25714-2

512
 STEERING
STEERING GEARBOX

6. Trucks with a serial number 1A382745 or less

have grade 8.8, 50 mm long studs. Torque the
locknuts 23 Nm.
– Trucks with a serial number 1A382746 or more
have grade 10.9, 55 mm long studs. Torque the
locknuts 33 Nm.
7. Attach the electrical cables to the motor terminals.
Torque the terminal nuts to 4.5 Nm.
8. Install the door on the power unit.
9. Examine the truck operation.

Crown 2012 PF25714-3 TSP 7000 SERIES M6.0-1970-202

513
Notes:

514
LIFTING MECHANISM
515
Notes:

516
 LIFTING MECHANISM
MAST

Mast ondary lift cylinder continues to raise the second and

third stage masts to the full lift height of the truck. As
the secondary lift cylinder raises the second stage
TN (Telescopic No Free Lift) Mast mast the secondary lift chains raise the third stage
The TN mast is a two-stage mast with a single lift cylin- mast.
der assembly. The mast chains are attached to the op-
erator compartment and are routed over a chain roller New Truck Installation Procedures
in the tip-out assembly at the top of the mast. The
If it is necessary to install the mainframe to the power
chains are attached to chain anchors at the top of the
unit on your truck, refer to the instructions that follow.
mainframe.
When you operate the raise function of the truck, the
mast and the platform raise at the same time to the full
lift height of the truck.
WARNING
A truck or mast that falls can cause injury or death.
TF (Telescopic Full Free Lift) Mast If the capacity of the lift device, straps or chains, or
The TF mast is a two-stage mast with twin primary lift hardwood blocks cannot hold the mainframe, platform,
cylinders on the mainframe and a secondary lift cylin- and load handler weight, the truck could fall.
der on the second stage mast. The lift chains are at- • A TF or TN mainframe and platform assembly
tached to chain anchors on the operator compartment. weighs as much as 5300 kg.
They are routed over a chain roller at the top of the • A TT mainframe and platform assembly weighs as
secondary lift cylinder and then through the yoke as- much as 7300 kg.
sembly of the primary lift cylinder. The chains are at-
tached to chain anchors at top of the tip-out assembly • The load handler and platform weigh approximately
on the second stage mast. 2300 kg.
When you operate the raise function of the truck, the  Make sure that the lift device, straps or chains and
primary lift cylinders extend fully and raise the operator hardwood blocks can safely hold the weight.
compartment to the top of the collapsed mast. Then,  Use equipment with sufficient capacity to connect
the secondary lift cylinder continues to raise the sec- the straps or chains safely.
ond stage mast to the full lift height of the truck.
Special Tools and Equipment:
TT (Triple Telescopic Full Free Lift) • Lift device that can safely handle the mast assem-
Mast bly and platform.
The TT mast has two primary lift cylinders (left hand
and right hand) that are attached to the third stage
mast. A lift chain is attached to the chain anchor near
the top of each primary lift cylinder. The lift chain is
routed through the applicable yoke assembly, one at
the top of each primary lift cylinder. Then it is attached
to chain anchor on the bottom of the platform.
The TT also has a secondary lift cylinder attached to
the mainframe and the top of the second stage mast. A
second pair of lift chains is attached to chain anchors
at the top of the mainframe. These chains are routed
through a set of rollers at the top of the second stage
mast. Then the chains are attached to chain anchors at
the bottom of the third stage mast.
When you operate the raise function of the truck, the
primary lift cylinders extend fully. As the primary lift cyl-
inders extend, the primary lift chains raise the operator
compartment to the top of the collapsed mast. As the
operator compartment goes near the top of the col-
lapsed mast, it touches a pair of stops. Then, the sec-

Crown 2012 PF25723-1 TSP 7000 SERIES M7.0-1970-001

517
LIFTING MECHANISM
MAST

Put the power unit and mainframe in position
1. Put chocks (2) against the load wheels to prevent
the movement of the mainframe. Refer to
Figure 390.
10. Install the flatwashers (6) and nuts (7) on the top
mounting bolts (4), but do not tighten them at this
time.
11. Install the bottom six mounting bolts (8) and flat-
washers (9).
 The head of the bolt must point in the direction of
the power unit.
12. Install the flatwashers (10) and nuts (11) on mount-
ing bolts (8), but do not tighten them at this time.

Fig. 390 (13036-02)

2. Attach the lift device to the shipping brackets at the
top and the bottom of the mainframe.
3. Carefully lift the mainframe and platform assembly
until the mast is in a vertical position.
4. Put blocks (1) below the mainframe. Refer to Fig. 391 (20932-01)
Figure 390. 1 060131-007, 3 mm thick
 Make sure that the blocks keep the mast from go- 2 060131-006, 6 mm thick
ing beyond a vertical position. 3 060131-008, 1.8 mm thick
5. Align the power unit with the mainframe and plat-
form.
6. Put blocks below the power unit.
7. Put chocks against the drive tire to prevent the
movement of the power unit.
Install the mounting hardware
8. Install the top two mounting bolts (4) and two flat-
washers (5). Refer to Figure 391.
 The head of the bolt must point in the direction of
the power unit.
9. Install the correct number and dimension of flat-
washers (1, 2, 3) between the power unit and the
mainframe.
Note: The factory sends the correct dimension and
quantity of shims for the mast back tilt. Make sure that
you install the shims in the correct locations.

M7.0-1970-002 TSP 7000 SERIES Crown 2012 PF25723-2

518
 LIFTING MECHANISM
MAST

13. In the correct sequence, torque the mounting bolts
to 305 Nm. Refer to Figure 392.
14. Then, in the correct sequence, torque the mount-
ing bolts to 435 Nm.
15. Then, in the correct sequence, make sure that
each bolt has the correct torque of 435 Nm.
29. Install the covers that were shipped loose with the
truck.
30. Make sure that all of the truck functions are correct.
Second Stage Mast Removal and In-
stallation - TF and TN
Dependent on the overhead clearance, you can re-
move the second stage mast with the mainframe in the
vertical position or with the mainframe in the horizontal
position. Complete the applicable procedures for your
location.

WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
Fig. 392 (20933-01)
• The load handler and platform weigh approximately
Prepare the hydraulics and electronics 2300 kg.
16. Connect the electrical connections from the power  Make sure that the lift device, straps or chains and
unit to the mainframe. Refer to WIRING DIA- hardwood blocks can safely hold the weight.
GRAMS.
 Use equipment with sufficient capacity to connect
17. Connect the manual lowering valve cable from the the straps or chains safely.
platform to the manual lowering valve.
18. Close MVL.
19. Remove non-vented shipping cap from the reser-
voir.
20. Install the filler/breather dipstick that was shipped
(loose) with the truck.
21. Keep the non-vented shipping cap to use again as
necessary.
Prepare the truck for operation
22. Remove the lift device from the shipping bracket
and the mainframe.
23. Remove the shipping bracket from the top of the
mast.
24. Keep the shipping bracket and hardware to use
again as necessary.
25. Install the battery.
26. If necessary, install the platform on mainframe. Re-
fer to PLATFORM > Platform > Platform Assembly.
27. If necessary, install the load handler.
28. Connect the battery.

Crown 2012 PF25723-3 TSP 7000 SERIES M7.0-1970-003

519
LIFTING MECHANISM
MAST
Second Stage Mast Removal without Suffi-
cient Overhead Clearance
Special Tools and Equipment:
• Lift device that can safely handle the mast assem-
bly and platform.
Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
Note: Make sure that there is sufficient space to fully
extend the second stage mast when it is horizontal.
2. Lower the mast fully.
3. Put chocks against the wheels to prevent the
movement of the truck and mainframe. Refer to
SAFETY > Control of Hazardous Energy > Lifting
and Blocking.
4. Disconnect the battery.
5. Complete the lockout/tagout procedures for the
truck. Refer to SAFETY > Control of Hazardous
Energy > Lockout/Tagout.
6. Open the manual lowering valve. Refer to SAFETY
> Control of Hazardous Energy > Hydraulic.
7. Put blocks below the mainframe (1) to make sure
that it is stable when you remove it from the power
unit. Refer to Figure 393.
8. Put blocks below the power unit (2) to make sure
that it cannot fall to the floor when you remove it
from the mainframe.
9. Put chocks (3) against the load wheels to prevent
the movement of the mainframe.
Fig. 393 (13039-02)
M7.0-1970-004 TSP 7000 SERIES
520
Remove the primary truck components
10. Remove the power unit doors and covers.
11. Remove load handler assembly.
12. Remove the platform from mainframe. Refer to
PLATFORM > Platform > Platform Removal.
13. Remove the primary lift cylinders from the main-
frame. Refer to the applicable section in CYLIN-
DERS.
14. Remove the battery.
Prepare the hydraulics and electrical connections
15. Replace the filler/breather dipstick on the reservoir
with the non-vented cap that was shipped with the
truck. Make sure that the cap is tight.
Note: If the non-vented cap is not available, then drain
the hydraulic reservoir.
16. Record the location of the wire termination points
of all electrical connections that prevent the sepa-
ration of the power unit and mainframe.
17. Disconnect the electrical connections that prevent
the separation of the power unit and the main-
frame.
18. If equipped, remove the harness that goes to the
height cable switch.
19. Record the power cable locations on the hydraulic
pump motor (M2).
20. Remove the power cables from the hydraulic pump
motor (M2).
21. On trucks equipped with wire guidance, record the
termination points for the harness from the sensor
bar at the front of the mainframe.
22. Remove the harness from the sensor bar at the
front of the mainframe.
23. To prevent damage, use cable ties to hold the dis-
connected harnesses to the mainframe.
Separate the power unit and the mainframe
24. Record the dimensions, quantities, and location of
the flatwashers (1, 2, 3) between the mainframe
and the power unit. Refer to Figure 391.
Note: This information is necessary to get the correct
back tilt of the mainframe when you assemble the
mainframe to the power unit.
25. Remove the eight bolts (4, 8) that hold the main-
frame to the power unit.
26. Make sure that all cables and hydraulic plumbing
between the power unit and the mainframe were
disconnected.
27. Carefully separate power unit and mainframe.
Crown 2012 PF25723-4

Lower the mainframe
28. Use the installation hardware supplied with the
shipping bracket to install the shipping bracket on
the top of the second stage mast. Refer to
Figure 394.
 The shipping bracket also holds the second stage
mast to the mainframe.
Fig. 394 (13040-02)
1 Shipping Bracket TF & TN (109431)
2 Two screws (060023-022)
Two lockwashers (060006-023)
Two flatwashers (060030-054)
3 Two roll pins (060000-022)
4 Pin (092832)
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
Crown 2012 PF25723-5 TSP 7000 SERIES
LIFTING MECHANISM
MAST
29. Attach the lift device to the shipping bracket and to
the bottom of the mainframe.
Note: Make sure that the lift device has sufficient ca-
pacity and dimensions to safely move the mainframe.
You must use extreme precaution during this proce-
dure.
WARNING
A mainframe or mast assembly that falls can cause
injury or death.
If the load wheel chocks are not in the correct position,
the mainframe or mast assembly could move or fall.
 Make sure that the load wheel chocks stay in place
throughout this procedure.
30. Make sure that the load wheel chocks (1) stay in
the correct position to prevent the movement of the
mainframe. Refer to Figure 395.
31. Carefully tilt the mainframe to the horizontal posi-
tion.
 As the mainframe and mast assembly becomes
horizontal, use a sufficient support (2) to hold the
mainframe.
Fig. 395 (13041-02)
32. Disconnect lift device from the shipping bracket at
top of second stage mast and the bottom of the
mainframe.
33. Remove the shipping bracket.
Remove the second stage mast
34. Remove the two covers (1) from the second stage
mast. Refer to Figure 396.
35. Remove the stop blocks (2) from the mainframe.
M7.0-1970-005
521
LIFTING MECHANISM
MAST

WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.

36. Attach a lift device and sling or chain to the second

stage mast. Crown recommends that you use a
spreader bar or other configuration that balances
the weight. Refer to Figure 397.

Fig. 397 (13043-02)

Note: Make sure you attach the lift device in a manner
that prevents the mast from falling when it passes the
end of the mainframe I-beam. Also make sure that it
prevents the shift of the mast or mainframe.
37. Lift the mast assembly only a sufficient height that
the second stage does not touch the support.
38. Carefully move the second stage mast toward the
top of the mainframe.
Fig. 396 (13042-02)

M7.0-1970-006 TSP 7000 SERIES Crown 2012 PF25723-6

522

39. As the mainframe and second stage mast are near
full extension, move the support below the main-
frame. Refer to Figure 398.
 If necessary, put supports below the mast and then
lower the mast and move the lift device to make
sure that the weight is applied equally.
Fig. 398 (13044-02)
40. Continue to move the second stage mast to the top
of the mainframe.
41. As necessary, remove the mast chains, hydraulic
plumbing, and electrical cables from the mast as-
sembly.
 Record the location of parts attached to the second
stage and mainframe.
42. Carefully move the second stage mast to the floor
or onto supports while you do repairs to the main-
frame or second stage mast.
Crown 2012 PF25723-7 TSP 7000 SERIES
LIFTING MECHANISM
MAST
Second Stage Mast Removal with Suffi-
cient Overhead Clearance
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
Special Tools and Equipment:
• Lift device that can safely handle the mast assem-
bly and platform.
M7.0-1970-007
523
LIFTING MECHANISM
MAST

Prepare the truck

1. Move the truck to a maintenance area with a level
floor.
2. Lower the mast fully.
3. Put chocks against the wheels to prevent the
movement of the truck. Refer to SAFETY > Control
of Hazardous Energy > Lifting and Blocking.
4. Disconnect the battery.
5. Complete the lockout/tagout procedures for the
truck. Refer to SAFETY > Control of Hazardous
Energy > Lockout/Tagout.
6. Open the manual lowering valve.
Remove the primary truck components
7. Remove the lift cylinders from the mainframe. Re-
fer to the applicable section in CYLINDERS.
8. Remove the two covers (2) from the second stage
mast. Refer to Figure 399.
9. Remove the stop blocks (1) from the mainframe.

Fig. 399 (13042-02)

M7.0-1970-008 TSP 7000 SERIES Crown 2012 PF25723-8

524
 LIFTING MECHANISM
MAST

Remove the second stage mast Special Tools and Equipment:

WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
10. Attach the lift device to the second stage mast.
Note: Make sure that the lift device has sufficient ca-
pacity and dimensions to safely move the second stage
mast. You must use extreme precaution during this
procedure.
11. Carefully move the second stage mast to the floor
or onto supports while you do repairs to the main-
frame or second stage mast.
• Lift device that can safely handle the mast assem-
bly and platform
• Pin tool.
Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
Note: Make sure that there is sufficient space to fully
extend the mast when it is horizontal.
2. Lower the mast fully.
3. Put chocks against the wheels to prevent the
movement of the truck and mainframe. Refer to
SAFETY > Control of Hazardous Energy > Lifting
and Blocking.
4. Disconnect the battery.
5. Complete the lockout/tagout procedures for the
truck. Refer to SAFETY > Control of Hazardous
Energy > Lockout/Tagout.
6. Open the manual lowering valve. Refer to SAFETY
> Control of Hazardous Energy > Hydraulic.
7. Put blocks (1) below the mainframe to make sure
that it is stable when you remove it from the power
unit. Refer to Figure 400.
8. Put blocks below the power unit (2) to make sure
that it cannot fall to the floor when you remove it
from the mainframe.

Second and Third Stage Mast Re-

moval - TT

WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains and Fig. 400 (13039-02)
hardwood blocks can safely hold the weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.

Crown 2012 PF25723-9 TSP 7000 SERIES M7.0-1970-009

525
LIFTING MECHANISM
MAST

Remove the primary truck components
9. Remove the power unit doors and covers.
10. Remove load handler assembly.
11. Remove the platform from mainframe. Refer to
PLATFORM > Platform > Platform Removal.
12. On the chain anchors at the bottom of the third
stage mast, loosen the nuts (1) until the bottom
nuts (2) touch the cotter pins (3). Do not remove
the chain anchors. Refer to Figure 401.
 This relieves the chain tension from the springs at
the top of the mainframe.
19. Remove the power cables from the hydraulic pump
motor (M2).
20. On trucks equipped with wire guidance, record the
termination points for the cable from the sensor bar
at the front of the mainframe.
21. Remove the cable from the sensor bar at the front
of the mainframe.
22. To prevent damage, use cable ties to hold the dis-
connected cables to the mainframe.
Separate the power unit and the mainframe
23. Record the dimensions, quantities, and location of
the flatwashers (1, 2, 3) between the mainframe
and the power unit. Refer to Figure 402.
Note: This information is necessary to get the correct
back tilt of the mainframe when you assemble the
mainframe to the power unit.
24. Remove the eight bolts (4, 8) that hold the main-
frame to the power unit.

Fig. 401 (20985-01)

13. Remove the primary lift cylinders from the third
stage mast. Refer to the applicable section in CYL-
INDERS.
14. Remove the battery.
Disconnect the hydraulics and electrical connec-
tions
15. Replace the filler/breather dipstick on the reservoir Fig. 402 (20932-01)
with the non-vented cap that was shipped with the 1 060131-007, 3 mm thick
truck. Make sure that the cap is tight.
2 060131-006, 6 mm thick
Note: If the non-vented cap is not available, then drain 3 060131-008, 1.8 mm thick
the hydraulic reservoir
16. Record the location of the wire termination points 25. Make sure that all cables and hydraulic plumbing
of all electrical connections that prevent the sepa- between the power unit and the mainframe were
ration of the power unit and mainframe. disconnected.
17. Disconnect the electrical connections that prevent 26. Carefully separate power unit and mainframe.
the separation of the power unit and the main-
frame.
18. Record the power cable locations on the hydraulic
pump motor (M2).

M7.0-1970-010 TSP 7000 SERIES Crown 2012 PF25723-10

526

Lower the mainframe
27. Use the installation hardware supplied with the
shipping bracket to install the shipping bracket on
the top of the mast. Refer to Figure 403.
 The shipping bracket also holds the second and
third stage mast to the mainframe.
Fig. 403 (20986-01)
1 Shipping Bracket - TT (143043)
2 Pin (092832)
3 Two roll pins (060000-022)
4 Two bolts (060099-006)
Two flatwashers (060131-005)
Crown 2012 PF25723-11 TSP 7000 SERIES
LIFTING MECHANISM
MAST
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, or
hardwood blocks cannot hold the mainframe, platform,
and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
28. Attach the lift device to the shipping bracket and to
the bottom of the mainframe.
Note: Make sure that the lift device has sufficient ca-
pacity and dimensions to safely move the mainframe.
You must use extreme precaution during this proce-
dure.
WARNING
A mainframe or mast assembly that falls can cause
injury or death.
If the load wheel chocks are not in the correct position,
the mainframe or mast assembly could move or fall.
 Make sure that the load wheel chocks stay in place
throughout this procedure.
29. Make sure that the load wheel chocks (1) stay in
the correct position to prevent the movement of the
mainframe. Refer to Figure 404.
30. Carefully tilt the mainframe to the horizontal posi-
tion.
 As the mainframe and mast assembly becomes
horizontal, use a sufficient support (2) to hold the
mainframe.
M7.0-1970-011
527
LIFTING MECHANISM
MAST

Fig. 404 (20987-01)
31. Disconnect lift device from the shipping bracket at
top of second stage mast and the bottom of the
mainframe. Do not remove the shipping bracket at
this time.
32. Insert the pin tool (1) through the hole at the top of
the second stage mast and through the hole in the
mainframe. Refer to Figure 405.
 This prevents the movement of the mainframe and
the second stage mast.
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, sup-
ports, or hardwood blocks cannot hold the mainframe,
platform, and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains, sup-
ports and hardwood blocks can safely hold the
weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
33. Attach a lift device and sling or chain to the third
stage mast. Refer to Figure 406.
Note: Make sure that you attach the lift device correctly
to prevent the mast from falling when it goes beyond
the end of the mainframe I-beam. Also make sure that
it prevents the movement of the mast or mainframe.
Crown recommends that you use a spreader bar or
other configuration that balances the weight.
34. Carefully extend the third stage mast 335 mm.
35. Set the mast down on the support.

Fig. 405 (20988-01)

Fig. 406 (20989-01)

Remove the shipping bracket
36. Loosen one bolt ½ to one full revolution.
37. Loosen the bolt opposite the first bolt ½ to one full
revolution.

M7.0-1970-012 TSP 7000 SERIES Crown 2012 PF25723-12

528
 LIFTING MECHANISM
MAST

38. Do Steps 36 and 37 again until there is no more

tension on the shipping bracket.
39. Remove the shipping bracket.
Disconnect the hydraulics and electrical connec-
tions
40. Remove the bottom cover from the mainframe.
41. Apply labels to identify the hoses and tubes on the
mainframe.
42. Disconnect the hydraulic fittings. Refer to
Figure 407.
43. Remove the hydraulic hoses and tubes from the
mainframe.
44. Install caps on the hydraulic hoses and tubes.

Fig. 408 (20991)

Fig. 407 (20990-01)
45. Remove connectors JC412, JC413, and JC414
from the attachment clip. Refer to Figure 408.
46. Record the positions of the wires in JC412 and
JC413. Apply labels to identify the control cables.
47. Remove the wires and pins from JC412 and
JC413.
Remove the control cables and hoses
48. Remove the control cables from the bracket and let
them hang down at the bottom of the mainframe.
49. Remove the cover at the top portion of the third
stage mast.
50. Remove the shipping bracket from the top of the
mast.
51. Use the access hole where you removed the cover
in Step 47. Remove the springs (2) on the control
cables (3) from the bracket (4). Refer to
Figure 409.
52. Remove the springs (2) from the cable clamps (1).

Fig. 409 (20992-01)

Crown 2012 PF25723-13 TSP 7000 SERIES M7.0-1970-013

529
LIFTING MECHANISM
MAST

53. Make a mark (1) to identify the position of the large

hydraulic hose. Refer to Figure 410.
54. Use this mark to align the hose and to prevent twist
when you assemble it again.

Fig. 412 (20995-01)

Fig. 410 (20993-01)
55. Disconnect the large hydraulic hose.
56. Install a plug and cap on the hose and tube to pre-
vent contamination.
57. From the top of the mast, write numbers on the hy-
draulic hoses and control cables to identify them.
Refer to Figure 411.
59. Pull the loose ends of the hydraulic hoses and con-
trol cables out of the top of the mast. Let them hang
on the floor.
60. Move the hoses and cables apart to make separa-
tion and to prevent entanglement when you re-
move the mast sections.
Remove the hose pulley assembly
61. Loosen the bolt (1) on each side of the hose pulley
assembly.
62. Record the quantity and location of the shims (2).
Refer to Figure 413.
63. Remove the shims.
64. Remove the bolts and hose pulley assembly from
the mast.

Fig. 411 (20994)

58. Remove the two shafts (1) on the hose pulley as- Fig. 413 (20996-01)
sembly at the top of the second stage mast.

M7.0-1970-014 TSP 7000 SERIES Crown 2012 PF25723-14

530
 LIFTING MECHANISM
MAST

Remove the lift chains and chain pulley support

65. Remove the chain slack assembly from the top of
the mainframe.
66. Remove the roll pins and dowel pins that hold the
lift chains to the top of the mainframe. Do not re-
move or loosen the nuts on the chain anchors. Re-
fer to Figure 414.

Fig. 415 (20998-01)

Fig. 414 (20997)
67. Remove the chains from the chain anchors.
68. Put the chains down through the chain pulley sup-
port at the top of the second stage mast. Let the
chains hang out of the end of the mast.
69. Remove the chain pulley support from the top of
the second stage mast.
Loosen the thrust rollers
70. At the top of the second stage mast, make a mark
(3) to identify the location of the two thrust roller
shafts (1). Refer to Figure 415.
71. Remove the bolts (2) and turn each thrust roller
shaft (1) to the loosest position.
72. Install the two bolts to hold the thrust roller shafts
in position.
73. At the bottom of the third stage mast, make a mark
to identify the location of the thrust roller cam
shafts.
74. Remove the bolts and turn each thrust roller shaft
to the loosest position.
75. Install the two bolts to hold the thrust roller shafts
in position.
Remove the third stage mast
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, sup-
ports, or hardwood blocks cannot hold the mainframe,
platform, and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains, sup-
ports and hardwood blocks can safely hold the
weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.

Crown 2012 PF25723-15 TSP 7000 SERIES M7.0-1970-015

531
LIFTING MECHANISM
MAST

76. Attach a lift device and sling or chain to the third
stage mast.
Note: Make sure that you attach the lift device correctly
to prevent the mast from falling when it goes beyond
the end of the mainframe I-beam. Also make sure that
it prevents the movement of the mast or mainframe.
Crown recommends that you use a spreader bar or
other configuration that balances the weight.
77. Remove the mast stops. Refer to Figure 416.
78. Lift the mast assembly only a sufficient quantity
that the third stage does not touch the support.
79. Make sure that the pin tool continues to hold the
mainframe and second stage together.
80. Carefully move the third stage mast toward the top
of the mast.
81. When the third stage is 1 m (3 ft) from the end of
the mast, put the support below the second stage
mast, immediately before the third stage mast. Re-
fer to Figure 417.

Fig. 416 (20999-01)

Fig. 417 (21000-01)

82. While you continue to hold the third stage mast

with the lift device, lower the second stage mast
and mainframe onto the support.
83. Put four 100 x 100 mm hardwood blocks (1) in po-
sition on the floor to hold the third stage mast when
you remove it from the truck. Refer to Figure 418.
 On each end, put one hardwood block on top of a
second to hold up the third stage mast and to pre-
vent damage to the hydraulic fittings.

Fig. 418 (21001-01)

M7.0-1970-016 TSP 7000 SERIES Crown 2012 PF25723-16

532

84. Use the lift device and sling to remove the third
stage mast from the mast assembly. Make sure
that the control cables, hydraulic hoses, and
chains do not become caught with the remaining
mast assembly.
85. Put the third stage mast on the hardwood blocks.
Loosen the thrust rollers
86. Install the lift device and sling on the second stage
mast.
Note: Make sure that you attach the lift device correctly
to prevent the mast from falling when it goes beyond
the end of the mainframe I-beam. Also make sure that
it prevents the movement of the mast or mainframe.
Crown recommends that you use a spreader bar or
other configuration that balances the weight.
87. Remove the pin tool from the mast.
88. At the bottom of the second stage mast, make a
mark (3) to identify the location of the two thrust
roller shafts (1). Refer to Figure 419.
89. Remove the bolts (2) and turn each thrust roller
shaft (1) to the loosest position.
Fig. 419 (20998-01)
90. Install the two bolts to hold the thrust roller shafts
in position.
91. At the top of the mainframe, make a mark to iden-
tify the location of the thrust roller cam shafts.
92. Remove the bolts and turn each thrust roller shaft
to the loosest position.
93. Install the two bolts to hold the thrust roller shafts
in position.
Crown 2012 PF25723-17 TSP 7000 SERIES
LIFTING MECHANISM
MAST
Remove the second stage mast
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, sup-
ports, or hardwood blocks cannot hold the mainframe,
platform, and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains, sup-
ports and hardwood blocks can safely hold the
weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
94. Lift the mast assembly only a sufficient quantity
that the second stage does not touch the support.
95. Carefully move the second stage mast toward the
top of the mainframe.
96. When the second stage is 1 m from the end of the
mainframe, put the support below the mainframe,
immediately before the second stage mast.
97. While you continue to hold the second stage mast
with the lift device, lower the mainframe onto the
support.
98. Put two 100 x 100 mm hardwood blocks in position
on the floor to hold the second stage mast when
you remove it from the truck.
99. Put the second stage mast on the hardwood
blocks.
M7.0-1970-017
533
LIFTING MECHANISM
MAST

Second Stage Mast Installation - TF
and TN
Second Stage Mast Installation without
Sufficient Overhead Clearance
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, sup-
ports, or hardwood blocks cannot hold the mainframe,
platform, and load handler weight, the truck could fall.
 A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
 A TT mainframe and platform assembly weighs as
much as 7300 kg.
 Make sure that the lift device, straps or chains, sup-
ports, and hardwood blocks can safely hold the
weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
Install the second stage mast
1. Attach a lift device and sling or chain to the second
stage mast.
Note: Make sure that the lift device prevents the move-
ment of the mast or mainframe. Crown recommends
that you use a spreader bar or other configuration that
balances the weight. Refer to Figure 420.
WARNING
A mainframe or mast assembly that falls can cause
injury or death.
If the load wheel chocks or supports are not in the cor-
rect position, the mainframe or mast assembly could
move or fall.
 Make sure that the load wheel chocks and supports
stay in place throughout this procedure.
 Make sure that the lift device prevents the move-
ment of the mast or mainframe.
2. With the load wheel chocks in the correct position
and the supports below the mainframe in the hori-
zontal position, align the second stage mast with
the mainframe.
3. Carefully move the second stage mast onto the
mainframe.

Fig. 420 (13044-02)

4. Install the stop blocks (2) on the mainframe. Refer

to Figure 421.
5. Install the covers (1).

M7.0-1970-018 TSP 7000 SERIES Crown 2012 PF25723-18

534
 LIFTING MECHANISM
MAST

Raise the mainframe and mast assembly

6. Use the installation hardware supplied with the
shipping bracket to install the shipping bracket on
the top of the second stage mast. Refer to
Figure 394.
 The shipping bracket also holds the second stage
mast to the mainframe.
7. Attach the lift device to the shipping bracket and to
the bottom of the mainframe.
Note: Make sure that the lift device has sufficient ca-
pacity and dimensions to safely move the mainframe.
You must use extreme precaution during this proce-
dure.

WARNING
A mainframe or mast assembly that falls can cause
injury or death.
If the load wheel chocks or supports are not in the cor-
rect position, the mainframe or mast assembly could
move or fall.
 Make sure that the load wheel chocks and supports
stay in place throughout this procedure.
 Make sure that the lift device prevents the move-
ment of the mast or mainframe.

8. Carefully lift the mainframe until the mast is in a

vertical position.

Fig. 421 (13042-02)

Crown 2012 PF25723-19 TSP 7000 SERIES M7.0-1970-019

535
LIFTING MECHANISM
MAST

9. Put blocks (1) below the mainframe. Refer to
Figure 422.
 Make sure that the blocks keep the mast from go-
ing beyond a vertical position.
19. Install the bottom six mounting bolts (8) and flat-
washers (9).
 The head of the bolt must point in the direction of
the power unit.
20. Install the flatwashers (10) and nuts (11) on mount-
ing bolts (8), but do not tighten them at this time.

Fig. 422 (13036-02)

10. Remove the lift device from the shipping bracket
and the mainframe.
Fig. 423 (20932-01)
11. Remove the shipping bracket from the top of the 1 060131-007, 3 mm thick
mast.
2 060131-006, 6 mm thick
12. Keep the shipping bracket and hardware to use 3 060131-008, 1.8 mm thick
again as necessary.
Assemble the mainframe to the power unit 21. In the correct sequence, torque the mounting bolts
to 305 Nm. Refer to Figure 424.
13. Align the power unit with the mainframe and plat-
form. 22. Then, in the correct sequence, torque the mount-
ing bolts to 435 Nm.
14. Put blocks below the power unit.
23. Then, in the correct sequence, make sure that
15. Put chocks against the drive tire to prevent the
each bolt has the correct torque of 435 Nm.
movement of the power unit.
16. Install the top two mounting bolts (1) and two flat-
washers (2). Refer to Figure 423.
 The head of the bolt must point in the direction of
the power unit.
17. Install the correct number and dimension of flat-
washers (3, 4, 5) between the power unit and the
mainframe.
Note: The factory sends the correct dimension and
quantity of shims for the mast back tilt. Make sure that
you install the shims in the correct locations.
18. Install the flatwashers (6) and nuts (7) on mounting
bolts (1), but do not tighten them at this time.

M7.0-1970-020 TSP 7000 SERIES Crown 2012 PF25723-20

536
 LIFTING MECHANISM
MAST

Fig. 424 (20933-01)

Install the primary truck components
24. Install the primary lift cylinders onto the mainframe.
Refer to the applicable section in CYLINDERS.
25. Install the mast chains, hydraulic plumbing, and
electrical cables in the mast assembly.
26. Attach the chain (2) to the mast and the cover (1).
Refer to Figure 425.
27. Install the cover on the top of the mast.
Fig. 425 (27325)
28. Install the battery.
29. If you did not drain the reservoir, remove non-
vented shipping cap from the reservoir.
– Install the filler/breather dipstick.
– Keep the non-vented shipping cap to use again
as necessary.
30. If you did drain the reservoir, add hydraulic oil to
the reservoir to the "FULL" line. Refer to HYDRAU-
LIC SYSTEM > Reservoir and Filters > Reservoir.
31. Connect the manual lowering valve cable from the
platform to the manual lowering valve.
32. Close the manual lowering valve. Refer to
SAFETY > Control of Hazardous Energy > Hydrau-
lic.
33. Connect the battery.
34. Install the power unit doors and covers.

Crown 2012 PF25723-21 TSP 7000 SERIES M7.0-1970-021

537
LIFTING MECHANISM
MAST

2. Lift the second stage mast into position above the

WARNING mainframe.
3. Carefully lower the second stage mast onto the
Missing stop blocks or safety devices could cause mainframe.
the mast to fall. 4. Install the stop blocks (2) on the mainframe. Refer
A mainframe or mast assembly that falls can cause in- to Figure 426.
jury or death.
5. Install the covers (1).
 Make sure that all the stop blocks and safety de-
vices are in the correction position before you ex-
tend the mast.

35. Make sure that the stop blocks are in the correct
position.
36. Make sure that all hydraulic and electrical connec-
tions are correct.
37. Install the platform on mainframe. Refer to PLAT-
FORM > Platform > Platform Assembly.
38. Install the load handler assembly.
39. Make sure that all of the truck functions are correct.

Second Stage Mast Installation with Suffi-

cient Overhead Clearance

WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, sup-
ports, or hardwood blocks cannot hold the mainframe,
platform, and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains, sup-
ports, and hardwood blocks can safely hold the
weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.

Install the second stage mast

1. Attach a lift device and sling or chain to the second
stage mast.
Note: Make sure that the lift device has sufficient ca-
pacity and dimensions to safely move the second stage
mast. You must use extreme precaution during this
procedure.

M7.0-1970-022 TSP 7000 SERIES Crown 2012 PF25723-22

538
 LIFTING MECHANISM
MAST

Install the primary truck components

7. Install the primary lift cylinders onto the mainframe.
Refer to the applicable section in CYLINDERS.
8. Install the mast chains, hydraulic plumbing, and
electrical cables in the mast assembly.
9. Attach the chain (2) to the mast and the cover (1).
Refer to Figure 427.
10. Install the cover on the top of the mast.

Fig. 427 (27325)

WARNING
Missing stop blocks or safety devices could cause
the mast to fall.
A mainframe or mast assembly that falls can cause in-
jury or death.
 Make sure that all the stop blocks and safety de-
vices are in the correction position before you ex-
tend the mast.

11. Make sure that the stop blocks are in the correct
Fig. 426 (13042-02) position.
6. Remove the lift device. 12. Make sure that all hydraulic and electrical connec-
tions are correct.

Crown 2012 PF25723-23 TSP 7000 SERIES M7.0-1970-023

539
LIFTING MECHANISM
MAST
13. Connect the battery.
14. Install the platform on mainframe. Refer to PLAT-
FORM > Platform > Platform Assembly.
15. Install the load handler.
16. Make sure that all of the truck functions are correct.
Second and Third Stage Mast Instal-
lation - TT
WARNING
A truck or mast that falls can cause injury or death.
If the capacity of the lift device, straps or chains, sup-
ports, or hardwood blocks cannot hold the mainframe,
platform, and load handler weight, the truck could fall.
• A TF or TN mainframe and platform assembly
weighs as much as 5300 kg.
• A TT mainframe and platform assembly weighs as
much as 7300 kg.
• The load handler and platform weigh approximately
2300 kg.
 Make sure that the lift device, straps or chains, sup-
ports, and hardwood blocks can safely hold the
weight.
 Use equipment with sufficient capacity to connect
the straps or chains safely.
Special Tools and Equipment:
• Lift device that can safely handle the mast assem-
bly and platform
• Pin tool.
Install the second stage mast
1. Attach a lift device and sling or chain to the second
stage mast.
Note: Make sure that the lift device prevents the move-
ment of the mast or mainframe. Crown recommends
that you use a spreader bar or other configuration that
balances the weight.
M7.0-1970-024 TSP 7000 SERIES
540
WARNING
A mainframe or mast assembly that falls can cause
injury or death.
If the load wheel chocks or supports are not in the cor-
rect position, the mainframe or mast assembly could
move or fall.
 Make sure that the load wheel chocks and supports
stay in place throughout this procedure.
 Make sure that the lift device prevents the move-
ment of the mast or mainframe.
2. With the load wheel chocks in the correct position
and the supports below the mainframe in the hori-
zontal position, align the second stage mast with
the mainframe.
Adjust the bottom side thrust rollers on the second
stage mast
3. Use the lift device to put the bottom of the second
stage mast approximately 810–915 mm below the
top of the mainframe.
4. At the bottom of the second stage mast, remove
the bolts on the cams and turn each thrust roller
shaft to the loosest position.
5. Push the column rollers against the stud shoulders
and then, push the second stage mast to one side.
6. Then, measure the distance on each side between
the face of the column roller face and the web of
the I-beam.
7. Add the two measurements.
8. Divide the sum by 2.
9. Put a shim with the same thickness of the result
from Step 8 between the column roller and the web
on one side of the mast.
10. Use a ¾ inch square socket extension to adjust the
cam on the opposite side until the thrust roller
touches the flange of the I-beam.
11. Install the bolt to keep the cam in the correct posi-
tion.
12. Remove the shim from Step 9.
13. Use a ¾ inch square socket extension to adjust the
other cam until the thrust roller touches the flange
of the I-beam.
14. Install the bolt to keep the cam in the correct posi-
tion.
15. Use a grease pencil to put a mark on the side thrust
rollers.
Crown 2012 PF25723-24
 LIFTING MECHANISM
MAST

16. Move the second stage up and down the main-

frame. WARNING
 The thrust rollers must roll 100% of the time.
 The thrust rollers must not make a mark on the A mainframe or mast assembly that falls can cause
mast. injury or death.
If the load wheel chocks or supports are not in the cor-
17. Make adjustments as necessary. rect position, the mainframe or mast assembly could
Adjust the top side thrust rollers on the second move or fall.
stage mast  Make sure that the load wheel chocks and supports
18. Fully retract the second stage mast. stay in place throughout this procedure.
19. At the top of the second stage mast, remove the  Make sure that the lift device prevents the move-
bolts and turn each thrust roller shaft to the loosest ment of the mast or mainframe.
position.
20. Do Steps 5 through 17 to adjust the top thrust roll-
ers.
Install the third stage mast
21. With the second stage mast fully retracted, install
the pin tool to hold it in position. Refer to
Figure 428.

Fig. 428 (20988-01)

22. Attach a lift device and sling or chain to the third
stage mast.
Note: Make sure that the lift device prevents the move-
ment of the mast or mainframe. Crown recommends
that you use a spreader bar or other configuration that
balances the weight. Refer to Figure 429.

Crown 2012 PF25723-25 TSP 7000 SERIES M7.0-1970-025

541
LIFTING MECHANISM
MAST
Fig. 429 (21000-01)
23. Make sure that the load wheel chocks are in the
correct position and the supports are below the
mainframe and second stage mast in the horizon-
tal position.
24. Align the third stage mast with the mainframe and
second stage assembly.
25. Use the lift device to put the third stage mast onto
mainframe and second stage assembly.
26. Put blue thread-locking adhesive on the eight bolts
that hold the mast stop blocks (1) to the second
stage mast. Refer to Figure 430.
27. Install the mast stop blocks (1).
Fig. 430 (20999-01)
Adjust the side thrust rollers on the third stage
mast
28. Use the lift device to extend the third stage mast
until it touches the mast stop blocks.
29. At the bottom of the third stage mast, remove the
bolts on the cams and turn each thrust roller shaft
to the loosest position.
30. Push the column rollers against the stud shoulders
and then, push the third stage mast to one side.
M7.0-1970-026 TSP 7000 SERIES
542
31. Then, measure the distance on each side between
the face of the column roller face and the web of
the I-beam.
32. Add the two measurements.
33. Divide the sum by 2.
34. Put a shim with the same thickness of the result
from Step 33 between the column roller and the
web on one side of the mast.
35. Use a ¾ inch square socket extension to adjust the
cam on the opposite side until the thrust roller
touches the flange of the I-beam.
36. Install the bolt to keep the cam in the correct posi-
tion.
37. Remove the shim from Step 33.
38. Use a ¾ inch square socket extension to adjust the
other cam until the thrust roller touches the flange
of the I-beam.
39. Install the bolt to keep the cam in the correct posi-
tion.
40. Use a grease pencil to put a mark on the side thrust
rollers.
41. Move the third stage up and down the mainframe.
 The thrust rollers must roll 100% of the time.
 The thrust rollers must not make a mark on the
mast.
42. Make adjustments as necessary.
Install the chain pulley support and lift chains
43. Install the chain pulley support on top of the sec-
ond stage mast.
44. Torque the bolts to 247–267 Nm.
45. Put the chains through chain anchor support.
Crown 2012 PF25723-26
 LIFTING MECHANISM
MAST

46. Attach the chains to the chain anchors at the top of Install the control cables
the mainframe. 56. Put the control cables through to the bottom of the
47. Install the chain slack assembly on the mainframe. mainframe near the termination point on the right
side of the mainframe.
Install the hose pulley assembly and hydraulic
hoses 57. Install the two extension springs onto the control
cable grips and bracket at the top of the main-
48. Install the hose pulley assembly on the top of the
frame.
second stage mast.
58. Adjust the cable grips to extend the springs ap-
Note: Make sure that the shims are in same position
proximately 140 mm.
that you recorded.
59. Use cable ties to hold the extension springs to the
49. Torque the bolts for the hose pulley assembly to
cable grips.
247–267 Nm.
60. Install connectors JC412 and JC413 onto the ap-
50. Install the hydraulic hoses and control cables on
plicable control cables.
the hose pulley assembly.
61. Install connectors JC412, JC413, and JC414 into
Note: Make sure that the hydraulic hoses and control
the attachment clip.
cables are in the same position that you recorded.
62. Install the retainer on the attachment clip to hold
Note: Make sure that you do not twist the hydraulic
the connectors in position.
hoses or control cables when you install them.
51. Install the shafts at each end of the hose pulley as- Raise the mainframe and mast assembly
sembly. 63. Install the bottom plate onto the bottom of the
52. Connect the large hydraulic hose to secondary cyl- mainframe.
inder. 64. Use the installation hardware supplied with the
Note: Do not twist the hose. Use the mark you made shipping bracket to install the shipping bracket on
before you removed the hose to make sure that you did the top of mast assembly.
not twist or turn the hose. 65. If necessary, use a crow bar through the access
53. Put the two smaller hydraulic hoses through to the hole (1) at the top of the third stage mast to col-
bottom of the mainframe. lapse the mast. Refer to Figure 432.
54. Pull the hoses out the bottom of the mainframe and
route them to the hydraulic fittings. Refer to
Figure 431.
55. Install the two hydraulic hoses.
Note: Do not twist the hoses.

Fig. 432 (21002-01)

Fig. 431 (20990-01)
1 Access hole at the top of the 3rd stage mast
2 The tab is part of the 2nd stage mast

Crown 2012 PF25723-27 TSP 7000 SERIES M7.0-1970-027

543
LIFTING MECHANISM
MAST

66. Remove the pin tool from the mainframe and sec- Note: The factory sends the correct dimension and
ond stage mast. quantity of shims for the mast back tilt. Make sure that
67. Attach the lift device to the shipping bracket and to you install the shims in the correct locations.
the bottom of the mainframe. 78. Install the flatwashers (6) and nuts (7) on mounting
Note: Make sure that the lift device has sufficient ca- bolts (1), but do not tighten them at this time.
pacity and dimensions to safely move the mainframe. 79. Install the bottom six mounting bolts (8) and flat-
You must use extreme precaution during this proce- washers (9).
dure.  The head of the bolt must point in the direction of
the power unit.
80. Install the flatwashers (10) and nuts (11) on mount-
WARNING ing bolts (8), but do not tighten them at this time.
A mainframe or mast assembly that falls can cause
injury or death.
If the load wheel chocks or supports are not in the cor-
rect position, the mainframe or mast assembly could
move or fall.
 Make sure that the load wheel chocks and supports
stay in place throughout this procedure.
 Make sure that the lift device prevents the move-
ment of the mast or mainframe.

68. Carefully lift the mainframe until the mast is in a

vertical position.
69. Put blocks (1) below the mainframe. Refer to
Figure 390.
 Make sure that the blocks keep the mast from go-
ing beyond a vertical position.
70. Remove the lift device from the shipping bracket
and the mainframe. Fig. 433 (20932-01)
71. Remove the shipping bracket from the top of the 1 060131-007, 3 mm thick
mast. 2 060131-006, 6 mm thick
72. Keep the shipping bracket and hardware to use 3 060131-008, 1.8 mm thick
again as necessary.
81. In the correct sequence, torque the mounting bolts
Assemble the mainframe to the power unit
to 305 Nm. Refer to Figure 434.
73. Align the power unit with the mainframe and plat-
82. Then, in the correct sequence, torque the mount-
form.
ing bolts to 435 Nm.
74. Put blocks below the power unit.
83. Then, in the correct sequence, make sure that
75. Put chocks against the drive tire to prevent the each bolt has the correct torque of 435 Nm.
movement of the power unit.
76. Install the top two mounting bolts (1) and two flat-
washers (2). Refer to Figure 433.
 The head of the bolt must point in the direction of
the power unit.
77. Install the correct number and dimension of flat-
washers (3, 4, 5) between the power unit and the
mainframe.

M7.0-1970-028 TSP 7000 SERIES Crown 2012 PF25723-28

544
 LIFTING MECHANISM
MAST

Fig. 434 (20933-01)

Install the primary truck components
84. Install the primary lift cylinders onto the mainframe.
Refer to the applicable section in CYLINDERS.
85. Install the mast chains, hydraulic plumbing, and
electrical cables in the mast assembly.
86. Attach the chain (2) to the mast and the cover (1).
Refer to Figure 435.
87. Install the cover (1) on the top of the mast.
Fig. 435 (27326)
88. Install the platform on mainframe. Refer to PLAT-
FORM > Platform > Platform Assembly.
89. Install the load handler assembly.

Crown 2012 PF25723-29 TSP 7000 SERIES M7.0-1970-029

545
LIFTING MECHANISM
MAST

Adjust the chain anchors
90. Do not lift the platform above free-lift stage, but lift
it a sufficient height to get access (1) to the chain
anchors at the bottom of the third stage mast. Re-
fer to Figure 436.
91. Put blocks in position to hold the platform. Refer to
SAFETY > Control of Hazardous Energy > Lifting
and Blocking.
92. In equal increments, adjust the chain anchors at
the bottom of the third stage mast (1). Refer to
Figure 436.
 The distance from the top of the cylinder mount
shelf (2) must be 381 mm above the mainframe top
plate (3).
98. Bleed the primary and secondary lift cylinders. Re-
fer to the applicable section in CYLINDERS.
WARNING
Missing stop blocks or safety devices could cause
the mast to fall.
A mainframe or mast assembly that falls can cause in-
jury or death.
 Make sure that all the stop blocks and safety de-
vices are in the correction position before you ex-
tend the mast.
99. Install the battery.
100.Install the power unit doors and covers.
101.Make sure that all of the truck functions are cor-
rect.

Column Roller Replacement - TF, TN, and

TT
You must disassemble and remove the mast to replace
the mast column rollers.
To clean and lubricate the column roller studs
1. Clean the column rollers studs.
2. If there is paint or corrosion on the studs, remove it
with an emery cloth.
3. Lubricate the studs with multi-purpose grease
(063002-024).
To install the column rollers
4. Lubricate the inner diameter of the column rollers
with multi-purpose grease (063002-024).
Fig. 436 (21006-01)
5. Install the column rollers with large radius of roller
93. Install the access cover on third stage mast. toward the stud shoulder. Refer to Figure 437.
Prepare the trucks for operation 6. Install new retaining rings.
94. If you did not drain the reservoir, remove non-
vented shipping cap from the reservoir.
– Install the filler/breather dipstick.
– Keep the non-vented shipping cap to use again
as necessary.
95. If you did drain the reservoir, add hydraulic oil to
the reservoir to the "FULL" line. Refer to HYDRAU-
LIC SYSTEM > Reservoir and Filters > Reservoir.
96. Connect the manual lowering valve cable from the
platform to the manual lowering valve.
97. Close the manual lowering valve. Refer to
SAFETY > Control of Hazardous Energy > Hydrau-
Fig. 437 (13045-02)
lic.

M7.0-1970-030 TSP 7000 SERIES Crown 2012 PF25723-30

546

Side Thrust Roller Adjustment - TF,
TN, and TT
You can adjust the side thrust rollers with the mast in-
stalled on the truck.
Special Tools and Equipment:
• ¾ inch square socket extension
Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
Note: Make sure that there is sufficient space to fully
extend the second stage mast.
2. Put chocks against the wheels to prevent the
movement of the truck and mainframe. Refer to
SAFETY > Control of Hazardous Energy > Lifting
and Blocking.
3. Complete the lockout/tagout procedures for the
truck. Refer to SAFETY > Control of Hazardous
Energy > Lockout/Tagout.
4. Open the manual lowering valve. Refer to SAFETY
> Control of Hazardous Energy > Hydraulic.
5. Remove the power unit doors and covers.
6. Remove load handler assembly.
7. Remove the platform from mainframe. Refer to
PLATFORM > Platform > Platform Removal.
8. Connect the battery.
9. Lift the second stage mast to the mainframe stops.
10. Use blocks to hold the mast. Refer to SAFETY >
Control of Hazardous Energy > Lifting and Block-
ing.
11. Disconnect the battery.
Adjust the bottom side thrust rollers - Second
stage mast
12. At the bottom of the second stage mast, remove
the bolts on the cams and turn each thrust roller
shaft to the loosest position.
13. Push the column rollers against the stud shoulders
and then, push the second stage mast to one side.
14. Then, measure the distance on each side between
the face of the column roller face and the web of
the I-beam.
15. Add the two measurements.
16. Divide the sum by 2.
17. Put a shim with the same thickness of the result
from Step 14 between the column roller and the
web on one side of the mast.
Crown 2012 PF25723-31 TSP 7000 SERIES
LIFTING MECHANISM
MAST
18. Use a ¾ in square socket extension to adjust the
cam on the opposite side until the thrust roller
touches the flange of the I-beam.
 The left and right cams should be at the same hole.
19. Install the bolt to keep the cam in the correct posi-
tion.
20. Remove the shim from Step 15.
21. Use a ¾ inch square socket extension to adjust the
other cam until the thrust roller touches the flange
of the I-beam.
22. Install the bolt to keep the cam in the correct posi-
tion.
23. Use a grease pencil to put a mark on the side thrust
rollers.
24. Move the second stage up and down the main-
frame.
 The thrust rollers must roll approximately 75% of
the time or more.
 There must not be heavy marking of the mast.
25. Make adjustments as necessary.
Adjust the top side thrust rollers - Second stage
mast
26. Fully retract the second stage mast.
27. At the top of the second stage mast, remove the
bolts and turn each thrust roller shaft to the loosest
position.
28. Do Steps 11 through 23 to adjust the top thrust roll-
ers.
Adjust the side thrust rollers - Third stage mast
29. Use the procedures above to adjust the side thrust
rollers for the third stage mast on TT trucks.
M7.0-1970-031
547
LIFTING MECHANISM
HOSE TAKE-UP CABLE

Hose Take-Up Cable 3. Turn the truck OFF.

4. Put the chocks against the tires to prevent the
The hose take-up cable is routed through a series of movement of the truck.
pulleys in the mast. As the mast is raised or lowered,
the cable keeps a constant tension on the hose take-up 5. Disconnect the battery.
assembly and keeps the hoses and cables tight. Refer 6. Lockout/tagout the truck. Refer to SAFETY > Con-
to Figure 438. trol of Hazardous Energy > Lockout/Tagout.
Remove the cable
1. Remove the cable access cover on the back of the
6 mast.
2. Loosen the clamp that holds the adjustment pulley
(2) in position. Refer to Figure 438.
3. Turn the adjustment pulley (2) so that full the cable
5 tension adjustment is available for the replacement
cable.
4. Remove the cover on the top of the mainframe.
7

2 8

Fig. 438 (21336-01)

1 Under cover on mast
2 Adjustment pulley
3 Pulley (part of take-up assembly)
4 Take-up assembly stop
5 Poly stop
6 Yoke
7 Pulley mounted at top of mast
8 Pulley on bracket fastened to primary lift cylinder

Hose Take-Up Cable Replacement

Special Tools and Equipment
• Spanner wrench (108641)
Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the forks.

M7.0-1970-100 TSP 7000 SERIES Crown 2012 PF25718-1

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 LIFTING MECHANISM
HOSE TAKE-UP CABLE

5. Attach a cable or chain to the pulley plate mounting 9. Lift the pulley bracket (2) up and out of the mast.
bracket (1) and secure. Refer to Figure 439. Refer to Figure 440.
Note: There is a hole in the bracket for this function.

3 4

1
1

Fig. 440 (21338-01)

Fig. 439 (21337-01) 1 V Slot
1 Pulley plate mounting bracket
2 Pulley bracket
2 Primary lift cylinder assembly
3 Cable
3 Mounting bolt
4 Pulley bracket with anchor access hole
10. Disassemble the cable and remove it from the
mast.
6. Remove the bolt (3) in the top of the bracket. Refer
to Figure 439.
7. The pulley plate mounting bracket is assembled
into a V-slotted bracket (1) on the bottom of the pri-
mary lift cylinder. Refer to Figure 440.
8. Attach a cable or chain to the V-slotted bracket and
let the pulley bracket (2) lower out of the V-slotted
bracket (1).

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LIFTING MECHANISM
HOSE TAKE-UP CABLE

Install the cable

1. Attach the cable to the yoke (5) at the top of the
mast. Refer to Figure 441. 5
2. Attach a cable or chain to the pulley plate mounting
bracket.
Note: Use the hole in the top of the pulley plate mount-
ing bracket.
3. Loop the hose take-up cable around the pulley and
lower the pulley bracket into the mast. 4
4. Put the pulley bracket into the V-slotted bracket on
the bottom of the primary lift cylinder.
5. Install the bolt in the pulley bracket and tighten.
6. Remove the cable or chain from the pulley bracket. 3
7. Route the take-up cable through the remaining pul-
leys and attach it to the adjustment pulley.
2

CAUTION
Too much clearance can result in premature wear
of the take-up assembly guide.
The clearance between the hose take-up assembly
1
stop and the poly stop must not be more than 9 mm.
 Adjust the cable tension so there is 9 mm of clear-
ance between the hose take-up assembly stop and
the poly stop.
 If the clearance is more than that it can cause in Fig. 441 (21339-01)
premature wear of the take-up assembly. 1 Adjustment pulley
2 Take-up assembly
8. Use a spanner wrench (108641) and adjust the ca- 3 6–9 mm clearance when the platform is lowered
ble tension so that there is 6–9 mm clearance be- 4 Poly stop
tween the hose take-up assembly stop (2) and the 5 Yoke
poly stop (4) when the platform is fully lowered.
Prepare the truck for operation
1. Connect the battery.
2. Remove the chocks.
3. Turn the truck ON.
4. Make sure that the truck operates correctly.

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 LIFTING MECHANISM
LOAD WHEELS

Load Wheels
The procedures that follow are for replacement of load
2
wheels and to lathe cut the load wheels to make sure
that the wheels are of equal diameter.
Note: The load wheels are usually replaced as a set. If 3
one of the load wheels is damaged and the other load
wheel is in good condition with minimum wear, it is ac- 1
ceptable to only replace the damaged load wheel.

Load Wheel Removal

Prepare the truck 4
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the platform and forks.
3. Turn the truck OFF.
5
4. Put the chocks against the load wheel that is not
being replaced.
Fig. 442 (21272-01)
5. Disconnect the battery. 1 Hub
6. Lockout/tagout the truck. Refer to SAFETY > Con- 2 Part of press
trol of Hazardous Energy > Lockout/Tagout.
3 Steel plate
Remove the load wheel assembly 4 Load wheel
7. Raise the mainframe until the load wheel does not 5 Steel plate work surface
touch the floor. Refer to SAFETY > Control of Haz-
ardous Energy > Jacking and Blocking. 16. Apply a light layer of oil to the outside of the hub.
8. Put a block under the mainframe. 17. Push the hub into the load wheel.
9. Remove the three screws from the cap on the load 18. Check for correct hub alignment and depth.
wheel hub and remove the cap. 19. Size the new load wheel. Refer to Lathe Cutting
10. Remove the load wheel assembly from the truck. (below).

Replace the load wheel

11. Push the hub out of the load wheel.
Note: Do not push the hub through the used tire and
directly into new tire in one operation. This procedure
is more likely to cause hub misalignment and result in
premature load wheel failure.
12. Examine the load wheel hub for damage. Replace
it if necessary.
13. Put the new load wheel on a flat, level steel plate,
shim plate as required. This will insure an even dis-
tribution of force and pressure when the hub is
pushed into the load wheel.
14. Put the hub on the load wheel.
15. Put a circular steel plate, 28 mm ± 1 mm thick with
an outside diameter (O.D.) of slightly less than the
outside diameter of the hub, on the hub. This will
let the hub be recessed into the load wheel 28 mm
± 1 mm. Refer to Figure 442.

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LIFTING MECHANISM
LOAD WHEELS

Lathe Cutting
A new load wheel must be sized down to a diameter of
355.6 mm ± 1.5 mm after the load wheel is pushed 1
onto the hub.
Note: The load wheel can not be lathe cut before the
hub is pushed in because of the requirement for hub-
bearing bore concentricity to the load wheel outside di-
ameter. 355.6 +/- 1.5 mm
(14.0 +/- .060 in)

WARNING
Loose fitting clothing could get caught in the lathe
and cause severe injury.
 Do not wear loose fitting clothing when you operate
a lathe.
 Wear safety gloves and safety glasses when you
operate a lathe.
Mount and cut load wheel
1. Install the load wheel assembly onto the lathe
chucking off the bearing inner race or the hub in-
side diameter.
2. Use an outside diameter caliper as a measuring
guide and cut the wheel down to 355.6 mm ±
1.5 mm in diameter. Approximately 6.3 mm needs
to be trimmed from load wheel. Refer to
Figure 443.
Note: Do not try to remove the full amount from the
load wheel on the first cut. Remove small amounts and
measure frequently.
2
3
Fig. 443 (21273-01)
1 Smooth cast urethane surface to be this side
2 Press flush on this side
3 Break sharp corners
Note: The outer load wheel diameter must be concen-
tric to the inner bearing diameter within 1.0 mm total
indicator run out.
Note: It is important that the load wheel assemblies are
the same to prevent premature wear on the load
wheels and for correct operation.
Install the load wheel assembly
3. Install the load wheel assembly on the truck.
4. Install the cap on the load wheel hub and install the
three screws to hold the cap on the hold.
5. Raise the mainframe and remove the block from
under the mainframe.
6. Lower the mainframe.
Prepare the truck for operation
7. Connect the battery.
8. Remove the chocks.
9. Turn the truck ON.
10. Make sure that the truck operates correctly.

M7.4-1970-002 TSP 7000 SERIES Crown 2012 PF27520-2

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 LIFTING MECHANISM
LIFT CHAINS

Lift Chains
The lift chains are very important components on your
truck. The lift chain system on your mast safely sends
the lift force from the hydraulic cylinder to the forks.
If the lift chain performance is not sufficient, this could
be because of the maintenance intervals. It is neces-
sary to do intermittent maintenance on the lift chains for
the maximum service life.

Inspection
After 250 hours of truck operation, you must examine
and lubricate the lift chains. If you use a truck in an
environment with corrosion, examine the lift chains at 106440
100 hour intervals. During the inspection, look for these
indicators:

Wear
As the lift chain bends on and off the pulleys, the joints
gradually wear.
The lift chain can extend during service because the
material is worn off of the pin outside diameter and pin
hole inside diameter on the inner plates. To measure
the lift chains for wear:
Note: You can use a plastic gauge (106440) for 25 mm
pitch lift chains on TF, TN, and TT masts, but a metal
gauge (144846) is easiest. On TT trucks, you must use
a metal gauge for 32 mm pitch lift chains. Refer to
Figure 444.
1. Measure the lift chain wear with a plastic gauge, a
metal gauge, or a steel tape measure. Refer to
Figure 444.

144846

Fig. 444 (27329)

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553
LIFTING MECHANISM
LIFT CHAINS

2. When the lift chains extend 3% on scale A (19 mm

or 25 mm pitch chain) or scale B (16 mm pitch
chain) of the lift chain scale, discard them. For ex- Lift chain with corrosion cracks
ample: on a lift chain with 19 mm between the pins,
305 mm of the chain contains 16 pitches (or links).
When 16 pitches measure 314 mm, replace the lift
chain. On a lift chain with 16 mm between the pins,
20 pitches (or links) equal 318 mm. When 20
pitches measure 327 mm, replace the lift chain.
Crown uses 16 mm pitch (20 links in 318 mm),
19 mm pitch (16 links in 305 mm) and 25 mm pitch Fig. 445 (27330)
(12 links in 305 mm) lift chains.
• Heavy motor oil is a joint lubricant and it also pre-
3. When you measure the lift chain wear, refer to vents corrosion.
these steps:
• During the inspection, carefully examine the outer
– On TF and TN masts, adjust the lift chains in this lift chain surfaces for a layer of oil.
sequence: primary lift chains (25 mm), then aux-
• In some conditions, it is necessary to lubricate the
iliary lift chains (25 mm).
lift chains more than 250 hour intervals. In all condi-
– On TT masts, adjust the lift chains in this se- tions, the outer surface of the lift chain must have a
quence: secondary lift chains (32 mm), primary layer of oil.
lift chains (25 mm), then auxiliary lift chains
• You must examine the lift chains with corrosion for
(25 mm).
cracks in the plates.
– Make sure that you measure a part of the chain
• If the lift chains have corrosion, you must remove
that operates above the pulley.
them from the mast for an inspection for cracks in
– Do not remove the worn section of a lift chain and the plates.
install a new piece.
• If the plates have cracks, you must replace the two
– If a part of the lift chain is worn, replace the two lift chains on the truck. Lubricate the lift chains
chains. when you install them on the mast.
– If the truck has a set of lift chains, replace the two
chains at the same time. Plates with Cracks
• Wear is frequently the cause of plate cracks. After
Corrosion many continuous heavy loads, the plates could
Corrosion causes the load capacity of the lift or roller have cracks and the lift chains could break.
chain to decrease because corrosion causes cracks in • The cracks from wear are usually through the pin
the side plates. holes. These cracks are different than the cracks
It is very important to make sure that there is no corro- from corrosion. Compare Figures 445 and 446.
sion on the lift chains in service or in storage. When you
examine the lift chains for corrosion, refer to these
steps: Lift chain with a crack from wear
Note: Do not clean the lift chains with steam.
• The initial factory lubricant on the lift chains pre-
vents corrosion. Do not clean or remove the grease
from the new lift chains.
• After the lift chain is in service, you must do the
planned maintenance on it. Refer to the INSPEC-
TION AND LUBRICATION section for more data on Fig. 446 (27331)
planned maintenance and lubrication.
• If you find cracks from wear during the planned
maintenance inspection, you must replace the two
lift chains. Carefully examine the plates without
cracks to make sure that they have no damage.

M7.5-1970-002 TSP 7000 SERIES Crown 2012 PF25725-2

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 LIFTING MECHANISM
LIFT CHAINS

Tight Joints
All joints in the lift chain must bend freely. Tight joints
Turned pins
increase the tension on the lift chain. Tension increases
wear. Refer to Figure 447.

Tight joints

Fig. 447 (27332)

These can cause tight joints in the lift chains:
• Bent pins or plates
• Joints with corrosion
• Damaged plate edges.
Lubricate the lift chains with corrosion and replace the
chains that are bent or damaged. These can cause
damaged plate edges:
• Pulleys with wear
• Unusually heavy loads
• When a lift chain hits a mast component
• Blockage in the mast.
Turned Pins
• When lift chains operate with a heavy load and a
small quantity of lubrication, the torque in the joint
could turn the pins in the outer plates. When this
occurs, the pins slowly move out of the lift chain and
chain does not operate correctly.
• You can identify the turned pins by the flat ends,
which do not align correctly.
• Replace the lift chains with turned pins immediately.
• Do not try to repair the lift chain and push the pins
into the chain.
• Refer to Figure 448, which shows a 45 degree
turned pin.
Fig. 448 (27333)
Lift Chain Side Wear
The pin heads and outer plates do not align correctly if
they show continuous wear. There are two causes that
the pin heads and outer plates do not align correctly:
Lift Chain Tension that is Not Equal
• When you install or adjust a lift chain, make sure
that they are equal. For example: when you change
the fork heel height or platform height, you must
loosen the chain anchors until the two forks touch
the floor. The two lift chains must have the same
tension.
• Tighten the chain anchor nuts an equal quantity of
revolutions on the two chain anchors to put equal
tension on the chains.
• When you are at the necessary height, tighten the
locknut.
The Lift Components Do Not Align Cor-
rectly
• The pulley and lift chain do not align correctly if the
shims of the mast are not correct, or if the mast or
cylinder components are bent or damaged. This is
also a cause of lift chain side wear.
• The truck must be in a maintenance area with a
level floor.
• Refer to the SAFETY > Control of Hazardous En-
ergy > Platform and Load Handler Lifting section to
correctly support the fork carriage.
• Disconnect each end of the lift chain at the chain
anchor and make sure that it aligns with the chain
anchor slots.

Crown 2012 PF25725-3 TSP 7000 SERIES M7.5-1970-003

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LIFTING MECHANISM
LIFT CHAINS
Lift Chain Lubrication
You must lubricate the lift chains at the specified main-
tenance intervals for maximum service life. A layer of
oil between parts and on all lift chain surfaces is neces-
sary for these results:
• Decreases wear on the joint
• Prevents corrosion
• Prevents turned pins
• Decreases tight joints in the roller chain
• Causes smooth lift chain movement
• Lowers the lift chain tension.
When you lubricate the lift chains, refer to these steps:
• Refer to the INSPECTION AND LUBRICATION
section for the applicable lubricant for your truck.
• The oil must go into the lift chain joint to prevent
wear. If you apply oil to the outer surfaces, there is
no corrosion, but oil must flow into the live bearing
surfaces for maximum service life. Refer to
Figure 449.
Lubricate
Fig. 449 (16850-01)
• Apply oil to the lift chains with a thin brush. Soak the
lift chain with oil during each lubrication inspection
period.
• The frequency of lubrication changes with the con-
ditions of operation and environment. The best lu-
brication period estimate is 250 hours of truck
operation.
Note: Do not clean the lift chains with steam.
• After 250 hours of truck operation, you must clean
and lubricate the lift chains.
M7.5-1970-004 TSP 7000 SERIES
556
Lift Chain Replacement
1. Find the part number for the lift chain in the parts
list in your service manual. Make sure that the re-
placement lift chain is applicable to your truck.
2. Replace the lift chains as a pair. You cannot easily
keep equal tension of the lift chain between a new
chain and a remaining chain.
3. If the factory lubricant dries, soak the new lift
chains in heavy engine oil for a minimum of 30 min-
utes before you install them. This also applies if
there is no factory lubricant on the new lift chains.
4. After you remove the remaining lift chains from the
mast, carefully examine the chain anchors and pul-
leys.
5. Replace the chain anchors that are broken, have
cracks in them, or are worn.
6. Replace the pulleys that are worn and examine the
pulley bearings for wear.
7. Do not paint the new lift chains. Paint helps prevent
corrosion, but also prevents satisfactory joint lubri-
cation.
8. Install the new lift chains with the new pins. Do not
use the remaining pins.
9. After you connect the new lift chains to the chain
anchors, adjust the chain tension for the correct
fork or platform lower height. The correct lift chain
installation and mast adjustment increases the
chain service life.
Chain Leaf Disconnect
To decrease the risk of damage to the lift chain, refer to
these steps and Figure 450 when you disconnect the
chain leaf:
Special Tools and Equipment:
• A stable work surface with an opening that is larger
than the pin diameter. The work surface must be of
sufficient thickness to let the pin extend below the
work surface as you push it through the bottom pin
link plate (1).
• A support ring (for example, a flatwasher) (2) with
an inside diameter more than the pin diameter and
a height that is equal to the head height of the pin.
• A grinding wheel (3).
• A pin punch with a diameter that is less than the pin
diameter or a hammer.
1. Grind the top head of the pin (4) flush with the pin
link plate (1). Do not to grind or do damage to the
pin link plate.
Crown 2012 PF25725-4
 LIFTING MECHANISM
LIFT CHAINS

2. Put the support ring (2) above the opening of the

work surface. The support ring holds the bottom
pin link plate (1) and prevents damage to the lift
chain components while you push the pin through
the chain.
3. Put the lift chain on its side and install the pin in the
support ring (2).
4. Remove the pin from the lift chain through the top
pin link plate (1).

3
1
4

Fig. 450 (27334)

Crown 2012 PF25725-5 TSP 7000 SERIES M7.5-1970-005

557
LIFTING MECHANISM
FORK INSPECTION

Fork Inspection Abrasion

WARNING
Damaged forks or forks out of tolerance can break
down and cause loss of life or severe injury.
Wear, fatigue, bends, etc. can cause a fork to break
down. This can cause a load to fall.
 Carefully examine the forks. Follow the procedures
given in this section.
 Immediately replace damaged forks or forks which
are out of tolerance.
Abrasion gradually decreases the thickness of the fork.
Make sure that the fork thickness correct. Do not let the
forks rub the floor during normal operation. If the forks
rub the floor, do a check of the lift chain adjustment.
Fork wear at the heel and at the hanger bore must not
be more than 10% of the original thickness. At this
point the forks are adequate for approximately 80% of
the rated capacity. Refer to Chart 2 (Figure 457).
Crown has a fork wear calipers (part no. 107330) avail-
able for use or you can use a verniers or machinist
152.4 mm scale. Refer to Chart 1 for allowable fork
blade wear thickness.
i

 Do not operate the truck if a replacement is not

available. Chart 1

Standard Fork Allowable 10% Wear

Blade Thickness Fork Blade Thickness
mm in mm in
WARNING
31.5 1.25 28.5 1.12
Incorrect repair of a fork can cause the fork to
break down and cause a loss of life or severe in- 38.0 1.50 35.0 1.38
jury. 44.5 1.75 39.5 1.56
 Do not repair the forks unless you are approved to
51.0 2.0 46.0 1.80
do it by the manufacturer of the fork.
57.0 2.25 51.0 2.0
63.5 2.50 57.0 2.25

WARNING Refer to the information below if you are using fork

wear calipers.
Use of incorrect forks can cause a fork to break
down and cause loss of life or severe injury. Blade Measurement
 Do not use fork extensions. The fork wear calipers have two measuring points or
 Use only forks with the correct dimensions. jaws. The outer jaws measure 10% more than the inner
 Use forks which are approved for lift capacity of the jaws.
truck (see the Capacity Data Plate at the truck).

WARNING
1 2
If the fork locking pin is not fully engaged, the fork
could become accidentally disengaged.
 Make sure that the fork locking pin is fully engaged.

Fig. 451 (16854-02)

1 Outer jaws 100% (Fork shank)
2 Inner jaws 90% (Fork blade)

M7.8-1970-001 TSP 7000 SERIES Crown 2012 PF25722-1

558
 LIFTING MECHANISM
FORK INSPECTION

To set the outer jaws, measure the thickness of the

middle of the shank as 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: You can get an incorrect measurement if you do
not hold the calipers square across the shank.

3
1

Fig. 454 (16857-02)

2 1 Fork blade cross section

Hanger Bore Measurement

4 To do a check for elongation and wear of the hanger
bore:
1 • Turn the caliper so that the jaws face out. Refer to
Figure 455.

Fig. 452 (21294-01)

1 Fork blade 1
2 Fork shank
3 Hanger
4 Measure here to set outside jaws

Fig. 455 (21295-01)

1 Use outside jaws for bore measurement

• Put the outer jaws into the hanger bore along the
vertical axis.
• Turn the calipers 180 degrees and find the largest
diameter of the bore.
Note: Lightly tap on the calipers with a metal object to
1 set the jaws to the feel of the bore. Hold the calipers so
they are square across the bore of the hanger or you
can get an incorrect measurement.
Fig. 453 (16856-02)
1 Fork shank cross section

When the outer jaws are set, do a check to see if the

inner jaws of the calipers pass over the flanks of the
fork blade at a point between the end of the taper and
the heel of the fork blade. After you examine the blade,
use the calipers to measure the shank a second time to
make sure that the setting did not change.

Crown 2012 PF25722-2 TSP 7000 SERIES M7.8-1970-002

559
LIFTING MECHANISM
FORK INSPECTION

• After the jaws are set, remove the caliper and use a
verniers or machinist 152.4 mm scale to measure
across the outer jaws.
Rotate Calipers • Replace the fork if the jaws measure more than
180 degrees 50 mm.

Fig. 456 (21296)

Chart 2
Wear vs. Capacity
Percentage Reduction in Fork Blade Thickness

Percentage Remaining of Specified Fork Capacity

Fig. 457 (21298)

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560
 LIFTING MECHANISM
FORK INSPECTION

Overloading
Know the capacity of the forks and truck. The fork ca-
pacity and load center is stamped on the fork. Refer to
Figure 458. Overloading can cause permanent defor-
mation or severe fatigue conditions.
130 mm (5 in.)

130 mm (5 in.)

Fig. 459 (21299)

Bent or Twisted Forks

You can bend or twist a fork if you hit the forks against
Fig. 458 (21297-01)
solid objects or lift up loads unevenly. Replace a bent
1 Location of capacity and load center rating
or twisted fork. The maximum difference in fork tip ele-
vation from one fork to the other is 3% of the fork
Fatigue length.
A fatigue crack usually starts in the heel area of the The angle between the top of the fork (blade) to the
fork. You can usually find a crack in the initial stages rear surface of the vertical leg (shank) must be less
when you examine the heel area. Examine for cracks than 93 degrees. You must replace the fork if the angle
that transverse the fork in an area up to 130 mm one of is more than that. Do not repair the forks unless you are
the sides of the inner heel radius. These cracks are a approved by the manufacturer of the fork.
sign that the area has weakened. You must replace the
fork when it is in this condition. A visual inspection for
cracks must be made each work day. If a more accu-
rate inspection is necessary, use dyes on the forks or
Magnaflux® the forks.

Fig. 460 (21300-01)

1 93 degrees max.

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561
LIFTING MECHANISM
FORK INSPECTION

You can use a square (1) to do a check on the fork.

Refer to Figure 461. Hold the square against the shank
and stay above the radius of the heel as shown. Meas-
ure the distance closest to the radius of the heel of the
fork blade and the square. Add 31.8 mm to this meas-
urement and record. If the distance between the end of
the square and blade is more than this measurement,
replace the blade because the fork angle is more than
93 degrees.

60.9 cm
(2 ft)

1 Fig. 462 (21302)

"x" "x" + 31.8 mm (1.25 in)

Fig. 461 (21301-01)

Hanger
• Examine for cracks or damage in the area where
the fork attaches.
• Examine the carriage and fork rod for excessive
wear or cracks.
• Make sure the fork locking pin, spring, and other
parts are in good condition.
• Repair or replace parts if necessary.
• Make sure that the fork rod and locking pin are lu-
bricated.

M7.8-1970-005 TSP 7000 SERIES Crown 2012 PF25722-5

562
CYLINDERS
563
Notes:

564

TF Lift Cylinders
WARNING
A platform and load handler that falls can cause in-
jury or death.
Make sure that the capacity of the lift device, straps or
chains and hardwood blocks can hold the platform and
load handler weight. If not, the platform and load han-
dler could fall.
 The load handler and platform weigh approximately
2300 kg. Make sure that the lift device, straps or
chains and hardwood blocks can hold more than
2300 kg.
WARNING
High pressure fluid can go through the skin and
cause injury.
High pressure fluid that goes into the skin is a medical
emergency. There is a delayed start of pain, and se-
vere tissue damage may occur. You must get medical
aid from a specialist who has had experience with this
type of injury.
 Avoid high pressure fluids
 Release the pressure before you disconnect the hy-
draulic lines.
 Tighten all connections before you apply the pres-
sure.
 Keep your hands and body away from pin holes
which eject high pressure fluids.
 Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
WARNING
A cylinder that falls can cause injury or death.
The capacity of the lift device, straps or chains and
hardwood blocks must hold the cylinder. You must con-
nect the straps or chains to safely hold the cylinder. If
not, the cylinder could fall.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the cylinder.
Crown 2012 PF25721-1 TSP 7000 SERIES
CYLINDERS
TF LIFT CYLINDERS
Access to the Lift Cylinders
Note: You must tilt the tip-out assembly for access to
the lift cylinders.
Special Tools and Equipment
• Two 250 mm square, 13 to 25 mm thick steel plates
• One steel rod approximately 0.6 m long.
To prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Raise the second stage mast to access the covers
for the mast column rollers at the bottom of the
mast.
3. Turn the truck OFF.
4. Disconnect the battery.
5. Lockout/tagout the truck.
6. Put chocks against the wheels to prevent move-
ment of the truck. Refer to SAFETY > Control of
Hazardous Energy > Lockout/Tagout.
7. Put hardwood blocks below the platform. Refer to
SAFETY > Control of Hazardous Energy > Jacking
and Blocking.
To put steel plates below the second stage mast
Refer to Figure 463.
8. Remove the covers for the mast column rollers.
CAUTION
You can cause truck damage if you put steel plates
below the second stage mast that are too thick.
Do not lower the second stage mast on steel plates that
are thicker than 25 mm. This can cause damage to the
hydraulic tubes at the top of the mast.
 Lower the second stage mast on 13 to 25 mm steel
plates.
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9. Put 250 mm square, 13 to 25 mm thick steel plates

(1) on top of the mainframe. Put the plates on each
side of the mainframe and against the mainframe
I-beam.

1 1

2
Fig. 463 (27225)
10. Remove the hardwood blocks below the platform.
11. Connect the battery.
12. Fully lower the second stage mast on the steel
plates.
13. Disconnect the battery.
To make the chains, hoses and cables loose
Refer to Figure 464.
14. Remove the cover on the top of the mast and hang
it to the side of the mast.
Note: A short chain is attached to the cover that lets
you hang it from the mast. Fig. 464 (27226)
15. Attach a chain, cable or strap to the hole (1) in the 16. Attach a chain or strap to the platform.
top mounting plate of the pulley plate. Hold the pri-
17. Use a lift device and lift the platform approximately
mary lift cylinder (2) in position.
0.5 m.
Note: You must hold the primary lift cylinder in position
 This will cause the mast lift chains, cables and
with a chain, cable or strap. If you do not, the cylinder
hoses to become loose.
will fall in the mast when you remove the bolts from the
cylinder rams. 18. Put hardwood blocks below the platform.
To disassemble the components from the tip-out
assembly
Refer to Figure 465.
19. Remove the one bolt (1) and lockwasher that holds
the secondary lift cylinder (2) to the tip-out assem-
bly (3).

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To tilt the tip-out assembly

24. Lift the rear cover on the power unit.
4 25. Open the manual lowering valve. Refer to
Figure 466.
 This will cause the ram in the secondary lift cylinder
6 8 to retract.

10

7
3
9
1
5
12

Fig. 466 (27228)

26. Pull the cables and hoses from the tip-out assem-
11 bly and move them to the side. Hold them in posi-
tion with a chain or strap.
27. Tilt the tip-out assembly until you can remove the
sleeves (8) and button rests (9) from the top of the
primary cylinder rams. Refer to Figure 465.
28. Tilt the tip-out assembly until you can pull the pin
(7) out of the chain anchor (10).
 The chain anchor will fall from the tip-out assembly
and hang from the chain, cable or strap.
Fig. 465 (27227)
20. Remove the two bolts (4), lockwashers and wash-
ers that hold each ram (5) of the primary lift cylinder
to the tip-out assembly (3).
21. Remove the four bolts (6) and lockwashers that
hold the tip-out assembly (3) to the mast.
22. Attach a cable, chain or strap to the chain anchor
on the back of the tip-out assembly.
Note: The cable, chain or strap attached to the chain
anchor keeps the chain and chain anchor from falling
in the mast.
23. Remove one of the retaining rings (12) from the
chain anchor pin (7).

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29. Tilt the tip out assembly (1) and put a steel rod (2) 4. Put electrical tape (4) around the shank.
between the I-beam and tip-out assembly. Refer to  The electrical tape will help to prevent damage to
Figure 467. the cylinder bore and ram.

1
2

Fig. 468 (27230)

To remove the seals
5. Make sure that the manual valve is open to remove
all hydraulic pressure from the lift cylinders.
6. Remove the hydraulic fittings from the lift cylinder
2 rams.
7. Use oil absorbent material to remove oil that drains
from the hydraulic tubes.
Fig. 467 (27229)
8. Remove the cylinder cap (1). Refer to Figure 469.
30. Remove the blocks (11) from the second stage
mast. Refer to Figure 465.

To Replace the Seals in the Primary

Lift Cylinder
Note: Replace the cylinder seals if a large quantity of
hydraulic oil is on the top of the cylinder cap around the
ram. 1
Special Tools and Equipment
• Oil absorbent material
• 091240-018 seal sleeve
• 061004-026 thread-locking adhesive (blue)
• Two seal removal tools. Refer to To make the seal
removal tools below.
To make the seal removal tools
Refer to Figure 468.
1. Remove the head from a M4 (no. 8) metal screw.
2. Weld the M4 (no. 8) metal screw (1) to the end of a Fig. 469 (27232)
screwdriver with a shank (2) 150 mm long or
longer and 4 mm in diameter.
3. Examine the weld area of the shank. If it is larger
than 4 mm in diameter, use a grinder to decrease
it to 4 mm in diameter.

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CAUTION
You can cause a hydraulic leak if you cause dam- 3
age to the cylinder and ram.
When you use the seal removal tools, you can cause
4
damage to the cylinder and ram. This can cause hy-
draulic leaks.
 Do not touch the cylinder or ram with the seal re-
moval tools.

1
9. Put the seal removal tools (1) between the ram (2)
and cylinder (3), 180 degrees apart. Refer to
Figure 470. 2

1
Fig. 471 (27233)
13. Remove the wiper ring (3) from the cylinder cap
(3).
3
Note: Replace the seal and wiper ring at the same
time.
Note: Clean the seal and wiper ring area of the cylinder
2 cap and cylinder. Examine the cap and cylinder for
damage that could cause leaks.
4 To install the seals
Refer to Figure 472.

Fig. 470 (27231)

10. Push and turn the tips of the seal removal tools (1)
into the seal (4).
11. Pull the seal removal tools (1) from the cylinder to
remove the seal (4).
12. Remove the collar (1) from the cylinder (2). Refer
to 27233.
CAUTION
Sharp edges can cause damage to the seals and
cause hydraulic leaks.
Tools with sharp edges can cause damage to the
seals. The threads and sharp edges on the cylinder
and cylinder cap can cause damage to the seals. Dam-
aged seals can cause hydraulic leaks.
 Use tools that do not have sharp edges to push the
seal in the cylinder.
 Use a 091240-018 seal sleeve to keep the cylinder
threads and shoulders from damaging the seal.
 Make sure that you do not cause damage to the
wiper ring on sharp edges. Install the cylinder cap
on the ram slowly.

14. Lightly lubricate the wiper ring and seal with hy-
draulic oil.
15. Install the wiper ring in the cylinder cap.

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16. Put the 091240-018 seal sleeve (1) in the end of

the cylinder (2).
17. Install the collar (3).
18. Install the seal (4). 5
19. Remove the 091240-018 seal sleeve (1). 4
20. Install the cylinder cap.
3

1
2

2
3 4

Fig. 473 (27236)

Fig. 472 (27234)
To install the tip-out assembly
21. If you removed the blocks (11), assemble them to
the mainframe. Refer to Figure 465.
22. Put the button rests (9) on the rams (5).
23. Lower the tip-out assembly (3) to its usual position.
24. Install the four bolts (6) that hold the tip-out assem-
bly to the second stage mast. Torque the bolts to
108–122 Nm.
25. Make sure that the button rests (9) are in the cor-
rect position and install the sleeves (8) in the tip-out
assembly.
26. Apply 061004-026 thread-locking adhesive (blue)
to the four bolts that hold the rams to the tip-out
assembly.
27. Install the four bolts, lockwashers and washers that
hold the rams to the tip-out assembly.
Note: If you apply to much torque to the bolts you can
compress the sleeves. Refer to Figure 473.
1 Button rest
2 Primary cylinder ram
3 Sleeve
4 Tip-out assembly
5 Mainframe
28. Assemble the chain anchor to tip-out assembly.
29. Examine the chains, hoses and cables and make
sure that they are in the correct position in the top
of the mast.
To assemble the tip-out assembly to the secondary
ram
30. Remove the blocks from the platform.
31. Connect the battery.
32. Fully lower the platform.
33. Operate the platform lift function until the second-
ary lift cylinder ram extends into the tip-out assem-
bly.
34. Disconnect the battery.
35. Use the lift device and lift the platform to cause the
mast chains to become loose.
36. Put hardwood blocks below the platform.
37. Install the bolt and lockwasher that holds the sec-
ondary lift cylinder ram to the tip-out assembly.
To examine the truck operation
38. Assemble the cover to the top of the mast.
39. Remove the hardwood blocks below the platform.

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 CYLINDERS
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40. Lower the platform. 7. Hold 0.250-20 UNC bolt and disassemble the stop
41. Connect the battery. block from the mainframe.
42. Raise the 2nd stage mast. 8. Do steps 6 and 7 for the other stop block.
43. Remove the steel plates. To remove the cylinders
44. Examine the truck operation. 9. Attach a strap or chain below the yoke and to a lift
device.
Primary Lift Cylinder Removal 10. Use a lift device and tighten the strap or chain to
Special Tools and Equipment hold the cylinders in position.
• Oil absorbent material 11. Remove the chain, cable or strap from the hole (3)
• 0.250-20 UNC bolt in the top of the pulley plate. Refer to Figure 475.

To disassemble the components from the cylin-

ders
1. Tilt the tip-out assembly. Refer to Access to the Lift
Cylinders.
2. Disconnect the lift chains from the chain anchor.
3. Remove the lift chains from the yoke at the top of
the primary lift cylinders (1). Put the chains on top
of the tip-out assembly. Hold them in position with
a chain or strap. Refer to Figure 475.
4. Disconnect the hydraulic hoses from the lift cylin-
der rams.
5. Use oil absorbent material to remove oil that drains 3
from the hydraulic hoses.
6. Install a 0.250-20 UNC bolt (1) in one of the stop
blocks (2) at the top of the mainframe. Refer to 1
Figure 474.

1
2

Fig. 475 (27238)

12. Slowly lift the cylinders until you can get access to
the pulley (2) near the bottom of the cylinders.
13. Remove the take-up cable from the pulley.
14. Remove the cylinders from the mainframe.
Fig. 474 (27237)

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CYLINDERS
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Primary Lift Cylinder Installation

1. Attach a strap or chain below the yoke and to a lift
device.
2. Slowly lower the cylinder until you can put the roll-
ers on the mainframe I-beam flange.
3. Lower the cylinder in the mainframe. Make sure
that all the components are correctly assembled to
the cylinder.
4. Assemble the stop blocks to the mainframe.
5. Assemble the hydraulic hoses to the cylinders.
6. Install the tip-out assembly. Refer to To install the
tip-out assembly and To assemble the tip-out as-
sembly to the secondary ram.
Examine the truck operation 1
7. Remove the blocks from the platform.
8. Lower the platform.
9. Connect the battery. Fig. 476 (27239)
10. Raise the 2nd stage mast.
7. Disconnect the hydraulic tube from the bottom of
11. Remove the steel plates. the cylinder.
12. Bleed the lift cylinders. Refer to To Bleed the Lift 8. Use oil absorbent material to remove the oil that
Cylinders. drains from the hydraulic tube and cylinder.
13. Assemble the cover to the top of the mast. 9. Remove the two screws (1), lockwashers (2) and
14. Examine the truck operation. spacers (3) that hold the cylinder to the bottom of
the mainframe. Refer to Figure 477.
Secondary Lift Cylinder Removal
Special Tools and Equipment
• Oil absorbent material
To disassemble the components from the cylinder
1. Do the steps in Access to the Lift Cylinders.
2. Disconnect the lift chains from the chain anchor.
3. Remove the lift chains from the yoke at the top of
the primary lift cylinders. Put the chains on the top
of the tip-out assembly. Hold them in position with
a chain or strap. 2 3
1
4. Disconnect the hydraulic tubes from the lift cylinder
ram.
Fig. 477 (27240)
5. Use oil absorbent material to remove the oil that
drains from the hydraulic tubes. 10. Remove the cylinder from the mainframe.
6. Attach a strap or chain to the cylinder lift rings (1)
and to a lift device. Refer to Figure 476.

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 CYLINDERS
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Secondary Lift Cylinder Installation

1. Attach a strap or chain to the cylinder and to a lift
device.
2. Slowly move the cylinder to the top of the main-
frame.
3. Turn the cylinder until the mounting flange at the
bottom of the cylinder is in the direction of the tip-
out assembly. Refer to Figure 478.

1
1

Fig. 479 (27242)

Fig. 478 (27241)
4. Lower the cylinder until the stabilizers at the top of
the mainframe (2) fit in the holes of the cylinder sta-
bilizer bar (1). Refer to Figure 479.
5. Assemble the spacers, lockwashers and screws
that hold the cylinder to the bottom of the main-
frame.
6. Assemble the hydraulic tubes to the cylinder.
7. Install the tip-out assembly. Refer to To install the
tip-out assembly and To assemble the tip-out as-
sembly to the secondary ram.
Examine the truck operation
8. Remove the hardwood blocks from the platform.
9. Lower the platform.
10. Connect the battery.
11. Raise the 2nd stage mast.
12. Remove the steel plates.
13. Bleed the lift cylinders. Refer to To Bleed the Lift
Cylinder.
14. Assemble the cover to the top of the mast.
15. Examine the truck operation.

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CYLINDERS
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To Bleed the Lift Cylinders

Note: You must bleed the air from the hydraulic system
after you install a cylinder.
To prepare the truck.
1. Move the truck to a maintenance area with a level
floor.
Note: In step 2 below, do not operate the platform lift
function until the cylinders extend. 1
2. Operate the platform lift function until the lift cylin-
ders are pressurized.
 This forces air in the hydraulic system to flow to the Fig. 481 (27253)
top of the cylinders.
9. Tighten the bleed screw.
3. Turn the truck OFF.
10. Clean the oil from the cylinder.
4. Disconnect the battery.
To Bleed the Primary Lift Cylinders
5. Lockout/tagout the truck.
11. From the top of the mainframe, use a flat blade
6. Put chocks against the wheels to prevent move-
screwdriver and loosen the bleed screws (4). Refer
ment of the truck. Refer to SAFETY > Control of
to Figure 480.
Hazardous Energy > Lockout/Tagout.
12. Loosen the bleed screw until the air is out of the
To Bleed the Secondary Lift Cylinder cylinders and only oil flows from the cylinders.
7. Put a flat blade screwdriver (2) through the access 13. Tighten the bleed screws.
hole (3) of the second stage mast and mainframe.
14. Clean the oil from the cylinders.
Refer to Figure 480.
Note: A small drift of the platform can occur. This can
be from an internal leak in the cylinder seals. It can also
be from an internal leak in the hydraulic valves. When
4 this occurs, raise and lower the platform to remove the
contamination from the valve seat. Also examine the
truck for external leaks.

Fig. 480 (27248)

8. Loosen the bleed screw (1) until the air is out of the
cylinder and only oil flows from the cylinder. Refer
to Figures 480 and 481.

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 CYLINDERS
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TN Lift Cylinder Access to the Lift Cylinder

Note: You must tilt the tip-out assembly for access to
the lift cylinder.
WARNING Special Tools and Equipment
• Two 250 mm square, 13–25 mm thick steel plates
A platform and load handler that falls can cause in-
jury or death. • One steel rod approximately 0.6 m long.
Make sure that the capacity of the lift device, straps or To prepare the truck
chains and hardwood blocks can hold the platform and
1. Move the truck to a maintenance area with a level
load handler weight. If not, the platform and load han-
floor.
dler could fall.
2. Raise the platform approximately 0.5 m.
 The load handler and platform weigh approximately
2300 kg. Make sure that the lift device, straps or 3. Turn the truck OFF.
chains and hardwood blocks can hold more than 4. Disconnect the battery.
2300 kg. 5. Lockout/tagout the truck.
6. Put chocks against the wheels to prevent move-
ment of the truck. Refer to SAFETY > Control of
Hazardous Energy > Lockout/Tagout.
WARNING 7. Put hardwood blocks below the platform. Refer to
SAFETY > Control of Hazardous Energy > Jacking
High pressure fluid can go through the skin and
and Blocking.
cause injury.
High pressure fluid that goes into the skin is a medical To make the chains, hoses and cables loose
emergency. There is a delayed start of pain, and se- 8. Connect the battery.
vere tissue damage may occur. You must get medical
9. Turn the truck ON.
aid from a specialist who has had experience with this
type of injury. 10. Fully lower the cylinder.
 Avoid high pressure fluids  This will cause the lift chains, cables and hoses to
become loose.
 Release the pressure before you disconnect the hy-
draulic lines. 11. Turn the truck OFF.
 Tighten all connections before you apply the pres- 12. Disconnect the battery.
sure. 13. Pull the loose lift chains to the top of the platform
 Keep your hands and body away from pin holes until they are tight. Use cable ties or straps to hold
which eject high pressure fluids. the chains in place.
 Use a piece of cardboard or paper to examine for To disassemble the components from the tip-out
leaks. Do not use your hand. assembly
Refer to Figure 482.
14. Remove the cover on the top of the mast and hang
it to the side of the mast.
WARNING Note: A short chain is attached to the cover that lets
A cylinder that falls can cause injury or death. you hang it from the mast.
The capacity of the lift device, straps or chains and 15. Remove the retaining rings (1) from the chain an-
hardwood blocks must hold the cylinder. You must con- chor pin (2).
nect the straps or chains to safely hold the cylinder. If
not, the cylinder could fall.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the cylinder.

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CYLINDERS
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20. Lift the tip-out assembly (7) until the tip-out assem-
bly pulls out of the cylinder (5).
To put steel plates below the second stage mast
8 Refer to Figure 483.
6

5
Fig. 483 (27225)
21. Put 250 mm square, 13–25 mm thick steel plates
(1) on top of the mainframe. Put the plates on each
side of the mainframe and against the mainframe
I-beam.
22. Fully lower the second stage mast on the steel
plates.
To tilt the tip-out assembly
23. Remove the four bolts (8) and lockwashers that
hold the tip-out assembly (3) to the mast. Refer to
3 Figure 482
1
24. Tilt the tip-out assembly (1) and put a steel rod (2)
between the I-beam and tip-out assembly. Refer to
Figure 484.
2

Fig. 482 (27347)

16. Remove the chain anchor pin (2).
Note: Holes in the mainframe and second stage mast
are in line with the chain anchor pin (2).
17. Attach a strap or chain to the lift chain and hang the
lift chain to the mast.
18. Remove the one bolt (4) and lockwasher that holds
the lift cylinder (2) to the tip-out assembly (7).
19. Attach a chain, cable or strap to the lifting bar (6)
on the tip-out assembly (7) and to a lift device.

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 CYLINDERS
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To Replace the Seals in the Lift Cyl-

inder
1 Note: Replace the cylinder seals if a large quantity of
hydraulic oil is on the top of the cylinder cap around the
ram.
Special Tools and Equipment
• Oil absorbent material
• 091240-019 seal sleeve
• 061004-026 thread-locking adhesive (blue)
• Two seal removal tools. Refer to To make the seal
removal tools below.
To make the seal removal tools
Refer to Figure 486.
1. Remove the head from a M4 (no. 8) metal screw.
2. Weld the M4 (no. 8) metal screw (1) to the end of a
screwdriver with a shank (2) 150 mm long or
2 longer and 4 mm in diameter.
3. Examine the weld area of the shank. If it is larger
Fig. 484 (27229) than 4 mm in diameter, use a grinder to decrease
it to 4 mm in diameter.
25. Open the manual lowering valve. Refer to
4. Put electrical tape (4) around the shank.
Figure 485.
 The electrical tape will help to prevent damage to
 This will release the hydraulic pressure in the cir-
the cylinder bore and ram.
cuit and cause the ram in the lift cylinder to retract.

2
1

Fig. 486 (27230)

Fig. 485 (27228)

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CYLINDERS
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To remove the seals

5. Make sure that the manual valve is open to remove
all hydraulic pressure from the lift cylinder.
1
6. Remove the cylinder cap (1). Refer to Figure 487.

2
1
4

Fig. 488 (27231)

8. Push and turn the tips of the seal removal tools (1)
into the seal (4).
9. Pull the seal removal tools (1) from the cylinder to
remove the seal (4).
10. Remove the collar (1) from the cylinder (2). Refer
to Figure 489.
Fig. 487 (27232)

CAUTION 3
You can cause a hydraulic leak if you cause dam-
age to the cylinder and ram. 4
When you use the seal removal tools, you can cause
damage to the cylinder and ram. This can cause hy-
draulic leaks.
 Do not touch the cylinder or ram with the seal re-
moval tools. 1

7. Put the seal removal tools (1) between the ram (2)
2
and cylinder (3), 180 degrees apart. Refer to
Figure 488.

Fig. 489 (27233)

11. Remove the wiper ring (3) from the cylinder cap
(3).
Note: Replace the seal and wiper ring at the same
time.
Note: Clean the seal and wiper ring area of the cylinder
cap and cylinder. Examine the cap and cylinder for
damage that could cause leaks.
To install the seals
Refer to Figure 490.

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 CYLINDERS
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CAUTION
Sharp edges can cause damage to the seals and 8
cause hydraulic leaks. 6
Tools with sharp edges can cause damage to the
seals. The threads and sharp edges on the cylinder
and cylinder cap can cause damage to the seals. Dam-
aged seals can cause hydraulic leaks. 7
 Use tools that do not have sharp edges to push the
seal in the cylinder.
 Use a 091240-019 seal sleeve to keep the cylinder
4
threads and shoulders from damaging the seal.
 Make sure that you do not cause damage to the
wiper ring on sharp edges. Install the cylinder cap
on the ram slowly.

12. Lightly lubricate the wiper ring and seal with hy-
draulic oil.
13. Install the wiper ring in the cylinder cap. 5
14. Put the 091240-019 seal sleeve (1) in the end of
the cylinder (2).

1
2

3
3 4 1

Fig. 490 (27234) Fig. 491 (27347)

15. Install the collar (3). 20. Install the four bolts (8) that hold the tip-out assem-
16. Install the seal (4). bly to the second stage mast. Torque the bolts to
108–122 Nm.
17. Remove the 091240-019 seal sleeve (1).
21. Attach a chain, cable or strap to the lifting bar (6)
18. Install the cylinder cap.
on the tip-out assembly (7).
To install the tip-out assembly 22. Raise the 2nd stage mast.
Refer to Figure 491. 23. Remove the steel plates from the mainframe.
19. Lower the tip-out assembly (7) to its usual position. 24. Lower the tip-out assembly (7) on the lift cylinder
ram (5).

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CYLINDERS
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25. Install the bolt and lockwasher (4) that holds the lift
cylinder ram to the tip-out assembly.
26. Align the chain anchor (3) hole with the holes in the
mainframe and second stage mast.
27. Install the chain anchor pin (2).
28. Install the retaining rings (1) to the chain anchor pin
(2).
3. Disconnect the hydraulic tube from the bottom of
the cylinder.
4. Use oil absorbent material to remove the oil that
drains from the hydraulic tube and cylinder.
5. Remove the two screws (1), lockwashers (2) and
spacers (3) that hold the cylinder to the bottom of
the mainframe. Refer to Figure 493.

Examine the truck operation

29. Remove the cable ties or strap that holds the lift
chain to the platform.
30. Connect the battery.
31. Raise the platform.
32. Remove the hardwood blocks from below the plat-
form.
33. Lower the platform.
34. Bleed the lift cylinder. Refer to To Bleed the Lift 3
Cylinders. 1 2
35. Assemble the cover to the top of the mast.
36. Examine the truck operation. Fig. 493 (27240)
6. Remove the cylinder from the mainframe.
Lift Cylinder Removal
Special Tools and Equipment Lift Cylinder Installation
• Oil absorbent material 1. Attach a strap or chain to the cylinder and to a lift
To disassemble the components from the cylinder device.
1. Do the steps in Access to the Lift Cylinders. 2. Slowly move the cylinder to the top of the main-
frame.
2. Attach a strap or chain to the cylinder lift rings (1)
and to a lift device. Refer to Figure 492.

Fig. 492 (27239)

M8.0-1970-105 TSP 7000 SERIES Crown 2012 PF25730-6

580
 CYLINDERS
TN LIFT CYLINDER

3. Turn the cylinder until the mounting flange (1) at 7. Install the tip-out assembly. Refer to To install the
the bottom of the cylinder is in the direction of the tip-out assembly.
tip-out assembly. Refer to Figure 494.
Examine the truck operation
8. Remove the cable ties or strap that holds the lift
chain to the platform.
9. Connect the battery.
1
10. Raise the platform.
11. Remove the hardwood blocks from below the plat-
form.
12. Lower the platform.
13. Bleed the lift cylinder. Refer to To Bleed the Lift
Cylinders.
14. Assemble the cover to the top of the mast.
15. Examine the truck operation.

To Bleed the Lift Cylinders

Fig. 494 (27241)
4. Lower the cylinder until the stabilizers at the top of
the mainframe (2) fit in the holes of the cylinder sta-
bilizer bar (1). Refer to Figure 495.
1
Note: You must bleed the air from the hydraulic system
after you install a cylinder.
To prepare the truck.
1. Move the truck to a maintenance area with a level
floor.
Note: In step 2 below, do not operate the platform lift
function until the cylinders extend.
2. Operate the platform lift function until the lift cylin-
ders are pressurized.
 This forces air in the hydraulic system to flow to the
top of the cylinders.
3. Turn the truck OFF.
4. Disconnect the battery.
5. Lockout/tagout the truck.
6. Put chocks against the wheels to prevent move-
ment of the truck. Refer to SAFETY > Control of
Hazardous Energy > Lockout/Tagout.

Fig. 495 (27242)

5. Assemble the spacers, lockwashers and screws
that hold the cylinder to the bottom of the main-
frame.
6. Assemble the hydraulic tube to the cylinder.

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CYLINDERS
TN LIFT CYLINDER

To Bleed the Lift Cylinder

7. Put a flat blade screwdriver (5) through the access
hole (4) of the second stage mast (2) and main-
frame (3). Refer to Figure 496.

1 2

5 4 3

Fig. 496 (27348)

8. Loosen the bleed screw (1) until the air is out of the
cylinder (6) and only oil flows from the cylinder. Re-
fer to Figures 496 and 497.

Fig. 497 (27253)

9. Tighten the bleed screw.
10. Clean the oil from the cylinder.
Note: A small drift of the platform can occur. This can
be from an internal leak in the cylinder seals. It can also
be from an internal leak in the hydraulic valves. When
this occurs, raise and lower the platform to remove the
contamination from the valve seat. Also examine the
truck for external leaks.

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 CYLINDERS
AUXILIARY LIFT CYLINDER

Auxiliary Lift Cylinder
WARNING
High pressure fluid can go through the skin and
cause injury.
High pressure fluid that goes into the skin is a medical
emergency. There is a delayed start of pain, and se-
vere tissue damage may occur. You must get medical
aid from a specialist who has had experience with this
type of injury.
 Avoid high pressure fluids
 Release the pressure before you disconnect the hy-
draulic lines.
 Tighten all connections before you apply the pres-
sure.
 Keep your hands and body away from pin holes
which eject high pressure fluids.
 Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
1. Remove the head from a M4 (no. 8) metal screw.
2. Weld the M4 (no. 8) metal screw (1) to the end of a
screwdriver with a shank (2) 150 mm long or
longer and 4 mm in diameter.
3. Examine the weld area of the shank. If it is larger
than 4 mm in diameter, use a grinder to decrease
it to 4 mm in diameter.
4. Put electrical tape (4) around the shank.
 The electrical tape will help to prevent damage to
the cylinder bore and ram.
2
1
4
3

Fig. 498 (27230)

To prepare the truck
WARNING 1. Move the truck to a maintenance area with a level
A cylinder that falls can cause injury or death. floor.
The capacity of the lift device, straps or chains and 2. Fully lower the forks.
hardwood blocks must hold the cylinder. You must con- 3. Turn the truck OFF.
nect the straps or chains to safely hold the cylinder. If
4. Disconnect the battery.
not, the cylinder could fall.
5. Lockout/tagout the truck.
 Make sure that the lift device, straps or chains and
hardwood blocks can safely hold the cylinder. 6. Put chocks against the wheels to prevent move-
ment of the truck. Refer to SAFETY > Control of
Hazardous Energy > Lockout/Tagout.
To Replace the Seals in the Auxiliary
Lift Cylinder
Note: Replace the cylinder seals if a large quantity of
hydraulic oil is on the top of the cylinder cap around the
ram.
Special Tools and Equipment
• Oil absorbent material
• 091240-004 seal sleeve
• 061004-026 thread-locking adhesive (blue)
• Two seal removal tools. Refer to To make the seal
removal tools below.
To make the seal removal tools
Refer to Figure 498.

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CYLINDERS
AUXILIARY LIFT CYLINDER

To remove the hydraulic pressure

7. Remove the cover for the load sensor (1) on the
back of and near the bottom of the load handler.
Refer to Figure 499.

1
1

Fig. 499 (27344)

8. Put oil absorbent material below the load sensor.
9. Put a towel on the load sensor fitting to decrease
the risk of spray.
10. Slowly loosen the load sensor fitting to remove the Fig. 500 (27345)
pressure in the hydraulic circuit.
To get access to the cylinder cap CAUTION
11. Attach a chain or strap to the fork carriage.
You can cause a hydraulic leak if you cause dam-
12. Use a lift device and lift the platform approximately
age to the cylinder and ram.
0.5 m.
When you use the seal removal tools, you can cause
 This will cause the lift chains, cables and hoses to damage to the cylinder and ram. This can cause hy-
become loose. draulic leaks.
13. Put hardwood blocks below the fork carriage.  Do not touch the cylinder or ram with the seal re-
14. Remove the yoke from the lift cylinder. moval tools.
To remove the seals
16. Put the seal removal tools (1) between the ram (2)
15. Remove the cylinder cap (1). Refer to 27345.
and cylinder (3), 180 degrees apart. Refer to
Figure 501.

M8.0-1970-201 TSP 7000 SERIES Crown 2012 PF25729-2

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 CYLINDERS
AUXILIARY LIFT CYLINDER

Note: Replace the seal and wiper ring at the same

time.
Note: Clean the seal and wiper ring area of the cylinder
1 cap and cylinder. Examine the cap and cylinder for
damage that could cause leaks.
To install the seals
3 Refer to Figure 503.

2 CAUTION
Sharp edges can cause damage to the seals and
4 cause hydraulic leaks.
Tools with sharp edges can cause damage to the
seals. The threads and sharp edges on the cylinder
Fig. 501 (27231) and cylinder cap can cause damage to the seals. Dam-
aged seals can cause hydraulic leaks.
17. Push and turn the tips of the seal removal tools (1)  Use tools that do not have sharp edges to push the
into the seal (4). seal in the cylinder.
18. Pull the seal removal tools (1) from the cylinder to  Use a 091240-004 seal sleeve to keep the cylinder
remove the seal (4). threads and shoulders from damaging the seal.
19. Remove the collar (2) from the cylinder. Refer to  Make sure that you do not cause damage to the
27345. wiper ring on sharp edges. Install the cylinder cap
on the ram slowly.

21. Lightly lubricate the wiper ring and seal with hy-
draulic oil.
22. Install the wiper ring in the cylinder cap.
3
23. Put the 091240-004 seal sleeve (1) in the end of
the cylinder (2).
1

1
2

3 4

Fig. 502 (27345)

Fig. 503 (27234)
20. Remove the wiper ring (3) from the cylinder cap
(1). 24. Install the collar (3).

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CYLINDERS
AUXILIARY LIFT CYLINDER

25. Install the seal (4).

26. Remove the 091240-004 seal sleeve.
27. Install the cylinder cap.
Examine the truck operation
28. Install the yoke.
29. Remove the blocks from the fork carriage.
30. Remove the chain or strap from the fork carriage.
31. Tighten the load sensor fitting.
32. Install the load sensor cover.
33. Connect the battery.
34. Bleed the lift cylinders. Refer to To Bleed the Aux-
iliary Lift Cylinder.
35. Examine the truck operation. 1

To Bleed the Auxiliary Lift Cylinder

Note: You must bleed the air from the hydraulic system
after you install a cylinder and cylinder seals.
To prepare the truck.
1. Move the truck to a maintenance area with a level
floor.
2. With no load on the forks, fully raise and lower the
forks.
3. Turn the truck OFF. Fig. 504 (27346)
4. Disconnect the battery. 12. Tighten the bleed screw.
5. Lockout/tagout the truck. 13. Clean the oil from the cylinder.
6. Put chocks against the wheels to prevent move-
ment of the truck. Refer to SAFETY > Control of
Hazardous Energy > Lockout/Tagout.
7. Examine the oil in the hydraulic reservoir. If neces-
sary, add oil to the full line.
8. Connect the battery.
9. Fully raise and lower the forks five times.
 This forces air in the hydraulic system to flow to the
top of the cylinder.
10. Disconnect the battery.
To Bleed the Auxiliary Lift Cylinder
11. Loosen the bleed screw (1) until the air is out of the
cylinder and only oil flows from the cylinder. Refer
to Figure 504.

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 CYLINDERS
FORK CYLINDERS

Fork Cylinders
Refer to Figure 505.
The fork cylinders on your truck are double-acting, pis-
ton-type, cylinders. Use extreme care when you make
adjustments or repairs to the cylinders. It is important
to maintain the relationship of ports and hydraulic lines
to prevent problems in reassembly or replacement of
parts.
• Replace the rod packing and wiper ring if there is a
large quantity of hydraulic oil at the rod end of the
fork cylinder.
• Replace the o-ring and backup ring if there is hy-
draulic oil on the outer surface of the fork cylinder.
• Replace the piston seals if it becomes hard to ex-
tend and retract the load.

2 4
1 3 5 16 7 8
6

14 12
13 9
15
11 10

Fig. 505 (21328-01)

1 Nut 5 Bearing slide 9 Clamp block 13 Fork
2 O-ring 6 Rod packing 10 Wiper ring 14 Seal
3 Spacer 7 Piston rod 11 Backup ring 15 Piston
4 Fork extension 8 .250 shoulder screw 12 End cap 16 O-ring

Cylinder Disassembly
Refer to Figure 506.
Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the platform and forks.
3. Pivot the forks to a straight forward position.
4. Raise the forks approximately 914 mm (36 in) and
put hardwood blocks below the forks to keep them
at that height.
5. Turn the truck OFF.
6. Put chocks against the tires to prevent the move-
ment of the truck.
7. Disconnect the battery.
8. Lockout/tagout the truck. Refer to SAFETY > Con-
trol of Hazardous Energy > Lockout/Tagout.

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CYLINDERS
FORK CYLINDERS

Release the hydraulic pressure from the fork cylin-

ders
5

WARNING
High pressure hydraulic system 5
There is a risk of injury from high pressure hydraulic oil.
 Before you open a section of the hydraulic system, 7
release the pressure.
 Before you pressurize the hydraulic system, tighten 6
2 4
all hydraulic connections.
 Keep your hands and body away from pin holes
which eject high pressure hydraulic oils. 6
 Use a piece of paper or cardboard to do a leak 3
check. Do not use your hand or body.
 High pressure fluid that goes into the skin is a med- 1
ical emergency although the skin can look usual at
first. Fig. 506 (21329-01)
 There is a delayed start of pain and severe tissue 13. Remove the bearings (5) from the top and bottom
damage can occur. of the fork (4).
 Get medical aid from a specialist who has experi- 14. Clean the rod end area of the fork before more dis-
ence with this type of injury. assembly.
15. Remove the screws (6) used to hold the block
9. Put a catch pan or an oil absorbent pad below the clamps (7) on the fork (4). Then remove the two
forks. block clamps (7).
10. Open the hydraulic fittings connected to the forks,
two on each fork.
CAUTION
Remove the piston rod assembly
Sharp edges can cause damage.
11. Remove the shoulder screw (1) from the tip of the
Use precaution when you remove the piston rod as-
fork extension (2) that connects the fork extension
sembly from the fork.
to the piston rod (3).
 Do not let the piston rod come in contact with sharp
12. Remove the fork extension (2) from the fork (4) and
edges.
put it aside.

16. Carefully remove the piston rod assembly (3) from

the fork (4).
17. Examine the fork cylinder bore for signs of scoring.
If scoring is found, replace the fork. Hone the fork,
as necessary, to remove burrs.
Disassemble the piston rod
18. Put the clevis end of the piston rod in a vise.
Note: Make sure that you hold the piston rod near the
welded area of the clevis to prevent permanent defor-
mation of the clevis.
19. Remove the nut and remove all of the components
off the piston rod.
20. Examine the piston rod for scoring. If scoring is
found, replace the piston rod.

M8.0-1970-301 TSP 7000 SERIES Crown 2012 PF25727-2

588

21. Use a hooked tool like the one shown in Figure 507
to remove the backup ring 11), o-ring (16), wiper
ring (10), and rod packing (6) from the end cap (12)
(refer to Figure 505).
Note: The tool must be aluminum or brass so it does
not cause damage to surfaces.
127 mm (5 in)
Fig. 507 (21330)
22. Remove the o-ring (2) and seal (14) from the piston
(15). Refer to Figure 505.
23. Examine all of the parts and give special attention
to seal seating areas. Remove burrs, dirt, and seal
debris.
WARNING
Injury can occur if you do not wear protective
equipment when you use low pressure com-
pressed air.
 Wear a protective face shield when you use low
pressure compressed air.
24. Clean all metal cylinder components in a good
grade solvent and blow dry with low pressure com-
pressed air.
25. Put the parts in a clean area for reassembly later.
Reassemble the cylinder
CAUTION
Burrs, nicks, and contamination can cause the
seals to fail.
 Examine the areas where the seals seat.
 Burrs, nicks, and contamination can cause a seal to
deform and lose its sealing ability
26. Put the piston in a vise.
Crown 2012 PF25727-3 TSP 7000 SERIES
CYLINDERS
FORK CYLINDERS
Note: Put a cover on the area of the piston that will be
in the vise to prevent damage to the piston.
27. Apply hydraulic oil to the o-ring, piston, and piston
seal.
CAUTION
Incorrect seal installation tools can cause damage.
Use the correct seal installation tools to prevent dam-
age to the seals or the sealing edges.
 Seal installation tools must be made of soft metal or
plastic.
 Seal installation tolls must be free of burrs and
sharp edges.
 Do not use a screwdriver or other equivalent tool.
 Do not use cone-shaped installation tools to install
snap-in piston seals.
Note: Cone-shaped installation tools will cause the
seal to stretch to a much larger diameter and will re-
quire very high assembly force.
28. Push one side of the piston seal into the groove in
the piston. Refer to Figure 508. Then hold the seal
with your thumb and push the seal into the groove.
Refer to Figure 509.
Critical Seal
Seating Area
Fig. 508 (21331)
M8.0-1970-302
589
CYLINDERS
FORK CYLINDERS
Fig. 509 (12891)
29. Install the o-ring (2) in piston (15). Refer to
Figure 505.
30. Apply hydraulic oil to the o-ring (16), backup ring
(11), wiper ring (10), rod packing (6), and end cap
(12). Refer to Figure 505.
31. Carefully put the o-ring (16), backup ring (11), and
wiper ring (10) in the end cap (12). Refer to
Figure 505.
32. Install the rod packing (6) in end cap (12). Refer to
Figure 505.
Note: Two tools are necessary to help with the installa-
tion.
 First, a groove alignment plug is necessary (refer
to Figure 510). It must be flush with the groove
edge and any metal or plastic material which is
smooth and lubricated may be used.
 Second, a soft metal or plastic pusher rod.
Squeeze the rod packing together and put one end into
the bore first. When the lower end is engaged in the
installation groove, use the pusher rod to push the
other end of the rod packing into the installation
groove.
Note: Make certain the rod packing is installed in
groove so that the lips will face the piston when the end
cap is installed on the piston rod.
M8.0-1970-303 TSP 7000 SERIES
590
3
Fig. 510 (21332-01)
1 Pusher rod
2 Critical seal seating area
3 Groove alignment plug
33. Apply hydraulic oil to the cylindrical portion of pis-
ton rod.
34. Install the end cap (12), spacer (3), and piston as-
sembly (14 & 15) on the piston rod (7). Then install
the nut (1) on the piston rod (7) and tighten. Refer
to Figure 505.
35. Carefully guide the piston rod assembly into the
fork (13). Refer to Figure 505.
36. Install clamp blocks (9) to hold the end cap (12) on
the end of the fork. Refer to Figure 505.
37. Bleed the fork cylinders. Refer to To Bleed the Fork
Cylinders.
38. Examine the bearings (5) and replace if necessary.
Then install the bearings (5) on the fork (4). Refer
to Figure 506.
39. Install the fork extension (2) on the piston rod (3).
40. Install shoulder screws (6) to hold the fork exten-
sion (2) on the piston rod (3).
Prepare the truck for operation
41. Connect the battery.
42. Remove the chocks.
43. Remove the catch pan or oil absorbent pad from
below the forks.
44. Remove the blocks from below the forks.
45. Turn the truck ON.
46. Fully lower the forks.
Crown 2012 PF25727-4
 CYLINDERS
FORK CYLINDERS

47. Do a check for hydraulic leaks. Repair as neces-

sary.
48. Make sure that the truck operates correctly.

To Bleed the Fork Cylinders

Note: You must bleed the air from the hydraulic system
after you install a cylinder.
Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. Fully lower the platform and forks.
3. Pivot the forks to a straight forward position.
4. Raise the forks enough to put a catch pan or an oil
absorbent pad below the forks.
Bleed the fork cylinders
5. Open the hydraulic fittings connected to the forks,
two on each fork.
6. Extend the forks slowly.
7. Retract the forks slowly.
8. Tighten the hydraulic fittings when a steady flow of
oil is coming out at the hydraulic fittings.
Prepare the truck for operation
9. Remove the catch pan or oil absorbent pad from
below the forks.
10. Fully lower the forks.
11. Turn the truck OFF.
12. Wipe off the forks.
13. Turn the truck ON.
14. Do a check for hydraulic leaks. Repair as neces-
sary.
15. Make sure that the truck operates correctly.

Crown 2012 PF25727-5 TSP 7000 SERIES M8.0-1970-304

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CYLINDERS
PIVOT CYLINDERS

Pivot Cylinders General Information

WARNING
High pressure fluid can go through the skin and
cause injury.
High pressure fluid that goes into the skin is a medical
emergency. There is a delayed start of pain, and se-
vere tissue damage may occur. You must get medical
aid from a specialist who has had experience with this
type of injury.
 Avoid high pressure fluids
 Release the pressure before you disconnect the hy-
draulic lines.
 Tighten all connections before you apply the pres-
sure.
 Keep your hands and body away from pin holes
which eject high pressure fluids.
 Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
Two single-acting, piston-type, pivot cylinders are in
the top of the load handler. As the pressure in one cyl-
inder increases and retracts, the pressure in the other
cylinder decreases and extends. A mechanical linkage
between the cylinders turns the fork carriage.
You must follow special procedures when you remove
or repair hydraulic cylinders.
• Make sure that there is no oil or other contamination
on the cylinder surfaces before you disassemble or
remove a cylinder.
Basic Troubleshooting
Refer to Figure 511.
• If there is a large quantity of hydraulic oil at the rod
end (3) of the pivot cylinder, then replace the rod
packing (4) or wiper ring (5) as necessary.
• If the area around the outside of the cylinder at the
rod end (3) has oil present, then replace the O-ring
(8) or back-up ring (7) as necessary.
• If you cannot extend and retract the load correctly,
then replace the piston seal (11).

Fig. 511 (21333-01)

1 Piston 5 Wiper ring 9 Piston rod
2 Cylinder 6 Wire retainer 10 Flatwasher
3 Rod end 7 Backup ring 11 Piston seal
4 Rod packing 8 O-ring 12 Nut

M8.0-1970-400 TSP 7000 SERIES Crown 2012 PF25731-1

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 CYLINDERS
PIVOT CYLINDERS

Pivot Cylinder Removal

Special tools and equipment
• Catch pan or other absorbent material
Prepare the truck
1. Move the truck to a maintenance area with a level 127 mm (5 in)
floor.
2. Lower the mast and forks fully.
3. Put chocks against the wheels to prevent the
movement of the truck and mainframe. Refer to
SAFETY > Control of Hazardous Energy > Lifting
and Blocking.
Fig. 512 (21330)
4. Disconnect the battery.
5. Complete the lockout/tagout procedures for the Refer to Figure 513.
truck. Refer to SAFETY > Control of Hazardous Disassemble the pivot cylinder
Energy > Lockout/Tagout.
1. Use an adjustable spanner wrench to carefully turn
6. Open the manual lowering valve. Refer to SAFETY the rod end (2).
> Control of Hazardous Energy > Hydraulic.
 This backs the wire retainer (4) out of the slot on
7. Remove the cover from the top of the load handler. the cylinder (5)
Disconnect and remove the pivot cylinder(s) 2. Remove the wire retainer (4) and rod end (2).
Note: The hydraulic pressure in this circuit is
1378 kPa, if MVL is open or closed.
8. Prepare to catch hydraulic oil from the pivot cylin- CAUTION
der and hydraulic hoses.
Sharp edges could damage the piston rod.
Note: The hydraulic pressure in this circuit is
 Make sure that you do not permit the piston rod to
1378 kPa, if MVL is open or closed. When you open
touch any sharp edges as you remove it.
the first fitting, be prepared for the hydraulic oil pres-
sure.
9. Slowly, disconnect the hydraulic hoses from the 3. Remove the piston rod (1) from the cylinder.
pivot cylinders.
 This releases the pressure from the hydraulic cir-
cuit.
10. Disconnect the chain from the end of the piston
rods on the pivot cylinders.
11. Use a clamp to hold the fork carriage to the load
handler to prevent unwanted movement.
12. Remove the pins that hold the pivot cylinder(s) on
the load handler.
13. Remove the pivot cylinder(s).

Pivot Cylinder Disassembly

Special tools and equipment
• Adjustable spanner wrench
• Small hooked tool (Refer to Figure 512)

Crown 2012 PF25731-2 TSP 7000 SERIES M8.0-1970-401

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CYLINDERS
PIVOT CYLINDERS

8. Do an inspection to look for cuts or grooves in the

cylinder.
 If there are cuts or grooves in the cylinder, then re-
place the cylinder.
 Make sure that you remove the cause of the cuts
or grooves before you assemble the cylinder.
9. Do an inspection to look for cuts or grooves on the
piston rod.
 If there are cuts or grooves on the piston rod, then
replace the piston rod.
 Make sure that you remove the cause of the cuts
or grooves before you reassembly the cylinder.
Clean the cylinder components
10. Clean all metal cylinder components in a high-
grade solvent.

CAUTION
Compressed air can cause injury.
Compressed air can cause unwanted material or parti-
Fig. 513 (21334-01) cles to cause injury. Compressed air can also go into
1 Piston rod the body through areas without skin and cause pain or
2 Rod end severe injury.
3 Retainer groove  Use eye and face protection when you use com-
4 Wire retainer pressed air to clean components.
5 Cylinder  Do not use more than 206 kPa compressed air to
clean components.
Note: Do not remove the piston from the rod unless
you will replace the piston or rod.  Do not use compressed air on your skin or clothes.
 Use applicable protective devices for personnel in
the area.
CAUTION
11. Use low pressure compressed air to dry the com-
A screwdriver could cause damage to the cylinder ponents.
or cause leaks.
12. Keep the parts in a clean area until you assemble
 Do not use a screwdriver to remove the seals. the cylinder.
4. Use a small hooked tool to remove the piston seal
from the piston.
5. Remove the backup ring, O-ring, rod packing, and
wiper ring from the rod end (2).
Examine the pivot cylinder components for dam-
age
6. Do an inspection of the parts and seal seating ar-
eas.
Note: Burrs, cuts, grooves, and contamination in the
seal seating area can prevent a full seal.
7. Remove all burrs, contamination, or seal pieces.

M8.0-1970-402 TSP 7000 SERIES Crown 2012 PF25731-3

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 CYLINDERS
PIVOT CYLINDERS

Assemble the Pivot Cylinder

Special tools and equipment
1
• Groove alignment plug
• Soft metal or plastic pusher rod
Refer to Figure 511.

CAUTION 2

Burrs, cuts, grooves, and contamination in the seal

seating area can prevent a full seal.

1. Apply a light layer of hydraulic oil to the piston and

3
the piston seal.
2. Install the piston seal in the piston groove.
3. Apply a light layer of hydraulic oil to each of the
parts that follow:
Fig. 514 (21332-01)
– O-ring (8) 1 Piston rod
– Backup ring (7) 2 Critical seal seating area
– Wiper ring (5) 3 Groove alignment plug
– Rod packing (4)
– Rod end (3). Install the piston and rod end
4. Put the O-ring (8), the backup ring (7), and the Refer to Figure 511.
wiper ring (5) in the correct position in the rod end 8. Apply a light layer of hydraulic oil to the parts that
(3). follow:
Install the rod packing in the rod end – Outer diameter of the piston rod (9)
Refer to Figure 514. – Piston seal (11)
5. Install the groove alignment plug (3) until it is flush – Rod end (3)
with the edge of the installation groove. – Inner diameter of the rod end (3)
6. Compress the rod packing together and put the – Rod end seals.
end into the bore. 9. Install the piston rod (9) and piston (1) into the cyl-
 Make sure that you install the rod packing in the inder.
installation groove so that the lips point to the pis- 10. Install the rod end (3) and the related seals onto
ton when you install the rod end in the cylinder. the piston rod (9).
7. When the lower end is engaged in the installation Refer to Figure 513.
groove, release the packing and use the pusher
11. Push the rod end (2) into the cylinder until the re-
rod (1) to push the top end down until the rod pack-
tainer groove (3) in the rod end aligns with the slot
ing clicks into position (2).
in the cylinder (5).
12. Put the hooked end of the wire retainer (4) into the
hole of the rod end (2).
13. Use an adjustable spanner wrench to turn the rod
end (2) until the end of the wire retainer (4) is flush
with the cylinder (5).
 Do not turn the end of the wire retainer too far into
the cylinder for easy removal.

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CYLINDERS
PIVOT CYLINDERS

Pivot Cylinder Installation

Install the pivot cylinders
1. Put the pivot cylinder(s) in position on the truck.
2. Install the pins, retainers, and screws to hold the
pivot cylinder to the load handler.
3. Connect the chain to the piston rod ends of the
pivot cylinder.
4. Make sure that the fork carriage is synchronized
with the pivot cylinder position.
5. Connect the hydraulic plumbing to the cylinders.
6. Tighten the hydraulic connections.
7. Connect the battery.
8. Make sure that all truck functions are correct.
9. Make sure that there are no hydraulic oil leaks.
10. Install the cover on the top of the load handler.
11. Bleed the pivot cylinders. Refer to To Bleed the
Pivot Cylinders.
12. Remove the wheel chocks.

Pivot Cylinders Bleeding

1. Without a load on the forks, move the pivot cylin-
ders for the load handler through one full cycle.
2. Lower the mast fully.
3. Make sure that there is sufficient hydraulic oil in the
hydraulic reservoir.
 If necessary, add hydraulic oil to the reservoir to
the "FULL" line. Refer to HYDRAULIC SYSTEM >
Reservoir and Filters > Reservoir.
4. Without a load on the forks, move the pivot cylin-
ders for the load handler through a minimum of five
full cycles.
5. Loosen the bleed screw until the air is out of the
cylinder and only oil flows from the cylinder.
6. Tighten the bleed screw.
7. Clean the hydraulic oil from the cylinder.

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PLATFORM
597
Notes:

598

Platform
Inspection and Adjustment
Safe and satisfactory truck operation is dependent on
regular inspections. When you make a usual inspec-
tion of the platform, look for:
Column Roller Area
• Column rollers and thrust rollers that are worn or
not turning freely.
• Column roller plate pivots freely.
• Bushings, bearings and shafts for wear.
Overhead Guard Area
• Deformation and cracks.
• Traverse rack no broken teeth, secure and correctly
lubricated.
• Overhead guard cover.
• Mast shield.
• Correct location and operation of worklights, dome
lights, mirror and fan.
Operator Controls
• Operator Display Module (ACCESS 1).
• Steering indicator lights function correctly.
• Switch Panel (KYS, LGS1, LGS2, LGS3 (Opt), ZSS
(Opt) and JC.
• Left armrest controls (APS, ECR1, ECR2, HPSL,
POT1, POT2, TBS, TDS, RS and RSS) pivot re-
lease button and steering tiller.
• Right armrest controls (EDS, FS, GUS (Opt), HNS,
HPSR, ORS1, PLS, POT3 and PRS) ACCESS 8
and pivot release button.
• EMS1 switch, traverse override, located under
switch panel.
• Seat moves freely up and down and turns, only
when the truck is on, (SES, JC318, PC318, SLS
and EML) and condition of seat cushions.
• Left and right brake pedals (BRS1 through BRS4).
• Left, right and rear operator foot presence pedals
(FPS1 through FPS9).
• Safety belt and tether are present and in good con-
dition.
• Proper gate switch operation (GTSL, GTSR).
• Weakening of gate spring tension.
Lower Platform Area
• Traverse rack no broken teeth, tight and correctly
lubricated.
Crown 2012 PF25711-1 TSP 7000 SERIES
PLATFORM
PLATFORM
• Shock absorber pins, brackets, plungers, bumpers
and poly stops for wear behind seat.
• Height sensor reel turns freely behind seat.
• Control cable extension spring adjustment. Springs
must have a total length of 140 mm for the main
mast cable and 152 mm for the auxiliary mast ca-
ble. This will give approximately 71–80 N of pull on
each cable.
152 mm
(6.0 in)
140 mm
(5.5 in)
Fig. 515 (21303)
• Hydraulic hoses and control cables for wear and
cracks.
• Hydraulic fittings for leaks.
• Auxiliary hose and control cables for wear and
cracks.
• Correct adjustment of traverse hose. Traverse hose
must be adjusted so there is 6–16 mm clearance
between the traverse hose loop and right lower ex-
tension.
• Traverse hose tray liner for wear.
• Proper chain slack switch operation (CHS1, CHS2,
CHS3, CHS4,).
• Shaft, bushings and bearings for wear.
• Correct chain anchor adjustment. Chain anchors
must be adjusted so the distance from the platform
to the floor measures 467 mm when platform is fully
lowered. Adjust the two chain anchors in equal in-
crements to keep a balanced chain load. Refer to
Figure 516.
M9.0-1970-001
599
PLATFORM
PLATFORM

Mast Shield
Refer to Figure 517.
To do maintenance on some areas of the mast or plat-
form assembly, the mast shield can be removed. The
mast shield is installed in a rubber molding so it is fully
suspended. The molding and safety glass must be as-
sembled as shown in Figure 517. The wedge locking
strip must be pushed into the open groove to hold the
glass in position.
A wedge insertion tool (103792) will aid in the installa-
tion of the wedge locking strips. To use the tool:
1. Put the strip through the throat of the tool head and
keep approximately 25.4 mm of the strip exposed
below the head.
2. Put the tool into the V slot in the main molding
body.
3. Once started, with the strip and body ends flush,
clamp the end with your thumb and push the tool
through the slot.
If the tool pushes hard, apply a small quantity of heat to
the molding. This will melt the layer which covers the
molding and act as a lubricant.
467 mm from platform to
floor

Fig. 516 (21304-01)

• Lift chain for cracks in the plates, tight joints, pins
that extend from the chain, wear, etc. (refer to Lift
Chains for chain maintenance).

Lubrication
(Refer to Lubrication and Adjustment for lubrication in-
tervals and types of lubricants to use.)
Regular lubrication of the platform must include:
• An ample layer of grease (063002-024) or equiva-
lent to area on the mast where the column and
thrust rollers touch the mast.
• Apply a layer of chain & steel cable grease to the lift
chain.
• Spray an ample quantity of solvent (WD-40 or
equivalent) in the height sensor housing to clean it,
followed with a silicon spray, Lubriplate Spray Lube
or equivalent.
• Apply SAE 40 oil to the side gate shafts and bush-
ings and the shock absorber pins (can also use Lu-
briplate Spray Lube).
• Apply multi-purpose grease (063002-024) to the
traverse racks.

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 PLATFORM
PLATFORM

There is a gate on each side of the platform that can be

lifted up for entry or exit. The truck's lift, lower and trac-
tion functions will not work correctly if the gates are not
3 down.

2 To repair or replace the gate switches, torsion

springs, lower pivot shafts, etc.
1. Raise the gate to the up position.
2. Remove the two screws from the cover at the lower
4 arm pivot point.
3. Remove the switch assembly from the bottom of
the gate mounting bracket.

1
1

Fig. 517 (17030-02)

2
1 Main moulding body
2 Wedge locking strip 4 3
3 Wedge insertion tool
4 Glass Fig. 519 (21305-01)
1 Left platform gate shown
Gates 2 Switch and gate spring

Special Tools and Equipment 3 Spanner wrench location

• Spanner wrench (Crown part number 104712) that
has two 1.5 mm diameter pins that are 23.8 mm
apart. Refer to Figure 4.
Spanner Tool
Fig. 518 (17035-01)
4 Switch screws
4. Put the spanner wrench at the shaft end (3).
5. Keep the gate up and remove the roll pin that holds
the lower part of the gate to the shaft.
Note: As the roll pin is removed, the spring tension will
move to the spanner wrench. You will have to assume
this load with the spanner wrench to remove the punch
that you used to remove the roll pin.
6. Remove the switch screws (4).
7. Remove all the necessary parts and record their
location for the correct position when you assem-
ble the gate.
To apply spring tension when you assemble, turn the
pivot shaft in the direction of the front of the platform,
toward the load handler, until the roll pin can be in-
stalled through the lower part of the gate and shaft.

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PLATFORM
PLATFORM

GTSL & GTSR Chain Anchor and Platform Height

Gate Switches
The gate switches supply a signal if the gates are open
or closed. To access these switches, remove the two
screws from the bottom of the gate mounting bracket at
the lower arm pivot point. Remove the switch assembly
out through the bottom of the bracket. Refer to
Figure 5.
The gate switches are wired normally open and are
held closed when the gates are down. When one of the
gates is up the switch opens and prevents lift, lower
and traction functions. There are no adjustments for
these switches. Refer to Figure 520 for the location of
the components that make up the left and right gate
switches.
Adjustment
To balance the chain anchors, block the platform to re-
move the load from lift the chains so the platform is less
than 460 mm above the floor. Adjust the chain anchors
incrementally until each of the spring collars touch the
platform. Incrementally adjust each of the chain an-
chors in equal increments to tension the chains until
the platform lifts from blocking. Another procedure to
balance the chain anchors or to make sure of balance
is to use a direct readout torque wrench, not click style,
and equalize nut torque of the two chain anchors.
The chain anchors must be adjusted so the distance
from the platform to the floor measures 467 mm
(18.38 in) when the platform is fully lowered. Adjust the
chain anchors so equal tension is put on each of the lift
chains.

5 Side Thrust Roller Adjustment - Plat-

4
form (TF, TN and TT Mast)
1. Make sure the column rollers are installed with the
large radius toward the stud shoulder and the re-
1 taining rings are not damaged. Refer to
Figure 521. When you replace the column rollers,
clean the column roller studs.
2. If there is paint or corrosion on the studs, remove it
3 with emery cloth and lubricate with multi-purpose
grease (063002-024 or equivalent).

2 1 3 4
Fig. 520 (21306-01)
1 GTSL switch assembly
2 Cover
3 Switch
2
4 Insulators
5 Plate

0.75 mm (0.030 in)

1.60 mm (0.062 in)

Fig. 521 (21307-01)

1 Large radius towards mounting stud
2 2nd stage mast
3 Column roller
4 No shims

3. Adjust the cam shafts to their loosest setting.

M9.0-1970-004 TSP 7000 SERIES Crown 2012 PF25711-4

602

4. Apply a light layer of grease to each end of the cam
shaft if necessary.
5. Move the platform to one side of the 2nd stage and
push the column rollers against the stud shoulders.
6. Measure the gap, on each side, between the col-
umn roller face and web of the I-beam.
7. Divide the sum of these two gaps by two and put
this quantity of shim between the column roller and
the web on the side of the platform.
 Example:
Gap = 4.0 mm (0.157 in) + 1.0 mm (0.04 in) ÷ 2 =
2.5 mm (0.10 in)
8. Adjust the cam on the opposite side of the shim so
the thrust roller touches the flange of the I-beam.
9. Remove the shim and adjust the other cam so the
thrust roller touches the flange of the I-beam.
10. Repeat steps 1 through 8 for the upper set of thrust
rollers.
11. Move the platform up and down 2nd stage mast.
Make sure the thrust rollers roll approximately 75%
of the time and do not mark the mast.
12. Examine the platform to see if the gaps between
the uprights and 2nd stage mast are about the
same.
 If the platform rubs on the 2nd stage mast or you
think it does not sit square on the mast, adjust the
side thrust rollers.
Traverse Hose Replacement
Note: Right and left references shall be to the truck as
if the operator is facing the forks.
Prepare the truck
1. Traverse the load handler fully to the right
 This will give better access and easier disassembly
and assembly of the traverse hose connections at
the load handler.
Note: It is recommended the traverse hoses be re-
placed as a pair.
2. Raise the platform 915–1525 mm if possible.
3. Put blocks below the platform and lower the plat-
form onto blocks to release the hydraulic pressure
in the raise and lower circuit.
4. Disconnect the battery and put blocks against the
load wheels.
5. Remove the load handler covers.
Crown 2012 PF25711-5 TSP 7000 SERIES
PLATFORM
PLATFORM
WARNING
AVOID HIGH PRESSURE FLUIDS
• High pressure fluid can go through the skin and
cause serious injury.
• Release the pressure before you disconnect the hy-
draulic lines.
• Tighten all connections before you apply the pres-
sure.
• Keep your hands and body away from pin holes
which eject high pressure fluids.
• Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
• High pressure fluid that goes into the skin can be-
come a severe medical emergency even when the
skin looks normal.
• There is a delayed start of pain, and severe tissue
damage may occur.
• You must get medical aid from a specialist who has
had experience with this type of injury.
Remove the hoses
1. Disconnect the hoses at the bulkhead below the
left side of platform and at the load handler.
2. Record the location of connections.
3. Cut the cable ties.
4. Disconnect the hose clamps.
5. Remove the traverse hose assembly.
6. Examine the hoses and connectors for leaks, worn
hoses, missing clamps and hardware. Replace as
necessary.
Install the bulkhead bracket
1. Install the bulkhead bracket so there is a 6–16 mm
(0.25–0.625 in) gap between the hose and right
lower extension with the load handler all the way to
the right. Refer to Figure 9.
– For trucks with a traverse frame 152 mm wider
than the platform width (maximum design trav-
erse frame for platform), the bulkhead bracket
must use the hole near the center of the truck and
50.8 mm to the left.
– For each 25.4 mm drop in traverse frame width
from the maximum, put the bracket 1 hole
12.7 mm to the left.
Note: The bulkhead has slots in it to help with adjust-
ment.
M9.0-1970-005
603
PLATFORM
PLATFORM

– If you cannot get the necessary gap between the

hose and the extension, you can move the bolts
out by one.
2. When you have the correct gap between the hose
on the lower right extension and load handler,
torque the screws that hold the bracket to 25 Nm.
Prepare the truck for operation 1
1. Connect the battery.
2. Slowly move the load handler fully to the left. Be
careful to not damage the hose.
3. Make sure the load handler operates correctly.
4. Make sure the traverse hose clearance is correct
and check for hydraulic leaks.

Platform Removal
The weight of the platform, without the load handler, is 2
approximately 900 kg (2000 Ib) and with the load han-
dler is approximately 1450 kg (3200 Ib). Make sure
that equipment used to lift and hold the platform is of
sufficient capacity to safely handle this load and that 1
the overhead clearance is sufficient to remove the plat-
form. Fig. 522 (21309-01)
Prepare the truck
1. Raise the platform so the thrust roller covers can
be removed.
2. Disconnect the battery.
3. Put chocks against the wheels to prevent the
movement of the truck.
4. Put blocks below the platform.
5. Remove the four thrust roller covers (1) from the
back of the platform.
6. Turn the cam shafts (2) so that the thrust rollers will
not touch the mast when you remove the platform.

M9.0-1970-006 TSP 7000 SERIES Crown 2012 PF25711-6

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 PLATFORM
PLATFORM

4
5
3

12.7 mm
(0.50 in)
50.8 mm
8 (2.0 in)
9

Fig. 523 (21308-01)

1 Platform
2 Right side lower extension
3 Adjust to maintain a 6 to 16 mm (0.25 to 0.625 in) gap between the hose and extension with traverse fully to truck right
4 Hose support weldment in keyhole slot
5 Bulkhead bracket
6 Assemble this bolt to the hole nearest to the truck center when the traverse frame width is 127 mm (5.0 in) greater than the platform
width. Assemble 1 hole 12.7 mm (0.50 in) outward for each 25.4 mm (1.0 in) reduction in traverse frame width. If the gap cannot be
achieved, move the bolts out 1 hole.
7 Slots for final gap adjustment
8 Hole spacing
9 Bolt spacing

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PLATFORM
PLATFORM

Remove the load handler

1. Hold the height sensor cable (1) tight and loosen
the cable clamp screw.
Note: A ferrule (2) is crimped on the height sensor ca-
ble near the end to prevent the cable from being fully
reeled into the height sensor housing. Refer to 2
Figure 524.
2. Slowly let the cable be reeled into the height sen-
sor housing until the ferrule touches the housing. 1

Fig. 525 (21311-01)

1 Overhead guard
2 3 point hook-up
3 Hardwood block

7. Make sure that the platform is correctly blocked.

Fig. 524 (27215)
Remove the platform
1. Connect the battery.
2. Remove the blocks from platform.
3. Lower the platform.
4. Disconnect the battery.
5. Remove the load handler.
6. Attach straps or chain to the top of platform and
raise approximately 305 mm to let slack in the lift
chains, hydraulic hoses and electrical cable.
Note: If you use a chain, position wood blocks above
and below or on the upper spur rack teeth to prevent
damage when you lift the platform. Refer to SAFETY >
Control of Hazardous Energy > Lockout/Tagout for in-
structions.
8. Remove the floor mat and the covers behind and
below the seat.
Note: This will give you access to the hydraulic hose
and control cable connections, height sensor, chain an-
chors, and shock absorbers.
9. To prevent damage to the height sensor when you
remove the platform from the mast, install a bolt
with a minimum length of 31.75 mm (120962) into
the height sensor housing as shown in Figure 526.
Note: This bolt locks the reel in position to make sure
the cable does not fully reel into the housing.
10. Remove the bolts used to hold the height sensor.
11. Disconnect the connector CA310.
12. Remove the height sensor from platform.

M9.0-1970-008 TSP 7000 SERIES Crown 2012 PF25711-8

606

Fig. 526 (21312-01)
1 Bolt to hold height sensor reel
2 Remove the screws that hold the height sensor
13. Record the type and location of the control cables.
14. Disconnect the cables.
15. Disconnect the springs from the cable grips.
16. If you have a TF Mast, remove the shock absorber
mounting pins and remove the shock absorbers.
17. Disconnect the lift chains from the anchors in the
middle of the platform floor.
18. Pull the chains from the platform.
19. Record the location of the hydraulic hoses.
20. Disconnect the hoses.
Note: Be prepared to catch hydraulic oil spills.
21. Remove the two hose retainers at the top of the
mast. Refer to Figure 527.
Crown 2012 PF25711-9
PLATFORM
PLATFORM
Hose
Retainers
Fig. 527 (21313)
22. Pull cables, chains, and hoses free of the platform
and put them over the top of mast so they are out
of the way.
23. Slowly raise the platform out the top of the mast
and move to a clean work area for repair.
Platform Assembly
Install the platform
1. Before you assemble the platform to the 2nd stage
mast, apply a layer of multi-purpose grease
(063002-024) to the area on the mast that the col-
umn and thrust rollers touch.
2. Attach straps or chain to the top of the platform and
carefully lower the platform into the mast.
 As the platform is lowered into the mast, measure
the running clearance of the column and side
thrust rollers at different intervals. Refer to Column
Roller Adjustment and Side Thrust Roller Adjust-
ment.
3. Block the platform approximately 915 mm from the
floor.
TSP 7000 SERIES M9.0-1970-009
607
PLATFORM
PLATFORM
Install the hoses, cables, and chains
1. Assemble the two hose retainers at the top of the
mast. Also, be sure the hoses, cables and chains
are correctly routed through mast.
2. Apply thread sealant (061004-005) to the hydraulic
fittings and connect the hydraulic hoses.
3. Connect the lift chains to the chain anchors.
Note: Putting the chain through the platform is easier if
you attach a wire to the chain, pushing the wire through
the platform first, and then pulling the chain in position
for assembly to the chain anchors.
4. Adjust the chain anchors to an approximate set-
ting. Correct chain anchor adjustment will be made
later.
5. If you have a TF Mast, assemble the shock absorb-
ers.
6. Connect the control cables, cable grips and
springs.
Note: Correct spring extension adjustments will be
made after platform blocks are removed and lift chain
adjustments have been made.
Install the height sensor
1. Assemble the height sensor to the platform. Put
the height sensor cable below the platform.
2. Remove the locking bolt from the height sensor
housing.
3. Remove the blocks, lower the platform and remove
the chain or straps from the platform.
4. Assemble the shield onto the overhead guard.
Make final connections and adjustments
1. Adjust the chain anchors so the distance from the
platform to the floor is 467 mm with equal tension
on each lift chain.
2. Adjust the cable grips so there is approximately
140 mm main mast cable and 152 mm auxiliary ca-
ble of spring extension.
3. Install the load handler onto the platform.
4. Connect the battery and raise the platform high
enough to connect the height sensor cable.
5. Disconnect the battery.
6. Put blocks below the platform.
7. Connect the cable to the cable anchor plate (TF/
TN) or height sensor bracket (TT).
8. Connect JC and PC310 for the height sensor.
9. Connect the battery and check for hydraulic leaks,
binding, and correct switch operation.
10. Install covers and floor mat.
M9.0-1970-010 TSP 7000 SERIES
608
Seat Pivot Bearing Assembly
Refer to Figure 528.
1. Remove the pivot bearing from the seat support.
2. Before you install the tapered roller bearings (5),
pack them in multi-purpose grease (063002-025).
3. Install the seal (6) with the spring loaded lip of the
seal to the bearing side.
4. Install the lockwasher (4) and locknut (3) on the
pivot shaft (2).
5. Torque the locknut (3) to 170 Nm while you turn the
seat support (1) to its maximum in each direction a
minimum of three times.
6. Loosen the locknut (3) until it is free. Do Not move
the bearing settings as adjusted.
7. Torque the locknut (3) to 34 Nm. Turn the locknut
until one slot in the locknut is aligned with a tab on
the lockwasher and bend the tab up into the slot.
1
2
3
4
5
6
Fig. 528 (27214)
Seat Rotate Switch Adjustment
Refer to Figure 529.
1. Remove the floor mat and the cover to get access
to the seat switch at the bottom of the seat support.
2. Manually release the locking pin and turn the seat
support to the position shown so the support cast-
ing actuator arm will touch the switch lever arm of
the seat rotate switch.
3. Loosen screws one and two on the seat rotate
switch (SPS) so the switch mounting plate can
pivot around screw one.
Crown 2012 PF25711-10
 PLATFORM
PLATFORM

4. Turn the switch mounting plate until the switch le- Seat Power Cable Installation
ver arm touches the actuator arm and activates the
switch. Refer to Figure 530.
5. Adjust the switch mounting plate past this point to When you replace the seat power cable, you must turn
make sure the switch will always be activated in the cable coils as shown. If the cable coils are not ori-
this position. entated correctly, the cable will wear when the seat is
raised or lowered.
6. Make sure that the switch lever arm does not bot-
tom out against the switch body, as this could 1. Raise the seat to its highest position.
cause damage to the lever arm. 2. Loosen the screws that attach the protective tube
7. Tighten the screws on the switch and mounting to the bottom of the tube assembly.
plate. 3. Remove the cable from the seat support and plat-
8. Manually release the locking pin and turn the seat form floor.
support around to make sure the switch operates Note: Record the position of the cable with the cable tie
and works correctly. and clamps on the seat support before you remove it.
9. Install the covers and the floor mat. The new cable installation must be the same.
Note: You must remove one cable tie, two clamps, and
a connector to remove the cable from the truck.
5 4. Put the long straight end of the power cable and
the coils up through the seat support.
6
5. Push the power cable through the protective tube
7 and attach the connector.
6. Attach the lower end of the cable coil to the seat
4 8
support with a new cable tie.
9
Note: Make sure that the new cable is installed the
SLS same as the first cable.
7. Move the tube down the cable as far as it will go
into hole "A" as shown.
EML Note: Make sure that the cable does not move down in
3 tube.
8. Pull the cable and the tube together to the top of
2 hole "A". Refer to Figure 530.
1 9. Hold the protective tube in the same position that it
will be installed in the tube assembly and look in
Fig. 529 (21316-01) hole "A" to see the position of the coils. The coils
1 Locking pin must be toward the front of the seat support as
2 Switch mounting plate shown in Figure 530.
3 Screw number 2 10. Install the protective tube to the bottom of the tube
4 Switch lever arm assembly. Install the top clamp.
5 Seat support 11. Install the lower clamp and install the cable in the
6 Actuator arm platform floor the same as the first one.
7 Shield 12. Make sure that the seat operates correctly.
8 Screw number 1
9 Seat rotate switch (SPS)

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609
PLATFORM
PLATFORM

3. Apply a sufficient quantity of weight to the bottom

of the seat to get the seat pivot castings to touch
4 the seat support and actuator arm.
4. Turn the switch mounting plate until the switch le-
ver arm touches the actuator arm and activates the
switch.
3 5. Adjust the switch mounting plate past this point to
make sure the switch will always be activated in
this position.
5 6. Make sure that the switch lever arm does not bot-
2 tom out against the switch body, as this could
cause damage to the lever arm.
7. When the switch is adjusted, tighten the two
mounting block screws.
8. Remove the weight from the seat and check to
make sure that the switch deactivates and the le-
ver arm does not touch the actuator arm. Operate
1 the seat to make sure that the adjustment is cor-
rect.
9. Install the cover.
6

7 5

6
8

3
Fig. 530 (21317-01)
1 Hole “A”
2 Protective cable tube
3 Power cable
4 Install the connector after the cord is in the protective tube 2
1
5 Mounts to the underside of the tube assembly
6 Seat Support Fig. 531 (21318-01)
7 Coiled end of the power cable will be in the seat support 1 Switch mounting block
8 Correct orientation of the coiled end of the seat power cable 2 Mounting block screws
3 Actuator arm
4 Seat pivot
Seat Up/Down Switch Adjustment
5 Seat support
Refer to Figure 531.
6 Switch lever arm
1. Remove the cover from the back of the seat to get
access to the seat switch (SES).
2. Loosen the two screws that hold the mounting
block for the switch and then tighten the same
screws.

M9.0-1970-012 TSP 7000 SERIES Crown 2012 PF25711-12

610
 PLATFORM
PLATFORM

Mirror Installation To install the mirror on a 1220 mm platform

1. Measure 368 mm from the rear edge of the over-
head guard to the edge of the tube clamp. Make
sure that the mirror is in the position as shown in
Figure 532.
2. Make sure that the mirror tube clamp is tight and
measure the distance a second time.
3. Make sure that the face of the mounting bracket is
horizontal with the overhead guard. Refer to
Figure 532.
Refer to Figure 533.
1. Move the mirror onto the mounting bracket until the
mirror clamp aligns with the groove on the shaft.
2. Equally tighten the two mirror clamp screws so the
clamp is snug on the shaft, but can be turned
around on the shaft.
3

368 mm
(14.5 in)

75 mm
(3.0 in)
1

Fig. 533 (21320-01)

2
1 Mounting location of mirror on shaft for trucks with a
1219 mm platform
2 Groove in shaft
3 Mounting bracket

3
4

Fig. 532 (21319-01)

1 Top view of the overhead guard
2 Tube clamp
3 This face of the mounting bracket to be horizontal
4 Front view of the overhead guard

Note: The mirror's mounting ball and socket are not in

the middle of the mirror. It is important to install the mir-
ror as shown depending upon platform size in order to
supply the operator with optimum vision when they use
the mirror.

Crown 2012 PF25711-13 TSP 7000 SERIES M9.0-1970-013

611
PLATFORM
PLATFORM

To install the mirror on a 1320, 1473, and 1625 mm

platforms
Refer to Figure 534. 5
1. Move the mirror onto the mounting bracket shaft
until the mirror clamp aligns with the groove on the
shaft.
2. Equally tighten the two mirror clamp screws so the
clamp is snug on the shaft, but can be turned 4
around on the shaft.

2 Fig. 535 (21322-01)

1 View “A”
2 Mirror contour
3 Mounting plate contour
4 Bottom view of Figures 533 and 534
5 See View “A”

106.6 mm Apply the label

(4.0 in) 1
1. Apply the mirror label "Objects In The Mirror Are
Fig. 534 (21321-01)
Closer Than They Appear" in the lower right hand
corner of the mirror.
1 Mounting location of mirror on shaft for trucks with a 1320,
1473 & 1625 mm platform 2. Adjust the mirror.
2 Groove in shaft
3 Mounting bracket

3. From the bottom, look up the center of the mirror

mounting bracket. Turn the mirror clamp on the
shaft until the contour of the mounting bracket vis-
ually aligns with the contour of the mirror clamp as
shown in Figure 535, view "A". Tighten the two mir-
ror clamp screws.

M9.0-1970-014 TSP 7000 SERIES Crown 2012 PF25711-14

612
 PLATFORM
PLATFORM

Mirror Adjustment
Refer to Figure 536.
1. Sit in the operator seat at the correct truck opera-
tion height and lock the seat in the 60 degree
turned position.
2. While you look in the mirror, adjust side "A" of the
mirror until it is in line and parallel to the edge of
side "B" of the platform wall.
3. Adjust side "C" of the mirror and tilt it down until
you can see the rear top power unit cover.

Fig. 536 (21323-01)

1 Side “A”
2 Side “C”
3 Side “B”

4. Have the operator make sure that the mirror ad-

justment is correct for all the other operating posi-
tions.

Crown 2012 PF25711-15 TSP 7000 SERIES M9.0-1970-015

613
PLATFORM
HEIGHT SENSOR ASSEMBLY - ECR5

Height Sensor Assembly - 5. Put blocks in position to prevent the movement of

the mast and platform. Refer to SAFETY > Control
ECR5 of Hazardous Energy > Lifting and Blocking.
6. Put chocks against the wheels to prevent the
movement of the truck and mainframe. Refer to
WARNING SAFETY > Control of Hazardous Energy > Lifting
and Blocking.
Injury can occur. 7. Disconnect the battery.
Injury can occur if you do not wear the appropriate pro-
8. Complete the lockout/tagout procedures for the
tective equipment when you do maintenance on lift
truck. Refer to SAFETY > Control of Hazardous
trucks.
Energy > Lockout/Tagout.
 Wear eye protection.
To remove the height sensor assembly
 Wear work gloves.
 Wear Steel-toed shoes.
WARNING
A mast, platform, or fork that falls or lowers can
WARNING cause injury or death.
 Do not stand below a raised fork or platform.
A mast, platform, or fork that falls or lowers can
cause injury or death.  Do not do work around or below a truck that is not
correctly blocked.
 Do not stand below a raised fork or platform.
 Make sure that the blocks are sufficient to hold the
 Do not do work around or below a truck that is not weight.
correctly blocked.
 Make sure that the blocks are sufficient to hold the
9. Do not put your hands, fingers, arms, or feet
weight.
through the mast or at pinch points.
 Do not put your hands, fingers, arms, or feet
10. While you tightly hold the cable (1), loosen the
through the mast or at pinch points.
screw (2) that holds the cable. Refer to Figure 537
(TF/TN mast) or Figure 538 (TT mast).
11. Slowly let the cable wind into the sensor housing
until the ferrule touches the sensor housing.
CAUTION
!
Note: There is a ferrule (3) on the cable that does not
Sufficient overhead clearance is necessary to pre- let the cable wind fully into the sensor housing.
vent damage to the truck or the work area.
 Make sure that there is sufficient overhead clear-
ance to raise the platform safely.

Height Sensor Assembly Removal

Prepare the truck
1. Move the truck to a maintenance area with a level
floor.
2. For TF and TN masts, raise the platform a suffi-
cient height for access to the cable anchor plate on
the bottom of the mainframe.
3. For TT masts, raise the platform a sufficient height
to get access to the height sense bracket on the
second stage mast.
4. Turn the truck OFF. Fig. 537 (27327)

M9.0-1970-100 TSP 7000 SERIES Crown 2012 PF25721-1

614
 PLATFORM
HEIGHT SENSOR ASSEMBLY - ECR5

Height Sensor Assembly Installation

To install the height sensor assembly
1. Use two bolts (2) to install the height sensor as-
sembly on the platform. Refer to Figure 540.
2. Put the cable through the opening in the bottom of
the platform.
3. Connect CA310 which comes from ECR5.
4. While you tightly hold the cable, remove the bolt (1)
from the sensor housing.

Fig. 538 (27328)

12. Remove the cover from the platform wall under the
seat.
13. Disconnect CA310 which comes from ECR5.
14. Install a 3/16-16 x 1¼ in bolt (1) into the sensor
housing. Refer to Figure 539.
 The bolt locks the cable reel.
Fig. 540 (21341-01)
15. Remove the bolts (2) that hold the height sensor
assembly.
16. Remove the height sensor assembly from the plat- WARNING
form.
A mast, platform, or forks that falls or lowers can
cause injury or death.
 Do not stand below a raised fork or platform.
 Do not do work around or below a truck that is not
correctly blocked.
 Make sure that the blocks are sufficient to hold the
weight.

5. Working under the platform, pull the cable down to

the bottom of the mainframe.
6. Use the screw (2) to attach the end of the cable to
the anchor plate (TF/TN masts) or the height sense
bracket (TT masts).
Fig. 539 (21341-01) Prepare the truck for operation
7. Connect the battery.
8. Remove the blocks from below the platform and
mast.
9. Remove the wheel chocks.
10. Remove the lockout/tagout device.
11. Make sure that all truck functions are correct.

Crown 2012 PF25721-2 TSP 7000 SERIES M9.0-1970-101

615
PLATFORM
HEIGHT SENSOR ASSEMBLY - ECR5
Height Sense Encoder (ECR5) Re-
placement
Refer to Figure 541.
To replace the height sense encoder (ECR5)
1. Remove the height sensor assembly from the
truck. Refer to PLATFORM > Height Sensor As-
sembly - ECR5 > Height Sensor Assembly Re-
moval.
2. Remove the case (1).
3. Loosen the set screw (2) that holds the shaft of
ECR5 (3) on the cable reel shaft.
4. Pull ECR5 (3) from the cable reel (4) shaft.
5. Remove the retainer (5) from ECR5.
6. Install the retainer on the new height sense en-
coder.
7. Put the shaft of the new ECR5 into the cable reel
shaft.
Note: The flat part of the ECR5 shaft must align with
the set screw.
8. Make sure that the notch in the retainer (5) goes on
the top of the taper pin (6) when you install ECR5.
9. Tighten the set screw (2).
10. Install the case (1).
11. Install the height sensor assembly on the truck.
Refer to PLATFORM > Height Sensor Assembly -
ECR5 > Height Sensor Assembly Installation.
Fig. 541 (21343-01)
M9.0-1970-102 TSP 7000 SERIES
616
Cable Replacement
Special tools and equipment:
• Swaging tool
Disassemble the height sensor assembly from the
truck
1. Remove the height sensor assembly from the
truck. Refer to PLATFORM > Height Sensor As-
sembly - ECR5 > Height Sensor Assembly Re-
moval.
Remove the cable from the cable reel
2. Remove the cable reel from the sensor housing.
3. Cut the cable where the sleeve attaches to the ca-
ble reel.
Install the new cable on the cable reel
4. Install one end of the replacement cable in the hole
on the cable reel.
5. Use a swaging tool to attach the sleeve (1) and
crimp it in position. Refer to Figure 542.
Fig. 542 (21344-01)
6. Install the cable reel into the sensor housing.
7. Install the bearing and height sense encoder as-
sembly on the sensor housing.
8. Put the assembly in a vise.
9. As you turn the cable reel, put the cable on the reel.
Refer to Figure 542.
 Make sure that the cable winds equally on the ca-
ble reel.
 Make sure that the cable is not cross-threaded on
the cable reel.
 Keep empty the last groove on the outer groove of
the cable reel.
Crown 2012 PF25721-3
 PLATFORM
HEIGHT SENSOR ASSEMBLY - ECR5

Note: It is easier to wind the cable on the reel with the

cable reel in the sensor housing.
10. Secure the cable.
Assemble the height sensor assembly
11. Install the sensor housing on the cable reel.
12. Clean the spacer (5). Refer to Figure 543.
13. Install the spacer on the cable reel (6).
14. Clean the cover (2).
15. Put a mark (1) on one of the holes on the cover (2)
to identify a start point. Refer to Figure 543.
16. Install the cover (2) without the screws (3) and
lockwashers (4).
17. Turn the cover six complete clockwise turns to pre-
load the spring.
18. Install the screws (3) and lockwashers (4).

Fig. 543 (21345-01)

Install the height sensor assembly
19. Install the height sensor assembly on the truck.
Refer to PLATFORM > Height Sensor Assembly -
ECR5 > Height Sensor Assembly Installation.

Crown 2012 PF25721-4 TSP 7000 SERIES M9.0-1970-103

617
Notes:

618
GLOSSARY
619
Notes:

620
 GLOSSARY
GLOSSARY

Glossary The Component column shows the designator or the

connector number that is in the electrical diagrams.
To help you find the components in the electrical dia- The Location column gives the general location on the
grams and the parts breakdown pages, the chart that truck (for example, in the power unit). The Function col-
follows shows these items: umn gives the function or circuit of the component. The
• Component Diagram column gives the page number of the electri-
• Location cal diagram on which you can find the component. The
value in parentheses after the page number is the
• Function same as the grid coordinate on the electrical diagram.
• Diagram The Parts Breakdown column includes the page num-
• Parts Breakdown. ber on which you can find the component and an index
number (in parentheses, if applicable).

CONNECTIONS
Location Function Diagram Parts Breakdown
CA101 Platform Seat Forward, Seat Lock DIA-1970-004 (A-3) 04.8-1970-001
Distribution Panel Switch, Brake Pedal DIA-1970-005 (A-1)
CHS1, 2, 3 and 4
CA102 Platform Factory Use Only DIA-1970-004 (A-2) 04.8-1970-001
Distribution Panel DIA-1970-005 (B-1)
CA103 Platform PS1, B+, To ODM, VCM, DIA-1970-004 (B-2) 04.8-1970-001
Distribution Panel OCM, PS2 DIA-1970-005 (C-1)
CA104 Platform +48 V To KYS, EDS, BATT DIA-1970-004 (B-2) 04.8-1970-001
Distribution Panel Neg To OCM, ODM DIA-1970-005 (B-2)
CA105 Platform +48 V, BNEG To ACM DIA-1970-004 (B-3) 04.8-1970-001
Distribution Panel DIA-1970-005 (B-2)
CA106 Platform CAN L/CAN H To ODM, OCM DIA-1970-004 (B-3) 04.8-1970-001
Distribution Panel VCM, ACM DIA-1970-005 (A-2)
CA107 Platform Mast Cable 2 DIA-1970-004 (B-4) 04.8-1970-001
Distribution Panel DIA-1970-005 (A-2)
CA108 Platform Mast Cable 1 DIA-1970-004 (B-4) 04.8-1970-001
Distribution Panel DIA-1970-005 (A-1)
CA201 Power Unit CAN L/H To GCM, HCM DIA-1970-006 (A-3) 04.8-1970-001
Distribution Panel Platform, SCM, TCM
CA202 Power Unit Dropping Resistors Drive/Tow DIA-1970-006 (A-2) 04.8-1970-001
Distribution Panel Resistors
CA203 Power Unit Drive/Tow Brake Connection DIA-1970-002 (A-2) 04.8-1970-001
Distribution Panel DIA-1970-006 (A-2)
CA204 Power Unit ED1, K2, K3 Switch Inputs DIA-1970-006 (B-2) 04.8-1970-001
Distribution Panel
CA205 Power Unit Switch Inputs DIA-1970-006 (B-3) 04.8-1970-001
Distribution Panel +48 V To SCM, VCM, Platform
CA206 Power Unit Brake, TCM, HCM, BRES, DIA-1970-006 (B-3) 04.8-1970-001
Distribution Panel Strobe, CTS

Crown 2012 PF25666-1 TSP 7000 SERIES M10-1970-001

621
GLOSSARY
GLOSSARY

CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA207 Power Unit ED Override RES5 DIA-1970-006 (C-3) 04.8-1970-001
Distribution Panel
CA301 Switch Panel FAN1, LGT5, LGT7, DIA-1970-007 (B-1) 04.8-1970-001
CA302 Switch Panel LGT2, LGT3, SB31 DIA-1970-007 (B-2) 04.8-1970-001
CA303 Switch Panel LGT4, LGT6, FAN2 DIA-1970-007 (B-3) 04.8-1970-001
CA304 Platform Operator Display DIA-1970-008 (B-1) 04.8-1970-001
ACCESS 1
CA305 Switch Panel KYS, LGS1, LGS2, LGS3, DIA-1970-008 (B-1) 04.8-1970-001
FNS, PS1, JC, ZSS
CA306 Switch Panel Power for Customer DIA-1970-008 (B-4) 04.8-1970-001
Accessories
CA308 Platform GTSR, HGTRS1 DIA-1970-009 (B-1) 04.8-1970-001
CA309 Platform CHS1, CHS2, CHS3, CHS4 DIA-1970-009 (B-2) 04.8-1970-001
CA310 Platform Main Height Encoder ECR5 DIA-1970-009 (B-3) 04.8-1970-001
CA311 Platform Vehicle Control Module AC- DIA-1970-010 (B-1) 04.8-1970-001
CESS 4
CA312 Platform Vehicle Control Module AC- DIA-1970-010 (B-2) 04.8-1970-001
CESS 4
CA313 Platform Vehicle Control Module AC- DIA-1970-010 (B-3) 04.8-1970-001
CESS 4
CA314 Platform Vehicle Control Module AC- DIA-1970-010 (B-3) 04.8-1970-001
CESS 4
CA315 Platform GTSL DIA-1970-011 (B-1) 04.8-1970-001
CA316 Platform EML, SLS, SPS DIA-1970-011 (B-1) 04.8-1970-001
CA317 Platform 8 Conductor Cable Under Seat DIA-1970-011 (B-2) 04.8-1970-001
CA318 Platform 8 Conductor Cable Under DIA-1970-011 (B-3) 04.8-1970-001
Seat, SES
CA319 Platform Right Front Foot Presence DIA-1970-012 (B-1) 04.8-1970-001
FPS7, FPS8, FPS9
CA320 Platform Left Front Foot Presence DIA-1970-012 (B-1) 04.8-1970-001
FPS4, FPS5, FPS6
CA321 Platform Left Rear Foot Presence DIA-1970-012 (B-2) 04.8-1970-001
FPS1, FPS2, FPS3
CA322 Platform Right Brake Pedal DIA-1970-012 (B-2) 04.8-1970-001
BRS1, BRS2
CA323 Platform Left Brake Pedal DIA-1970-012 (B-3) 04.8-1970-001
BRS3, BRS4
CA324 Platform Platform Strobe Light Power DIA-1970-012 (B-3) 04.8-1970-001
Supply (Optional)

M10-1970-002 TSP 7000 SERIES Crown 2012 PF25666-2

622
 GLOSSARY
GLOSSARY

CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA325 Platform Platform Right Strobe Light DIA-1970-012 (B-4) 04.8-1970-001
LGT8 (Optional)
CA326 Platform Platform Left Strobe Light DIA-1970-012 (B-4) 04.8-1970-001
LGT9 (Optional)
CA401 Power Unit Traction Control Module DIA-1970-013 (B-1) 04.8-1970-001
ACCESS 3
CA402 Power Unit Steering Control Module AC- DIA-1970-014 (B-1) 04.8-1970-001
CESS 5, CAN L/H
CA403 Power Unit Steering Control Module AC- DIA-1970-014 (B-2) 04.8-1970-001
CESS 5
CA404 Power Unit BRES, RGSL, RGSR DIA-1970-014 (B-4) 04.8-1970-001
CA405 Power Unit Strobe Light LGT1 DIA-1970-015 (B-1) 04.8-1970-001
CA406 Contactor Panel CS1, ED1, K2, HN, ALM2, DIA-1970-015 (B-1) 04.8-1970-001
Negative Bus, K3
CA407 Power Unit Traction Brake DIA-1970-002 (B-2) 04.8-1970-001
DIA-1970-016 (B-1)
CA408 Traction Motor Traction Feedback Splitter DIA-1970-016 (B-2) 04.8-1970-001
FSB1 DIA-1970-023 (A-3)
CA409 Traction Motor Traction Feedback Splitter DIA-1970-016 (C-2) 04.8-1970-001
FSB1 DIA-1970-023 (B-3)
CA410 Power Unit Steering Feedback Encoder DIA-1970-016 (B-3) 04.8-1970-001
ECR6
CA411 Power Unit Hydraulic Control Module AC- DIA-1970-017 (B-1) 04.8-1970-001
CESS 2, EMS2
CA412 Mainframe Mast Cable 1 DIA-1970-018 (B-1) 04.8-1970-001
CA413 Mainframe Mast Cable 2 DIA-1970-018 (B-1) 04.8-1970-001
CA414 Mainframe Mainframe Manifold Block, DIA-1970-018 (B-2) 04.8-1970-001
PVML, SVA, SVML, SVMR
CA415 Mainframe Hydraulic Motor M2, ECR8, DIA-1970-018 (B-3) 04.8-1970-001
TS2
CA416 Power Unit CTS (TF Mast Only) DIA-1970-018 (B-3) 04.8-1970-001
CHS 5, 6, 7, 8 (TT Mast Only) DIA-1970-018 (B-4)
CA417 Power Unit PC CAN PORT DIA-1970-019 (B-1) 04.8-1970-001
CA418 Power Unit PS3 DIA-1970-019 (B-2) 04.8-1970-001
CA419 Power Unit PS4 DIA-1970-019 (B-3) 04.8-1970-001
CA422 Mainframe TS 5 (Option) DIA-1970-019 (B-3) 04.8-1970-001
CA426 Mainframe TS 5 (Option) DIA-1970-019 (B-3) 04.8-1970-001
CA501 RH Armrest Operator Control Module DIA-1970-020 (B-1) 04.8-1970-001
GUS, HPSR, TBS, TDS, RSS

Crown 2012 PF25666-3 TSP 7000 SERIES M10-1970-003

623
GLOSSARY
GLOSSARY

CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA502 RH Armrest Operator Control Module DIA-1970-020 (B-2) 04.8-1970-001
POT1, POT2, POT4
CA503 RH Armrest Operator Control Module DIA-1970-020 (B-3) 04.8-1970-001
Switch Inputs
CA504 RH Armrest Operator Control Module DIA-1970-020 (B-3) 04.8-1970-001
Switch Inputs
CA505 RH Armrest GUS, HNS, TBS, TDS DIA-1970-020 (B-2) 04.8-1970-001
CA506 RH Armrest Hand LED, +48 V DIA-1970-020 (B-2) 04.8-1970-001
CA507 LH Armrest APS, HPSL, PLS, ORS1, DIA-1970-021 (B-1) 04.8-1970-001
POT3, PRS
CA508 LH Armrest Steer Command Encoders DIA-1970-021 (B-2) 04.8-1970-001
ECR1, ECR2
CA509 LH Armrest Battery Negative, C/C DR+, DIA-1970-021 (B-3) 04.8-1970-001
ECR1, ECR2
CA510 Overhead Guard LGT7 (Option) DIA-1970-007 (C-1) 04.8-1970-001
CA511 Overhead Guard LGT5 DIA-1970-007 (C-1) 04.8-1970-001
CA512 Overhead Guard LGT4 DIA-1970-007 (C-3) 04.8-1970-001
CA513 Overhead Guard LGT6 (Option) DIA-1970-007 (C-4) 04.8-1970-001
CA601 Power Unit (Optional) Guidance/EAC Control DIA-1970-022 (B-1) 04.8-1970-001
Module ACCESS 6
CA602 Power Unit (Optional) Guidance/EAC Control DIA-1970-022 (B-1) 04.8-1970-001
Module ACCESS 6
CA603 Power Unit (Optional) Steer Wheel Sensor Bar GS1 DIA-1970-022 (A-3) 04.8-1970-001
CA604 Mainframe (Optional) Load Wheel Sensor Bar GS2 DIA-1970-022 (A-4) 04.8-1970-001
CA605 Mainframe Bumper EAC Distribution Module DIA-1970-022 (A-1) 04.8-1970-001
(Optional) EAC Sensor B1
CA606 Mainframe Bumper EAC Distribution Module DIA-1970-022 (A-1) 04.8-1970-001
(Optional) EAC Sensor A1
CA607 Mainframe Bumper EAC Distribution Module DIA-1970-022 (A-2) 04.8-1970-001
(Optional) Digital/Analog Inputs
CA608 Mainframe Bumper EAC Distribution Module DIA-1970-022 (A-1) 04.8-1970-001
(Optional)
CA609 Mainframe Bumper EAC Distribution Module DIA-1970-022 (A-2) 04.8-1970-001
(Optional) EAC Sensor A2
CA610 Mainframe Bumper EAC Distribution Module DIA-1970-022 (A-2) 04.8-1970-001
(Optional) EAC Sensor B2
CA611 Power Unit PDS (Option) DIA-1970-023 (A-2) 04.8-1970-001
CA612 Power Unit PDS (Option) DIA-1970-023 (B-2) 04.8-1970-001

M10-1970-004 TSP 7000 SERIES Crown 2012 PF25666-4

624
 GLOSSARY
GLOSSARY

CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA613 Power Unit FSB2 (Option) DIA-1970-023 (B-2) 04.8-1970-001
CA614 Power Unit FSB2 (Option) DIA-1970-023 (B-3) 04.8-1970-001
CA701 Platform Battery Inputs, CAN H/L DIA-1970-024 (B-3) 04.8-1970-001
CA702 Platform Accessory Control Module DIA-1970-024 (B-1) 04.8-1970-001
Aux. Raise/Lower, Traverse
CA703 Platform Accessory Control Module DIA-1970-024 (B-2) 04.8-1970-001
Aux. Reset, Fork Home
CA704 Platform Accessory Control Module DIA-1970-024 (B-3) 04.8-1970-001
Load Sense, Pivot, Traverse
CA705 Platform Traverse Position Encoder DIA-1970-024 (B-4) 04.8-1970-001
ECR4
CA706 Platform Pivot Position Sense DIA-1970-024 (B-4) 04.8-1970-001
POT5
CA707 Platform Switch Input DIA-1970-024 (B-2) 04.8-1970-001
FHSL, FHSR, HGTLS2
CA708 Platform Switch Input DIA-1970-024 (B-2) 04.8-1970-001
SVAL
CA710 Platform Auxiliary Height Sense En- DIA-1970-024 (A-3) 04.8-1970-001
coder ECR3
CA711 Platform Load Sense Pressure DIA-1970-024 (A-2) 04.8-1970-001
Transducer LS
CA801 Power Unit CHS5, CHS6, CHS7, CHS8 DIA-1970-018 (B-4) 04.8-1970-001
(TT Mast Only)
CA909 Platform InfoLink DIA-1970-003 (B-4) 04.8-1970-001
CA910 Platform InfoLink DIA-1970-003 (B-4) 04.8-1970-001

Crown 2012 PF25666-5 TSP 7000 SERIES M10-1970-005

625
Notes:

626
SCHEMATIC DIAGRAMS
627
Notes:

628

Introduction to Diagram Use
Electrical Diagram
• The power up electrical diagram shows the circuits
that operate the truck (for example, CAN interface,
Access 1 2 3®, the contactor, and other compo-
nents).
• The circuits that do not operate the truck are on the
pictorials (for example, freezer condition, the wire
guidance system, lights, and other components).
• When you use the electrical diagrams, the lower
terminal board or connector numbers are to the
front of the section. The numbers increase the fur-
ther you go into the diagrams. For example: a con-
nector that starts with a 2 could be on DIA-7332-
032, while a connector that starts with a 4 could be
on DIA-7332-033.
Pictorials
• The terminal board and connector numbers on the
pictorials are in two different groups: power unit and
platform. The power unit terminal boards and con-
nectors are:
– 200s
– 400s
– 600s
– 800s.
The platform terminal boards and connectors are:
– 100s
– 300s
– 500s
– 700s
– 900s.
• The wires start at a specified location (for example,
the distribution board) and the connection points
start from the lowest number. The next connection
point from the distribution panel is with the next
group of 100s and continue for each connection
point away from the specified location.
Crown 1991 PF8974-1 Rev. 6/12 TSP 7000 SERIES
SCHEMATIC DIAGRAMS
INTRODUCTION TO DIAGRAM USE
• The terminal board and connector numbers are in
sequence on each page. A wire address with a con-
nector number or terminal board number shows
which direction to look in the electrical diagrams for
the other end of the wire. When the wire goes to a
component and not a terminal board or connector,
the pictorial shows a terminal board to refer to. This
terminal board is not a solid line and has the termi-
nal board number in parentheses. This terminal
board is not on the truck.
• The input and output arrows could be on terminal
boards and connectors. These show if the wire
transmits input or output signals. This helps to iden-
tify the source of the signal or voltage.
• Each page includes a section of the truck. When a
feature is on the truck that is not standard, a new
page includes the standard and feature wires. Only
one page of the truck section is necessary for the
applicable truck setup.
• Wires that you identify by color and not by number
are usually wires from a different manufacturer.
• The page titles, which are at the start of the electri-
cal diagrams, show the section of the truck wires on
each page.
DIA-ITD-001
03 Rev. 6/12
629
SCHEMATIC DIAGRAMS
INDEX

Index

This electrical diagram index contains the electrical di-

agrams that are applicable to your truck. Refer to the
ELECTRICAL > Electrical System section for wire color
codes, power cable codes, and electrical diagram sym-
bols.

Title Page Number Revision

Schematic - Power Unit DIA-1970-002 01 - 6/12

Schematic - Platform DIA-1970-003 01 - 6/12
Platform Distribution Panel DIA-1970-004
Platform Distribution Panel w/InfoLink® DIA-1970-005
Power Unit Distribution Panel DIA-1970-006
Lights & Fans DIA-1970-007
ACCESS 1, PS1, ZSS DIA-1970-008
Platform Chain Switches DIA-1970-009
ACCESS 4 (VCM) DIA-1970-010
Platform Seat Area DIA-1970-011
Platform Floor Area DIA-1970-012
ACCESS 3 (TCM) DIA-1970-013
ACCESS 5 (SCM) DIA-1970-014
Contactor Panel DIA-1970-015
Traction Motor & Brake DIA-1970-016
ACCESS 2 (HCM) DIA-1970-017
Hydraulic Motor DIA-1970-018
PS3, PS4, CAN Port DIA-1970-019
ACCESS 8 (OCM) DIA-1970-020
Left Armrest - Platform DIA-1970-021
ACCESS 6 (EAC/GCM) DIA-1970-022
PDS, FSB1, FSB2 (Optional) DIA-1970-023
ACCESS 7 (ACM) DIA-1970-024
Power Cables DIA-1970-025
Power Cables P/N’s DIA-1970-026
Wire Harnesses DIA-1970-027 02 - 6/12

DIA-1970-001 TSP 7000 SERIES Crown 2011 PF25259-1 Rev. 6/12

02 Rev. 6/12
630
 SCHEMATIC DIAGRAMS
SCHEMATIC - POWER UNIT

Schematic - Power Unit

A B C
M1-2 M1-4 M2-6 M2-7 M1-1 M3-2 M3-4 M2-1 M2-2 M1-7
M1-5 M1-3 M2-5 M2-4 M2-8 M3-1 M3-3 M1-6 M2-3 M1-8
+48V (KYS) FU7

1 2 3 4 1

SPARE
CAN H

CAN L
BRAKE

+48V AK
+48V FU1

+BV FU3

+BV (KYS) FU5

IMPACT SENSOR ACCESS 3

+48V (KYS) FU6

B+ B-
1 TRACTION TRACTION 1
+48V (KYS) FU7

MOTOR CONTROL
U U
FU11 M1 V V
3 W
W
CA401-13 CA401-5 ED COIL DRIVER (-)
TRACTION
1 ALM2 RES4 FSB1 TEMP
TS1
CA401-4 CA409-5
CA401-8 TEMP CA408-9 +t
CA401-12 CA401-26 +5V CA408-5 CA409-6

CA401-23
CA401-35
CA401-10 CA401-31 CHB CA408-7
CHA CA409-1 +5V
BRES 1 CA401-32 CA408-8
CA401-1 CA401-7 NEG CA408-6 CA409-3 CHB
CA409-4 CHA

CAN H
CAN L

CA408-1
CA408-3
CHA CA408-4
CA408-2
DRIVE/TOW CA409-2 NEG NOTES:
CA408-10
SWITCH CA408-11 ECR7 OPTIONAL
1
CA203 TRACTION

+5V
MOTOR 2 C/C ONLY
SPEED

NEG
CHB
RES1 RES9 M3
3 TF MAST ONLY
+ ED1 4 TT MAST ONLY
DTS ACCESS 5

RES2 RES10 A1 STEER STEER A2 5 EE TRUCKS ONLY

+V STEERING B-
CONTROL
FU13 FU10 CA403-21 +5V
CA403-3 CHB
0+ CA403-9 CA403-4 CHA
NEG
FU9 CA403-22
I+ CA403-7 CA403-19 ED OUT
0+ +
CA407 CA403-18 ED IN
I+ +5V
CS1 CURRENT K2
2 CA403-27
2
1

BRK 2

I- CA403-24 SIG
I- 3

4
0-
CA403-6
CA403-8
CA403-28 NEG SENSE
5 CA403-20 +5V +
0- 6
BRK REL CA403-17 CA403-13 CHA ECR6
CA403-23
CA403-11 CA403-14
INDEX
CHB STEERING K3
CA403-2 CA403-12 NEG FEEDBACK
CA403-15 TRAV OVERRIDE
CA402-4

CA402-5

+48V LOGIC CA403-10 CA403-1 BNEG LOGIC

+BV SENSE CA403-25 CA403-26 BNEG SENSE
CA403-16
LGT1 RGSR RGSL
1
CAN H

CAN L

5 SIG
FU24 + -

ACCESS 2 HYDRAULIC
TEMP
B+ B-
HYDRAULIC
FU12 U CONTROL TS2
U CA411-8
M2 V +t

3
V
CA411-26 +5V
ECR8
W
W HYD PUMP
CA411-31 CHA MTR SPEED
SVML CA411-2
CA411-32 CHB
SVMR CA411-5 CA411-7 BNEG

PVML CA411-4
RES5
SVA CA411-3

HN CA411-19 CA411-24
TS5
+BV CA411-13 CA411-16
+t
EMS2
3 CTS 3
CA411-1
CA411-9
CA411-18

1
3
CA411-23
CA411-35

CA411-6
CA411-10
CHS5 4 CHS6 CA411-22 SB41 FAN3
CHS8 CHS7 TS4
CAN H

CAN L

RES6 2
3

1 EAC DIST PANL

LOAD WHEEL B1
SENSOR BAR 1 ACCESS 6 CA605-1 DIG 1
2
GS2 CA602-1 +12V CA608-1 CA605-2
CA605-3
BNEG
TST 3 EAC
CA602-2 BNEG CA608-2 CA605-4 ANA 4
CA604-1 COIL 1 CA602-24
CA602-3 A2 TST CA607-1 CA605-5 +12V 5
CA604-2 COIL 2 CA602-25
A2 ANA CA607-2
CA604-3 BNEG CA602-23 CA602-4
CA607-3
A1
CA604-5 +5V CA602-22 CA602-5 A2 DIG CA606-1 1
DIG
CA604-6 STEST CA602-28 CA602-6 A2 TST CA607-4 CA606-2 BNEG 2
1 CA604-7 COIL 3 CA602-26 CA602-7 A2 ANA CA607-5 TST 3 EAC
FU1

FU3

FU5

FU6

FU8

FU4

CA606-3
CA604-8 COIL 4 CA602-27 CA602-8 A2 DIG CA607-6 CA606-4 ANA 4
CA606-5 +12V 5
FU7 FU2 GUIDANCE/EAC CA602-9 B1 TST CA607-7
GS1 CONTROL CA602-10 B1 ANA CA607-8 A2
CA609-1 DIG 1
CA602-11 B1 DIG CA607-9 CA609-2 2
CA603-1 COIL 1 CA602-17 BNEG
CA603-2 COIL 2 CA602-18 CA609-3 TST 3 EAC
CA602-12 B2 TST CA607-10 CA609-4 ANA 4
CA603-3 BNEG CA602-16
1 CA603-5 +5V CA602-15
CA602-13 B2 ANA CA607-11 CA609-5 +12V 5
CA602-14 B2 DIG CA607-12
K2 K3 CA603-6 STEST CA602-21
B2
CA603-7 COIL 3 CA602-19 1
+ + CA610-1 DIG

4 4
CA601-4

CA601-5

CA601-2

CA603-8 COIL 4 CA602-20 CA610-2 BNEG 2

STEER WHEEL CA610-3 TST 3 EAC
CA601-1 CA610-4 ANA 4
PS3 PS4 SENSOR BAR CA610-5 +12V 5
DC/DC DC/DC
CONVERTER CONVERTER ED1
CAN H

CAN L

FU22 FU23 +48V

1 1 +
3 3
+48V
2 4 2 4 72/80V BAT1
+

A B C
149446 D 1 of 2

Crown 2011 PF25259-2 Rev. 6/12 TSP 7000 SERIES DIA-1970-002

01 Rev. 6/12
631
SCHEMATIC DIAGRAMS
SCHEMATIC - PLATFORM

Schematic - Platform

A B C
HPSL HPSR RIGHT
LEFT ACCESS 8
CA504-5 CA501-3 HAND PRESENCE
HAND PRESENCE CA504-6 CA501-4
CA504-10 CA501-6
OPERATOR CA502-7
CONTROLS CA502-8 3
ECR1 +5V CA503-9 CA502-2 SIG POT1 RES7
STEER CHA CA503-11 CA502-1 +5V TRACTION
COMMAND CHB CA503-12 CA502-3 NEG EDS HTR
NEG SIG
1 ECR2 +5V
CA503-10

CA503-5
CA502-5
CA502-4 +5V
POT4
TRAVERSE
1
STEER CHA CA503-7
CA502-6 NEG
COMMAND CHB CA503-8
CA502-11 SIG POT2 MAIN
NEG CA503-6
CA502-10 +5V R/L
POT3 SIG CA504-8
CA502-12 NEG
CA501-1 TDS
+5V CA504-7
AUX NEG CA504-9
CA501-2 TBS
CA501-5
CA501-11
HNS
CA504-11 CA501-12 GUS RSS
PLS 1
CA504-12 RED
PRS CA501-7 +5V VIO BLK
GRN FS
ORS1
CA503-4 CA501-8 NEG GRN OPTICAL WHT
BLU
CA504-1
CA502-9

CAN H CA504-3
CAN L CA504-4

CA504-2
SWITCH RED
CA503-3
SES APS CA501-9 REV WHT BLOCK BLK
GRN RS
CA503-2 CA501-10 FWD BLK WHT
BLU
+48V (KYS)
3 BNEG

TS3 ACCESS 4 HGTRS1

CA314-5 CA311-5
+5V CA313-9 CA311-2 SLS
3 CHA CA313-11 VEHICLE CA311-1 SPS
CONTROL CHS1 CHS2
CHB CA313-12
CA311-12
ECR5 NEG CA313-10
CHS3 CHS4
CA311-11
RES8 MAIN CA312-10 CA311-10
GRSR GRSL
SPS HEIGHT CA312-11
FPS8 FPS9
HEATER
2 CA312-12 CA313-4
CA311-8
FPS7 4 2
CA313-7 FPS6
1 CA313-8 CA313-3
FPS5
FPS4 5
CA314-12 CA313-2
ZSS
CA312-7 FPS2 FPS3
CA311-9 6
CA313-6
FPS1
CA314-1

CAN H CA314-3
CA314-4

CA314-2

EML CA312-8
BRS1 BRS3
CA312-9 CA314-11
BRS2 BRS4
CAN L

+48V (KYS) BNEG

7 8

ACCESS 7
PVLH CA702-6
CA704-2 SIG LS LOAD SENSE
CA704-3 +14V
CA702-4 ACCESSORY
CA704-4 +5V
+BV (KYS)
PVT1
CA704-10 CHA ECR4
CUSTOMER
PVF1 CA702-9 CONTROL TRAVERSE
PVP1 CA702-8
CA704-11 CHB POSITION
OPTIONS CA704-12 NEG
SVAL CA702-5
CA306-1 PVAL CA702-2
CA703-6 +5V ECR3 NOTES:
CA703-4 CHB AUXILIARY
CA306-3 +48V (KYS) CA702-11
CA703-5 CHA HEIGHT 1 OPTIONAL
TVRS
PVAR CA702-1 CA703-9
CA704-5
NEG 2 REMOVE WHEN
PVT2 FHSL FHSR INFOLINK® INSTALLED
CA703-12 CAN L

CA702-3
CA703-1 CAN H

CA703-3
+BV (KYS) CA702-10
PVF2
CA703-2 3 C/C ONLY
3 CUSTOMER PVP2 CA702-7 CA704-1
3
CA703-11

HGTRS2 4 RF FOOT PEDAL

CA703-7

CA703-8

OPTIONS +48V (KYS) CA702-12 CA704-8 +5V POT5

+48V (KYS) CA703-10 SIG
CA704-7 PIVOT
CA306-2 POSITION EMS1 5 LF FOOT PEDAL
NEG
CA704-9
CA306-3 +48V (KYS) RES3 SENSE 6 LR FOOT PEDAL
BNEG
7 RIGHT BRAKE PEDAL
+48V (KYS) ACCESS 1
CA304-1 CA304-2 BNEG 8 LEFT BRAKE PEDAL
CAN H CA304-4
CA304-5

+48V CA304-3
ALM1
C1
+
CAN L

+
C2
PS1
+B BNEG
FU20 OUTPUT I -
OUTPUT I 12V
FU21
+ +12V
ACCY -
FU14 PWR DOME/WORK LGTS FAN
FU17
FU19

FU18

+12V INPUT I NEG

+48V(KYS) BNEG
KYS
FU16 FU15
+48V (KYS) FU6

+48V (KYS) FU7

+48V (KYS) FU7

4 2 CR1 EDS 4
+BV (KYS) FU5

START K1
CAN H

CAN L

ACC K1
+48V AK
+48V FU1
+48V FU3

CR3
IGN 1 -B -B
BRAKE

SB11 24 25 INFOLINK®4 5 13 15 -B
SPARE
CAN H

OFF
CAN L

1112 6 7 8 9 2627 -B -B
-T
123 1 2 M1-6 M2-3 M1-8
M1-5 M1-3 M2-5 M2-4 M2-8 CA910 M3-1 M3-3 CA909
M1-2 M1-4 M2-6 M2-7 M1-1 M3-2 M3-4 M2-1 M2-2 M1-7

A B C
149446 D 2 of 2

DIA-1970-003 TSP 7000 SERIES Crown 2011 PF25259-3 Rev. 6/12

01 Rev. 6/12
632
 4
3
2
1
543 CA313-6 BNEG FROM ACCESS 4
579 CA321-2 BNEG TO LEFT REAR FOOT SW
596 (CA305) ZSS-GRN/BLK BNEG TO ZSS (OPT)
565 CA316-2 BNEG TO SEAT FWD SW 1 2 3 4 5 6
584 CA323-2 BNEG TO LEFT BRAKE PEDAL

A
A
525 CA316-3 BNEG TO SEAT LOCK SW 12 11 10 9 8 7
537 CA323-4 BNEG TO LEFT BRAKE PEDAL
533 CA309-2 BNEG TO CHS3 & CHS4
Platform Distribution Panel

532 CA309-1 BNEG TO CHS1 & CHS2 PC101 & PC106 SHOWN FROM
534 (CA315) GTSL-C BNEG TO GATE SW WIRE SIDE OF CONNECTOR
535 (CA308) HGTRS1-C BNEG TO HGTRS
518 CA314-2 BNEG TO ACCESS 4
CA101 1 2 3 4 5 6 7 8 9 101112 CA102 1 2 3 4 5

MAST CABLE 1 TP2 TP9 TP8

Crown 2011 PF25259-4

TP1 CA103
2
CA108 1 515 (CA305) BNEG TO PS1 INPUT
1
FU14 2
BLK CA412-1 BNEG 301 (CA305) PS1 OUTPUT +12V
WHT CA412-2 +BV TO UNSW OPT 2 3 907 CA306-1 +BV TO UNSW OPT
RED CA412-3 +BV TO SW OPT 3 4 309 (CA305) +12V FROM FU14
GRN CA412-4 +48V (KYS) TO L/F 4 5 908 CA306-2 +BV (KYS) TO SW OPT
ORG CA412-5 +48V TO KYS 5 6 4901 (CA316) RES8 C/C +BV (KYS)
BLU CA412-6 +48V (KYS) FROM EDS 6 7 2949 (CA305) +48V (KYS) TO PS1 INPUT
WHT/BLK CA412-7 BNEG 7
TP3 8 WHT CA324-1 +48V (KYS) TO PS2 (OPT)
RED/BLK CA412-8 BNEG 8
FU15 9 513 CA306-3 BNEG TO UNSW OPT
FU16 TP12 10 BLK CA324-2 BNEG TO PS2 (OPT)
11
TP6 12 2946 CA304-1 +48V (KYS) TO ACCESS 1
MAST CABLE 2 K1
13 2950 CA314-1 +48V (KYS) TO ACCESS 4
CA107 TP10 TP11 14 2957 CA312-9 +48V (KYS) TO ACCESS 4
BLK CA413-1 BNEG MODULES 1 15 2963 CA317-6 +48V (KYS) TO ACCESS 8
FU17
WHT CA413-2 BNEG MODULES 2 16 2962 CA317-3 +48V (KYS) TO ACCESS 8
RED CA413-3 BNEG MODULES 3 FU18
FU19 R1
GRN CA413-4 BRK SW TO ACCESS 5 4 K1

B
B

ORG CA413-5 +48V (KYS) MODULES 5

BLU CA413-6 +48V (KYS) MODULES 6 TP4 + C1

CR2
TP7 C3
WHT/BLK CA413-7 CAN H 7 +
RED/BLK CA413-8 CAN L 8 C2 +
TP5
TP13

TSP 7000 SERIES

CR1

CR3
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10111213141516
CA106 CA105 CA104 2942 CA305-3 +48V (KYS) FROM KYS START
1
028 CA314-4 CAN L TO ACCESS 4 2
2961 CA317-2 +48V (KYS) TO EDS
022 CA304-5 CAN L TO ACCESS 1 2943 CA305-2 +48V (KYS) FROM KYS IGN
3 206 CA305-1 +48V TO KYS
036 CA317-7 CAN L TO ACCESS 8 2
027 CA304-4 CAN H TO ACCESS 1 2960 CA317-1 +48V (KYS) FROM EDS
1 540 CA317-4 BNEG TO ACCESS 8
029 CA314-3 CAN H TO ACCESS 4
3 541 CA317-5 BNEG TO ACCESS 8
037 CA317-8 CAN H TO ACCESS 8
512 CA304-2 BNEG TO ACCESS 1
BLK CA701-1 BNEG TO ACCESS 7 29109 -T° 29108
WHT CA701-2 +48V TO ACCESS 7 SB11
RED CA701-3 +48V TO ACCESS 7 207 CA304-3 +48V TO ACCESS 8
GRN CA701-4 BNEG TO ACCESS 7 5922 CA322-3 BRK SW TO ACCESS 5
ORG CA701-5 BNEG FROM ACCESS 7
BLU CA701-6 EMS1 TO ACCESS 7 574 5994
BRN CA701-7 CAN L TO ACCESS 7 EMS1
YEL CA701-8 CAN H TO ACCESS 7

PLATFORM DISTRIBUTION PANEL TEST POINTS NOTES:

TP1 +48V FROM PU TO KYS TP8 +12V FROM PS1 AFTER FU14 1 FOR OPTIONAL INFOLINK® SEE NEXT PAGE

C
C

TP2 +48V FROM KYS TP9 BNEG FROM FU19

TP3 BNEG FROM FU15 TP10 BNEG FROM FU17 2 FU14 4 AMP FOR 1 SET OF WORKLIGHTS
TP4 CAN H TP11 BNEG FROM FU18 FU14 3/4 AMP FOR 2 ND SET OF WORKLIGHTS
TP5 CAN L TP12 BNEG FROM FU16
TP6 BNEG (NOT FUSED) FROM PU TP13 +48V FROM KYS START
TP7 +48V (KYS) FROM K2

4
3
2
1
PLATFORM DISTRIBUTION PANEL

DIA-1970-004
SCHEMATIC DIAGRAMS

633
149689 C 1 of 2
SCHEMATIC DIAGRAMS
PLATFORM DISTRIBUTION PANEL W/INFOLINK®

Platform Distribution Panel w/InfoLink®

A B C

1 1

CA101 1 2 3 4 5 6 7 8 9 10 1112 CA102 1 2 3 4 5

TP9
TP1 TP2 TP3 TP8
2
CA103
CA108 FU14 1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8
FU15 9
FU16 10
TP6 TP12
11 GND CAN
12 TO INFOLINK®
K1 13
CA107 TP10 TP11 14
1 15
FU17
2 16
2 3
FU18 2

CR2
FU19 R1
4
5 TP7 K1
6
7 + C1
+

C3
8 +
TP5 C2
TP4
CR3

CR1
TP13

1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10111213 141516

CA106 CA105 CA104

4
CAN L CAN TO INFOLINK® +48V CAN TO INFOLINK®
206 CA305-1 +48V TO KYS

4 KEY CAN TO INFOLINK®

CAN H CAN TO INFOLINK®

MAST CABLE 3
(INFOLINK®) IGN CAN TO INFOLINK®
3 PLATFORM END POWER UNIT END 3
SHOCK SHOCK
1 1 BLK 1 1 NOTES:
2 2 WHT 2 2
3 3 RED 3 3 1 OPTIONAL INFOLINK®
4 4 GRN 4 4
2 FU14 4 AMP FOR 1 SET OF WORKLIGHTS
FU14 3/4 AMP FOR 2 ND SET OF WORKLIGHTS

PLATFORM DISTRIBUTION PANEL TEST POINTS

TP1 +48V FROM PU TO KYS TP8 +12V FROM PS1 AFTER FU14
TP2 +48V FROM KYS TP9 BNEG FROM FU19
TP3 BNEG FROM FU15 TP10 BNEG FROM FU17
TP4 CAN H TP11 BNEG FROM FU18
TP5 CAN L TP12 BNEG FROM FU16
TP6 BNEG (NOT FUSED) FROM PU TP13 +48V FROM KYS START
TP7 +48V (KYS) FROM K2

4 4

A B C
149689 C 2 of 2

DIA-1970-005 TSP 7000 SERIES Crown 2011 PF25259-5

634
 4
3
2
1
064 CA417-1 CAN H TO CAN DROPPING RESISTORS
14 DRIVE/TOW OVERRIDE E
011 CA601-4 CAN H TO ACCESS 6
023 CA411-23 CAN H TO ACCESS 2 15
005 CA413-7 CAN H TO PLATFORM 16 912
003 CA402-4 CAN H TO ACCESS 5 17
019 CA401-23 CAN H TO ACCESS 3 18
065 CA417-2 CAN L TO CAN 909
14

A
012 CA601-5 CAN L TO ACCESS 6 910
RES5

RES9
15

RES10
024 CA411-35 CAN L TO ACCESS 2
006 CA413-8 CAN L TO PLATFORM 16
Power Unit Distribution Panel

004 CA402-5 CAN L TO ACCESS 5 17 DTS

18 DRIVE/TOW SWITCH 911 913
018 CA401-35 CAN L TO ACCESS 3
CA201 1 2 3 4 5 6 7 8 9 101112 CA202 1 2 CA203
1
TP1 CR1 2
RES2
RES1

TP5 TP4

Crown 2011 PF25259-6

CR4 R3 R5 3
T 4
HOLD DR/TOW
TP6 5
CR2 6
T
CA206
501 (CA406) NEG BUS 1 TP2 R2
560 (CA411) EMS 2 BATT NEG TO EMS2 2 FU10 HOLD
4915 CA407-1 +BV (DMS) TO OUTER BRAKE 3
4907 CA403-9 OUTER BRAKE SUPPRESSION 4 TP3 FU9 FU5
4916 CA407-2 +BV (DMS) TO INNER BRAKE 5 TP13 CR5 R4 R6
4906 CA403-7 INNER BRAKE SUPPRESSION 6 FU4
TP17 TP12 K2
7 FU8 T
4902 CA401-1 +BV (KYS) TO ACCESS 3 8 FU3
4904 CA401-12 +BV (KYS) TO ACCESS 3 ID 9 TP16 FU7 TP11
4917 CA411-1 +BV (KYS) TO ACCESS 2 10 FU2
4922 CA416-3 +BV (KYS) TO C/C RES6 11 TP10 R1
FU6 +
12 FU1 C3

B
4909 CA405-1 +BV (KYS) TO LGT1 13 +
4908 CA404-1 +BV (KYS) TO BRES 14
TP14
C2 CR3
15 TP15
TP9
TP18
TP8
TP7

TSP 7000 SERIES

16 TP19

CA205 1 2 3 4 5 6 7 8 9 10111213141516 CA204 1 2 3 4 5 6

4927 CA612-6 +BV (KYS) TO PDS 1
4928 CA612-7 +BV (KYS) TO PDS 1
29159 CA416-2 +48V (KYS) TO CTS/CHS6
29160 CA416-6 +48V (KYS) TO CHS8
2903 CA403-10 +48V (KYS) TO ACCESS 5
2905 CA601-1 +48V (KYS) TO ACCESS 6
NOTE:

2920 CA413-5 +48V (KYS) TO PLATFORM

TP5 CAN L

2923 CA413-6 +48V (KYS) TO PLATFORM

TP4 CAN H

29140 (CA411) FAN3+ +48V (KYS)1

2922 CA412-4 +48V (KYS) TO LGT/FAN PS

4920 CA412-3 +BV (KYS) TO SW OPTION

1 OPTIONAL
TP19 48V FROM PS2
TP18 +BV FROM ED1

405 CA412-2 +BV TO UNSW 1 OPTION

TP9 +BV(KYS) FROM K3
TP8 +48V(KYS) FROM K2

407 CA611-1 +BV TO PDS 1

TP1 BATTERY NEGATIVE

TP7 +BV(DMS) FROM ED1

403 CA403-25 +BV TO BATT SENSE

202 CA412-5 +48V TO KEY BAT
TP10 +48v FROM FU1 TO KYS

211 (CA406) K2+ UNSW +48V FROM PS2

TP11 +BV FROM FU2 TO ACCESS 5

404 (CA406) K3+ UNSW +BV FROM ED1

C
4910 (CA406) K3 SW +BV (KYS) FROM K3
29139 (CA406) K2 SW +48V (KYS) FROM K2
TP17 +BV(KYS) FROM FU8 TO ACCESS 2 & 3
TP13 +BV FROM FU4 TO DRIVE/TOW SWITCH
TP6 +BV FROM DRIVE/TOW SWITCH RELEASE

4911 (CA406) ED1 SW +BV (DMS) FROM ED1

POWER INIT DISTRIBUTION PANEL TEST POINTS

TP3 +BV(DMS) FROM FU9 FOR INNER BRAKE COIL

TP15 48V(KYS) FROM FU6 TO PLATFORM LGT/FAN

4912 (CA406) ED1 SW +BV (DMS) FROM ED1

TP16 48V(KYS) FROM FU7 TO PLATFORM MODULES
TP2 +BV(DMS) FROM FU10 FOR OUTER BRAKE COIL

TP12 +BV FROM FU3 TO UNSW PLATFORM OPTIONS

CA207
29116 (CA411) EMS2 +48V FROM EMS2 1 29118
TP14 +BV(KYS) FROM FU5 TO SW PLATFORM OPTIONS

29117 CA403-15 +48V (KYS) FOR TRAV OVERRIDE 2 29119

POWER UNIT DISTRIBUTION PANEL

DIA-1970-006
SCHEMATIC DIAGRAMS

635
149680 B
 4
3
2
1

636
064 CA417-1 CAN H TO CAN DROPPING RESISTORS
14 DRIVE/TOW OVERRIDE ED
011 CA601-4 CAN H TO ACCESS 6
023 CA411-23 CAN H TO ACCESS 2 15
16

Lights & Fans

005 CA413-7 CAN H TO PLATFORM 912
003 CA402-4 CAN H TO ACCESS 5 17

DIA-1970-007
019 CA401-23 CAN H TO ACCESS 3 18
065 CA417-2 CAN L TO CAN 909
14

A
A
012 CA601-5 CAN L TO ACCESS 6 910

RES5

RES9
15

RES10
024 CA411-35 CAN L TO ACCESS 2
006 CA413-8 CAN L TO PLATFORM 16
17
LIGHTS & FANS

004 CA402-5 CAN L TO ACCESS 5 DTS

18 DRIVE/TOW SWITCH 911 913
018 CA401-35 CAN L TO ACCESS 3
CA201 1 2 3 4 5 6 7 8 9 101112 CA202 1 2 CA203
1
TP1 CR1 2

RES2
RES1
TP5 TP4
CR4 R3 R5 3
T 4
HOLD DR/TOW
TP6 5
CR2 6
T
CA206
501 (CA406) NEG BUS 1 TP2 R2
SCHEMATIC DIAGRAMS

560 (CA411) EMS 2 BATT NEG TO EMS2 2 FU10 HOLD

4915 CA407-1 +BV (DMS) TO OUTER BRAKE 3
4907 CA403-9 OUTER BRAKE SUPPRESSION 4 TP3 FU9 FU5
4916 CA407-2 +BV (DMS) TO INNER BRAKE 5 TP13 CR5 R4 R6
4906 CA403-7 INNER BRAKE SUPPRESSION 6 FU4
TP17 TP12 K2
7 FU8 T
4902 CA401-1 +BV (KYS) TO ACCESS 3 8 FU3
4904 CA401-12 +BV (KYS) TO ACCESS 3 ID 9 TP16 FU7 TP11
4917 CA411-1 +BV (KYS) TO ACCESS 2 10 FU2
4922 CA416-3 +BV (KYS) TO C/C RES6 11 TP10 R1
FU6 +
12 FU1 C3

B
B

4909 CA405-1 +BV (KYS) TO LGT1 13 +

4908 CA404-1 +BV (KYS) TO BRES 14
TP14
C2 CR3
15 TP15

TP9
TP18
TP8
TP7
16 TP19

CA205 1 2 3 4 5 6 7 8 9 10111213141516 CA204 1 2 3 4 5 6

TSP 7000 SERIES

4927 CA612-6 +BV (KYS) TO PDS 1
4928 CA612-7 +BV (KYS) TO PDS 1
29159 CA416-2 +48V (KYS) TO CTS/CHS6
29160 CA416-6 +48V (KYS) TO CHS8
2903 CA403-10 +48V (KYS) TO ACCESS 5
2905 CA601-1 +48V (KYS) TO ACCESS 6

NOTE:
2920 CA413-5 +48V (KYS) TO PLATFORM
TP5 CAN L

2923 CA413-6 +48V (KYS) TO PLATFORM

TP4 CAN H

29140 (CA411) FAN3+ +48V (KYS)1

2922 CA412-4 +48V (KYS) TO LGT/FAN PS

4920 CA412-3 +BV (KYS) TO SW OPTION

1 OPTIONAL
TP19 48V FROM PS2
TP18 +BV FROM ED1

405 CA412-2 +BV TO UNSW 1 OPTION

TP9 +BV(KYS) FROM K3
TP8 +48V(KYS) FROM K2

407 CA611-1 +BV TO PDS 1

TP1 BATTERY NEGATIVE

TP7 +BV(DMS) FROM ED1

403 CA403-25 +BV TO BATT SENSE

202 CA412-5 +48V TO KEY BAT
TP10 +48v FROM FU1 TO KYS

211 (CA406) K2+ UNSW +48V FROM PS2

TP11 +BV FROM FU2 TO ACCESS 5

404 (CA406) K3+ UNSW +BV FROM ED1

C
C

Crown 2011 PF25259-7

4910 (CA406) K3 SW +BV (KYS) FROM K3
29139 (CA406) K2 SW +48V (KYS) FROM K2
TP17 +BV(KYS) FROM FU8 TO ACCESS 2 & 3
TP13 +BV FROM FU4 TO DRIVE/TOW SWITCH
TP6 +BV FROM DRIVE/TOW SWITCH RELEASE

4911 (CA406) ED1 SW +BV (DMS) FROM ED1

POWER INIT DISTRIBUTION PANEL TEST POINTS

TP3 +BV(DMS) FROM FU9 FOR INNER BRAKE COIL

TP15 48V(KYS) FROM FU6 TO PLATFORM LGT/FAN

4912 (CA406) ED1 SW +BV (DMS) FROM ED1

TP16 48V(KYS) FROM FU7 TO PLATFORM MODULES
TP2 +BV(DMS) FROM FU10 FOR OUTER BRAKE COIL

TP12 +BV FROM FU3 TO UNSW PLATFORM OPTIONS

CA207
29116 (CA411) EMS2 +48V FROM EMS2 1 29118
TP14 +BV(KYS) FROM FU5 TO SW PLATFORM OPTIONS

29117 CA403-15 +48V (KYS) FOR TRAV OVERRIDE 2 29119

4
3
2
1

149690 B
 SCHEMATIC DIAGRAMS
ACCESS 1, PS1, ZSS

ACCESS 1, PS1, ZSS

A B C
CA304
2946 CA103-12 +48V (KYS) FROM DISTRIBUTION PNL 1 +48V (KYS) ACCESS 1
512 CA104-6 BNEG FROM FU18 2 BNEG ALM1
207 CA104-3 +48V FROM DISTRIBUTION PNL 3 +48V
2
027 CA106-8 CAN H FROM DISTRIBUTION PNL 4 CAN H
1 2 1
022 CA106-2 CAN L FROM DISTRIBUTION PNL 5 CAN L
6
CA305 KYS
START
206 CA104-12 +48V FROM DISTRIBUTION PNL 1 ACC
2943 CA104-13 +48V (KYS) TO DISTRIBUTION PNL 2 IGN BATT
ACC
2942 CA104-15 +48V (KYS) TO DISTRIBUTION PNL 3 OFF BATT

START
4 IGN
GND

BACK VIEW
5 OF KYS
29145 (CA303) WRK LGT +48V TO 2ND WRK LGTS 29144
LGS3
307 (CA302) DOME LGT +12V INPUT TO DOME LGTS 304
6 LGS1
29147 (CA303) WRK LGT +48V TO WRK LGTS 29144
7 LGS2
2 4 2
FNS
2955 (CA303) FAN H +48V (KYS) TO FAN HIGH
2956 (CA303) FAN L +48V (KYS) TO FAN LOW 2954

2949 CA103-7 +48V (KYS) FROM DISTRIBUTION PNL + INPUT FU20

(36/48BV) PS1
522 (CA303) FAN NEG BNEG TO OHG 12V POWER
515 CA103-1 BNEG FROM FU16 SUPPLY
301 CA103-2 +12V TO DISTRIBUTION PNL FUSE + OUTPUT FU21
602 (CA303) DOME, WRK (—) NEG FOR LGTS (+12V)

601 JC
606 (CA303) LGT6 OPT WORK LGT —
POWER JACK
309 CA103-4 +12V FROM DISTRIBUTION PNL FU14 + 12V CUSTOMER ACCY
3 3
5992 CA313-7 ZONE SELECT A TO ACCESS 4 BRN
5993 CA313-8 ZONE SELECT B TO ACCESS 4 WHT BLK
3 ZSS
GRN
5991 CA314-12 ZONE SELECT C TO ACCESS 4 BLU
596 CA101-10 BNEG FROM DISTRIBUTION PNL FU19

CA306
907 CA103-3 +BV FROM DISTRIBUTION PNL 1 RED
1
908 CA103-5 +BV (KYS) FROM DISTRIBUTION PNL 2 WHT 2
513 CA103-9 BNEG FROM FU15 3 BLK
NOTES:
LGS3 LGS1 FNS LGS2
4 1 OPTIONAL 3 CONDUCTOR WIRE RED/WHT/BLK SHOWN 2955 4
2 POWER FOR CUSTOMER ACCESSORIES
29144
309 +

3 OPTIONAL ZONE SELECT SW 304 2954 29143

601
606
29145

29147
2956
307

4 NO CONNECTION ON EE/EU TRUCKS

5 OPTIONAL 2ND SET OF WORK LIGHTS
6 DOME LIGHTS
VIEW FROM BACK SIDE OF KYS PANEL
7 WORK LIGHTS

A B C
149691 B

Crown 2011 PF25259-8 TSP 7000 SERIES DIA-1970-008

637
SCHEMATIC DIAGRAMS
PLATFORM CHAIN SWITCHES

Platform Chain Switches

A B C
(CA308)
(REFERENCE ONLY)

5920 CA311-5 HGT RESET SW TO ACCESS 4 BLK

HGTRS1
1 1
535 CA101-2 BNEG FROM DISTRIBUTION PNL BLK

590 (CA314) BNEG TO TS3

COMM NO
5918 CA311-10 GATE SWITCHES TO ACCESS 4 5919
GTSR
5919 (CA315) GTSL N.O.

CA309
532 CA101-4 BNEG TO DISTRIBUTION PNL 1 BLK
533 CA101-5 BNEG FROM DISTRIBUTION PNL 2 BLK
2 BREAK 2
CHS3 CHS4
5916 CA311-11 CHAIN BREAK TO ACCESS 4 3 BLK BLK

5917 CA311-12 CHAIN SLACK TO ACCESS 4 4 BLK BLK

CHS1 CHS2
(RH) SLACK (LH)
CHAIN
SWITCHES

CHS1 CHS2
CHS3

CHS4
RIGHT LEFT
CHAIN CHAIN

CA310
3 5 3
032 CA313-11 HGT ECR CH A TO ACCESS 4 1 ORG
5
033 CA313-12 HGT ECR CH B TO ACCESS 4 2 WHT MAIN
5 ECR5 HEIGHT
709 CA313-9 +5V FROM ACCESS 4 3 RED ENCODER
5
519 CA313-10 BNEG FROM ACCESS 4 4 BLK
5
6

4 4

A B C
149692 B

DIA-1970-009 TSP 7000 SERIES Crown 2011 PF25259-9

638
 SCHEMATIC DIAGRAMS
ACCESS 4 (VCM)

ACCESS 4 (VCM)

A B C
CA311(GRAY) ACCESS 4
5914 CA316-4 FROM SEAT POSITION SW 1 SEAT POSITION SW IN
CA311 THRU CA314
5915 CA316-5 FROM SEAT LOCKED SW 2 SEAT LOCKED SW IN
3 SPARE 12 1
4 SPARE
1 1
5920 (CA308) HGTRS1 BNEG FROM HGT RESET SW 5 HEIGHT RESET SW IN
7 6
6 SPARE
7 SPARE
536 CA319-2 BNEG TO RIGHT FOOT SW 8 BNEG TO RIGHT FRONT FOOT SW
5927 CA321-1 FROM LEFT REAR FOOT SW 9 LEFT REAR FOOT SW IN
5918 (CA308) GTSR BNEG FROM GATE SWITCHES 10 GATE SW IN
5916 CA309-3 FROM CHAIN BREAK SWITCHES 11 CHAIN BREAK SW IN
5917 CA309-4 FROM CHAIN SLACK SWITCHES CHAIN SLACK SW IN
12 CHAIN
CA312(BLK)
1 SPARE
2 SPARE
3 SPARE
4 SPARE
5 SPARE
2 SPARE
6 SPARE 2
5913 CA316-1 BNEG TO SEAT SOLENOID 7 SEAT REL SOLENOID OUTPUT
2989 CA316-6 +48V (KYS) TO EML 8 +48V TO SEAT REL SOLENOID
2957 CA103-14 +48V (KYS) FROM DISTRIBUTION PNL FOR EML 9 +48V TO ACCESS 4 FOR SEAT REL SOLENOID
10 RS232 TRANSMIT
11 RS232 RECEIVE
12 RS232 COMM
CA313(GRN)
1 SPARE
578 CA320-2 BNEG TO LEFT FRONT FOOT SW 2 BNEG TO LEFT REAR FOOT SW
5926 CA320-1 FROM LEFT FRONT FOOT SW 3 LEFT FRONT FOOT SW IN
5925 CA319-1 FROM RIGHT FRONT FOOT SW 4 RIGHT FRONT FOOT SW IN
5 SPARE
543 CA101-12 BNEG FROM ACCESS 4 TO DISTRIBUTION PNL 6 BNEG TO PLATFORM DISTRIBUTION PNL

3 5992 (CA305) ZSS - BRN FROM ZSS SWITCH A 7 ZSS ZONE A SW IN (OPTION) 3
5993 (CA305) ZSS - WHT FROM ZSS SWITCH B 8 ZSS ZONE B SW IN (OPTION)
5
709 CA310-3 +5V TO ECR5 9 HGT ENCODER +5V
5
519 CA310-4 BNEG TO ECR5 10 HGT ENCODER BNEG
5
032 CA310-1 CH A FROM ECR5 11 HGT ENCODER CH A
5
033 CA310-2 CH B FROM ECR5 HGT ENCODER CH B
12 HGT
CA314(BRN)
2950 CA103-13 +48V (KYS) FROM DISTRIBUTION PNL 1 +48V IN
518 CA101-1 BNEG FROM DISTRIBUTION PNL 2 BNEG IN
1
029 CA106-9 CAN H FROM DISTRIBUTION PNL 3 CAN H
1
028 CA106-1 CAN L FROM DISTRIBUTION PNL 4 CAN L
590 (CA308) HGTRS1 N.O. 5998 5 C/C THERMOSTAT INPUT
TS3 6 SPARE
1
7 SPARE
4 4
59105 (CA316) RES8 C/C BNEG 8 SPARE
NOTES:
9 SPARE
1 C/C THERMOSTAT OPTIONAL
OPEN > 15.5° C (60° F) SPARE
10 SPARE
CLOSED < 4.5° C (40° F)
5921 CA322-1 FROM BRAKE SWITCHES 11 BRAKE SW IN
5991 (CA305) AZZ - BLU FROM ZSS SW C 12 ZSS ZONE C SW IN (OPTION)

A B C
149693 B

Crown 2011 PF25259-10 TSP 7000 SERIES DIA-1970-010

639
SCHEMATIC DIAGRAMS
PLATFORM SEAT AREA

Platform Seat Area

A B C
CA315
5919 (CA308) GTSR N.O. COMM NO
GTSL
534 CA101-3 BNEG FROM DISTRIBUTION PNL

1 1
CA316

5913 CA312-7 BNEG FROM ACCESS 4 1 BLK

565 CA101-9 BNEG FROM DISTRIBUTION PNL 2 591
525 CA101-7 BNEG FROM DISTRIBUTION PNL 3 592
5931 SEAT POS
5914 CA311-1 SEAT POS STATUS TO ACCESS 4 4 COMM NO
SPS SEAT LOCKED
5915 CA311-2 SEAT LOCKED TO ACCESS 4 5 5932 COMM NO
SLS
2989 CA312-8 +48V (KYS) FROM ACCESS 4 6 BLK EML
SEAT
RES8 1 ADJUST
59105 (CA314) TS3 BNEG FROM TS3
FOR SPS

4901 CA103-6 +BV (KYS)

2 2

CA317
2960 CA104-11 +48V (KYS) FROM EDS TO K1 1 BLK
2961 CA104-14 +48V (KYS) TO EDS 2 WHT
2962 CA103-16 +48V FROM DISTRIBUTION PNL FOR C/C 3 RED
540 CA104-8 BNEG TO ACCESS 8 4 GRN
541 CA104-7 BNEG TO ACCESS 8 5 ORG
2963 CA103-15 +48V (KYS) FROM DISTRIBUTION PNL 6 BLU
3
036 CA106-3 CAN L TO ACCESS 8 7 YEL
3
037 CA106-10 CAN H TO ACCESS 8 8 BRN

3 3
CA318
2967 (CA506) +48V (KYS) FROM EDS 1 BLK
2968 (CA506) +48V (KYS) TO EDS 2 WHT
2970 CA506-4 CC +48V (KYS) 3 RED
583 CA505 BNEG 4 GRN
582 CA505 BNEG 5 ORG
2995 CA504-1 +48V (KYS) 6 BLU
27 8 CONDUCTOR COILED
056 CA504-4 CAN L 7 YEL CABLE (UNDER SEAT)
27
057 CA504-3 CAN H 8 BRN
4 NOTES: 4
1 OPTIONAL C/C

5939 CA503 SES SW TO ACCESS 8 COMM NO

SES
577 CA505 BNEG

A B C
149694 B

DIA-1970-011 TSP 7000 SERIES Crown 2011 PF25259-11

640
 SCHEMATIC DIAGRAMS
PLATFORM FLOOR AREA

Platform Floor Area

A B C
FPS9
GRN/WHT GRN
C NO RIGHT FRONT FOOT
PRESENCE 3
FPS8
GRN/WHT GRN
C NO
CA319 FPS7
1 5925 CA313-4 RIGHT FRONT FOOT TO ACCESS 4 1 GRN/WHT 1
C NO
536 CA311-8 BNEG FROM ACCESS 4 2 GRN

FPS6
GRN/WHT GRN
C NO LEFT FRONT FOOT
PRESENCE 2
FPS5
GRN/WHT GRN
C NO
CA320
FPS4
5926 CA313-3 LEFT FRONT FOOT TO ACCESS 4 1 GRN/WHT C NO
578 CA313-2 BNEG FROM ACCESS 4 2 GRN
FPS3
GRN/WHT
C NO GRN LEFT REAR FOOT
PRESENCE 1
FPS2
GRN/WHT GRN
C NO
CA321
FPS1
2 5927 CA311-9 LEFT REAR FOOT TO ACCESS 4 1 GRN/WHT 2
C NO
579 CA101-11 BNEG FROM PLATFORM DIST PNL 2 GRN

CA322 BRS1
5921 CA314-11 BRAKE SWITCHES TO ACCESS 4 1 GRN/WHT C NC
5977 2 GRN
BRS2 RIGHT BRAKE
5922 CA104-2 BRAKE SWITCHES TO DIST PNL 3 GRN/WHT C NC
PEDAL 1
4 GRN

CA323 BRS4
5978 1 GRN/WHT C NC
584 CA101-8 BNEG FROM PLATFORM DIST PNL 2 GRN BRS3 LEFT BRAKE
3 5977 3 GRN/WHT PEDAL 2 3
C NC
537 CA101-6 BNEG FROM PLATFORM DIST PNL 4 GRN

1 1
CA324
1 PLATFORM
WHT CA103-8 +48V (KYS) FROM PLATFORM DIST PNL RED STROBE
BLK CA103-10 BNEG FROM PLATFORM DIST PNL BLK LIGHT
2 POWER
3 SUPPLY
NOTES: 4
1 OPTIONAL
1
CA325
LGT8 -
+ RED 1 RED
(RH) WHT 2 WHT
4 1 PLATFORM
BLK 3 BLK 4
STROBE LIGHTS 1
CA326
LGT9 -
+ RED 1 RED
(LH) WHT 2 WHT
BLK 3 BLK

A B C
149695 B

Crown 2011 PF25259-12 TSP 7000 SERIES DIA-1970-012

641
SCHEMATIC DIAGRAMS
ACCESS 3 (TCM)

ACCESS 3 (TCM)

A B C

ACCESS 3
CA401
4902 CA206-8 +BV (KYS) FROM DISTRIBUTION PNL (FU8) 1 +BV (KYS) INPUT
1 2 FAN4 (OPT) 1
5999 CA611-7 GUIDANCE ACTIVE TO PDS 1 3 GUIDANCE ACTIVE OUTPUT TO PDS
5912 (CA406) ALM2 - LO TO TRAVEL ALARM 4 TRAVEL ALARM DRIVER
5907 (CA406) ED1 COIL - ED1 TO ED COIL 5 ED1 COIL DRIVER
59101 CA611-8 EAC ACTIVE TO PDS 1 6 EAC ACTIVE OUTPUT TO PDS
514 CA408-6 BNEG TO FSB1 19
7 BNEG
103 CA408-9 TEMP SENSE IN 19
8 TRACTION MOTOR TEMP SENSE
29127 CA611-5 PDS BRAKE1 REQUEST 1 9 PDS BRAKE1 REQUEST INPUT
4903 CA404-2 +BV (KYS) FROM BRES 10 BRES SWITCH INPUT
11 MODULE ID INPUT
4904 CA206-9 +BV (KYS) FROM FU8 12 MODULE ID INPUT

2 4905 (CA406) ALM2+ +BV (KYS) TO TRAVEL ALARM 13 +BV/SUPPRESSION FOR ACCESS 3 DRIVERS 2
14 PROGRAM
NOTES: 15 POT HIGH 1
1 12
1 OPTIONAL 16 POT WIPER 1 13 23
24 35
17 POT WIPER 2 CA401
18 POT LOW 1+2
59103 CA612-1 PLATFORM LOWERED TO PDS 1 19 PLATFORM LOWERED TO PDS
59114 CA612-2 QUIT BUTTON TO PDS 1 20 QUIT (OVERRIDE) TO PDS

FUSE
21 CAN TERM HIGH
29123 CA612-3 ALARM REQUEST FROM PDS 1 22 PDS ALARM REQUEST
B- B+
18
019 CA201-7 CAN H FROM DISTRIBUTION PNL 23 CAN H

3 29128 CA611-6 PDS CREEP SPD REQUEST 1 24 PDS CREEP SPD REQUEST INPUT 3
25 +12V OUT
19
706 CA408-5 +5V TO FSB1 26 +5V OUT
W

27 POT HIGH 2
U
V

28 SERIAL TX W V U

29 SERIAL RX
30 ANALOG OUTPUT
009 CA408-7 TRACTION ENC CH B FROM FSB1 19 31 SPEED ENCODER CH B
010 CA408-8 TRACTION ENC CH A FROM FSB1 19 32 SPEED ENCODER CH A
29124 CA612-4 PDS ACTIVE FROM PDS 1 33 PDS ACTIVE INPUT
34 CAN TERM L
4 18
4
018 CA201-1 CAN L FROM DISTRIBUTION PNL 35 CAN L

A B C
149681 A

DIA-1970-013 TSP 7000 SERIES Crown 2011 PF25259-13

642
 SCHEMATIC DIAGRAMS
ACCESS 5 (SCM)

ACCESS 5 (SCM)

A B C
ACCESS 5

A1 B+ A2 B-
NOTES:
1 1 OPTIONAL 1
CA402 CA403 CA402
2 INDEX IS LOW
1 CAN 5V 10
20 5 4
1
2 SPARE 1 3
2
3 CAN COMM
17
003 CA201-8 CAN H FROM DISTRIBUTION PANEL 4 CAN H
17 9
004 CA201-2 CAN L FROM DISTRIBUTION PANEL 5 CAN L 19 28

CA403
505 (CA406) BNEG 1 L COMM INPUT
2 SPARE DRIVER
20
001 CA408-3 TRACTION ENC CH B FROM FSB1 3 TRACTION ENCODER CH B
20
002 CA408-4 TRACTION ENC CH A FROM FSB1 4 TRACTION ENCODER CH A
1
59102 CA611-3 PDS BRAKE REQUEST 2 5 PDS BRAKE REQUEST 2 INPUT
2 5901 CA407-3 BRK LO TO INNER BRAKE 6 INNER BRAKE LO 2
4906 CA206-6 SUPPRESSION FOR INNER BRAKE FU9 7 INNER BRAKE +BV
5902 CA407-4 BRK LO TO OUTER BRAKE 8 OUTER BRAKE LO
4907 CA206-4 SUPPRESSION FOR OUTER BRAKE FU10 9 OUTER BRAKE +BV
2903 CA205-3 +48V (KYS) FROM FU7 10 +48V INPUT
11
21
516 CA410-2 BNEG TO STEER FDBK ENC 12 STEER ENCODER COMM
21
013 CA410-1 CH A FROM STEER FDBK ENC 13 STEER ENCODER CH A
21
014 CA410-3 CH B FROM STEER FDBK ENC 14 STEER ENCODER CH B
29117 CA207-2 +48V (KYS) FROM RES5, EMS2 15 TRAVERSE OVERRIDE INPUT
5987
16 RAIL GUIDE SWITCH INPUT
5973 CA407-6 BRK CMD FROM BRAKE CONNECTOR 17 BRAKE SWITCH INPUT
2906 (CA406) K2 COIL+ +48V (KYS) FROM EDS 18 ED HIGH SIDE DR INPUT
3 3
2907 (CA406) ED1 COIL+ 19 ED HIGH SIDE DR TO CONTACTOR
21
707 CA410-4 +5V TO STEER FDBK ENC 20 +5V TO STEER ENCODER
20
702 CA408-1 +5V TO FSB1 21 +5V TO TRACTION ENCODER
20
511 CA408-2 BNEG TO FSB1 22 TRACTION ENCODER COMM
21
015 CA410-5 INDEX FROM STEER FDBK ENC 23 STEER ENCODER INDEX
22
101 CA406-2 ANALOG SIG FRM CURR SENSE 24 CURRENT SENSOR ANALOG INPUT
403 CA205-14 +BV BATT SENSE FROM FU2 25 BATTERY VOLTAGE SENSE/BDI (+)
509 (CA406) BNEG FOR BATT SENSE 26 BATTERY VOLTAGE SENSE/BDI (-)
22
701 CA406-1 +5V TO CURRENT SENSOR 27 CURRENT SENSE/BDI (+5V)
22
510 CA406-3 BNEG TO CURRENT SENSOR 28 CURRENT SENSE/BDI (-)

4 CA404 1 2 4
BRES
4908 CA206-14 +BV (KYS) FROM FU8 1 4924
COMM NO
4903 CA401-10 BRES TO ACCESS 3 2 4925
RGSR RGSL
581 (CA406) BNEG 3 5988 5975
COMM NC COMM NC
4 5974
5987
A B C
149682 A

Crown 2011 PF25259-14 TSP 7000 SERIES DIA-1970-014

643
SCHEMATIC DIAGRAMS
CONTACTOR PANEL

Contactor Panel

A B C
CA405
4909 CA206-13 +BV (KYS) FRM DISTRIBUTION PNL 1
+
502 2 - LGT1 FLASHING
LIGHT
1

1 CA406 1
22
701 CA403-27 +5V FROM ACCESS 5 1 VIO
22 VIO ++
O I
101 CA403-24 +5V CUR SEN TO ACCESS 5 2 BRN BRN O CS1 CURRENT
22 GRN - SENSE
510 CA403-28 +5V BNEG TO ACCESS 5 3 GRN
5112 CA418-3 BNEG TO PS3
5113 CA419-1 BNEG TO PS4
5114 CA419-3 BNEG TO PS4
502
5101 CA611-3 BNEG TO PDS 1
527 CA413-1 BNEG TO PLATFORM NEG BUS
528 CA413-2 BNEG TO PLATFORM
509 CA403-26 BNEG TO ACCESS 5
529 CA413-3 BNEG TO PLATFORM
NOTES:
5117 CA412-2 BNEG TO PLATFORM
1 OPTIONAL
530 CA412-7 BNEG TO PLATFORM
531 CA412-8 BNEG TO PLATFORM
581 CA403-3 BNEG TO RGSL
501 CA206-1 BNEG TO DISTRIBUTION PNL
505 CA403-1 BNEG TO ACCESS 5
2 507 CA601-2 BNEG TO ACCESS 6
2
5116

503
2913 CA412-6 +48V (KYS) FROM EDS
2906 CA403-18 +48V (KYS) TO ACCESS 5 ED DR
29114 (CA411) EMS2 +48V (KYS) TO EMS2
29139 CA204-4 +48V (KYS) DISTRIBUTION PNL
++ -

K2
210 CA418-2 +48V FROM PS3 + +
211 CA204-1 +48V TO DISTRIBUTION PNL

BATTERY POSITIVE
ED1
4911 CA204-5 +BV (DMS) TO DISTRIBUTION PNL
4912 CA204-6 +BV (DMS) TO DISTRIBUTION PNL
2 + -

3 3
2907 CA403-19 +BV (KYS) FROM ACCESS 5
5996 (CA411) EMS2 BNEG FROM EMS2
5907 CA401-5 ED1 LO FROM ACCESS 3

29141
5110
4910 CA204-3 +BV (KYS) TO DISTRIBUTION PNL + -
404 CA204-2 +BV TO DISTRIBUTION PNL
K3
409 CA418-4 +BV TO PS3 +
410 CA419-4 +BV TO PS4
4913 CA411-13 +BV (KYS) ACCESS 2
2 408
4 4914 CA414-1 +BV (KYS) TO MF HYD BLOCK
4
+
5928 CA411-19 +BV (KYS) HN LO FROM ACCESS 2 HN
-
5116
4905 CA401-13 +BV (KYS) FROM ACCESS 3 + 1
RES4 ALM2
5912 CA401-4 ALM2 LO FROM ACCESS 3 -

A B C

149683 C

DIA-1970-015 TSP 7000 SERIES Crown 2011 PF25259-15

644
 SCHEMATIC DIAGRAMS
TRACTION MOTOR & BRAKE

Traction Motor & Brake

A B C

OUTER
BRAKE
1 CA407 1
4915 CA206-3 +BV (DMS) FROM FU10 + WHT
1
4916 CA206-5 +BV (DMS) FROM FU9 2 + BLU
BRK
5901 CA403-6 I BRK LO FROM ACCESS 5 3 - YEL
- INNER
5902 CA403-8 0 BRK LO FROM ACCESS 5 4 ORG BRAKE
5972 CA413-4 BRK CMD FROM PLATFORM 5 5971
5973 CA403-17 BRK CMD TO ACCESS 5 6

TRACTION
TRACTIONBRAKE
BRAKE

FSB1

2 OPTO OPTO 2
CA408
2020
702 CA403-21 +5V FROM ACCESS 5 1
2020
511 CA403-22 COMM FROM ACCESS 5 2
20
20
001 CA403-3 CH B TO ACCESS 5 3 TRACTION MOTOR
20
20 SPD/DIR ENCODER
002 CA403-4 CH A TO ACCESS 5 4 CA409
19 M1
706 CA401-26 +5V FROM ACCESS 3 1 5 1 RED +5V
19
514 CA401-7 COMM FROM ACCESS 3 1 6 2 BLK BNEG
19 ECR7
009 CA401-31 CH B TO ACCESS 3 1 7 3 BLU CH B
19 19
010 CA401-32 CH A TO ACCESS 3 1 8 4 WHT CH A
19
103 CA401-8 T SENSE TO ACCESS 3 9 5 BLK
10
10 6 WHT
T°
TS1

3
595 11
12 FSB1
TRACTION FEEDBACK
SPLITTER
M1 TRACTION MOTOR
TEMP SENSOR
3

STEERING FEEDBACK
ENCODER
21
CA410
013 CA403-13 STRFDBK CH A TO ACCESS 5 1 BLU CH A
21
516 CA403-12 BNEG FROM ACCESS 5 2 BLK BATT COMM
21
014 CA403-14 STRFDBK CH B TO ACCESS 5 3 ORG CH B ECR6
21
707 CA403-20 +5V FROM ACCESS 5 4 RED +5V
21 INDEX
015 CA403-23 STRFDBK INDEX TO ACCESS 5 5 YEL
6

4 NOTES: 4
1 TO (CA613) IF EQUIPPED WITH PDS OPTION

A B C
149684 A

Crown 2011 PF25259-16 TSP 7000 SERIES DIA-1970-016

645
SCHEMATIC DIAGRAMS
ACCESS 2 (HCM)

ACCESS 2 (HCM)

A B C
ACCESS 2
CA411
4917 CA206-10 +BV (KYS) FROM FU8 1 +BV (KYS) INPUT
CA411
24 13 1
5976 CA414-4 SVML LO TO SVML 2 SVML DRIVER
5904 CA414-3 SVA LO TO SVA 3 SVA DRIVER
1 1
5906 CA414-2 PVML LO TO PVML 4 PVML DRIVER
59107 CA414-5 SVMR LO TO SVMR 5 SVMR DRIVER
35 23 12
5997 6 H/P HYD FAN DRIVER
23
526 (CA415) BNEG HYD SENS & TEMP SENSOR 7 BNEG OUTPUT
23
102 CA415-6 SIG FROM HYD MOTOR TEMP SENSOR 8 HYDRAULIC MOTOR TEMP SENSE INPUT
9 HCS SWITCH INPUT
4918 CA416-1 +BV (KYS) FROM CTS/CHS5 10 CTS/CHS5 SWITCH INPUT
29140 CA205-7 +48V (KYS) +
11 MODULE ID INPUT
3
FAN3 SB41
12 MODULE ID INPUT
4913 (CA406) HN+ +BV (KYS) 13 +BV/SUPPRESION FOR ACCESS 2 DRIVERS
14 PROGRAM
15 POT HIGH 1
122 CA426-1 SIGNAL FROM TS5 16 ANALOG TEMP INPUT
17 POT WIPER 2
2 2
608 CA426-2 NEG 18 POT LOW 1+2
5928 (CA406) HORN LO TO HORN 19 HORN LOW
20 DIGITAL OUT/IN
B- B+ FU
21 CAN TERM HIGH
4919 CA416-5 +BV (KYS) FROM CHS7 22 CHS7 & CHS8
15
023 CA201-10 CAN H FROM DISTRIBUTION PNL 23 CAN H
29120 24 TRAVERSE OVERRIDE INPUT
25 +12V OUT
23
708 CA415-1 +5V TO HYD MOTOR SENSE BEARING 26 +5V OUT
27 POT HIGH 2
28 SERIAL TX W V U
29 SERIAL RX
30 ANALOG OUTPUT
23
3 025 CA415-3 CH A FROM HYD MOTOR ENCODER
23
31 HYDRAULIC MOTOR SPEED ENCODER CH A 3
026 CA415-4 CH B FROM HYD MOTOR ENCODER 32 HYDRAULIC MOTOR SPEED ENCODER CH B
SWITCH INPUT
33 SWITCH
34 CAN TERM L
15
024 CA201-4 CAN L FROM DISTRIBUTION PNL 35 CAN L

(CA411)
29114 (CA406) K2 COIL+ +48V (KYS)
560 CA206-2 BNEG
561 (CA416) TS4 BNEG TO C/C 1
TRAVERSE
OVERRIDE
5996 (CA406) ED1 (—)
29120
29114

EMS2
560
561

29116 CA207-1 TO RES5

4 4
NOTES:
1 OPTIONAL
5996 29116
29120

SWITCH BACK VIEW

(MOMENTARY TO BOTTOM)

A B C
149685 B

DIA-1970-017 TSP 7000 SERIES Crown 2011 PF25259-17

646
 SCHEMATIC DIAGRAMS
HYDRAULIC MOTOR

Hydraulic Motor

A B C
CA412 (GRAY)
5117 (CA406) BNEG 1 BNEG CA108-1 BLK
405 CA205-12 +BV FROM FU3 2 +BV (KYS) UNSW OPTION CA108-2 WHT
4920 CA205-10 +BV FROM FU5 3 +BV (KYS) SW OPTION CA108-3 RED
1 2922 CA205-8 +BV FROM FU6 4 +48V (KYS) LGT/FAN CA108-4 GRN 1
202 CA205-16 +48V FROM FU1 TO KYS 5 +48V TO KYS CA108-5 ORG MAST
2913 (CA406) K2 COIL +48V (KYS) 6 +48V TO KYS CA108-6 BLU CABLE
BNEG CA108-7 WHT/BLK 1
530 (CA406) BNEG 7
531 (CA406) BNEG 8 BNEG CA108-8 RED/BLK
CA413 (BLK)
527 (CA406) BNEG 1 MOD BNEG CA107-1 BLK
MAST
528 (CA406) BNEG 2 MOD BNEG CA107-2 WHT CABLE
529 (CA406) BNEG 3 MOD BNEG CA107-3 RED 2
5972 CA407-5 BRK CMD TO ACCESS 5 4 BRK CMD FROM PLATFORM CA107-4 GRN
2920 CA205-5 +48V (KYS) FROM FU7 5 +48V (KYS) CA107-5 ORG
2923 CA205-6 +48V (KYS) FROM FU7 6 +48V (KYS) CA107-6 BLU
16
005 CA201-9 CAN H FROM DISTRIBUTION PNL 7 CAN H CA107-7 WHT/BLK
16
006 CA201-3 CAN L FROM DISTRIBUTION PNL 8 CAN L CA107-8 RED/BLK
CA414 (GRN)
2 4914 (CA406) HN+ +BV FROM ACCESS 2 1 4926 2
1 PVML
5906 CA411-4 PVML LO FROM ACCESS 2 2 5911
5910 SVA
5904 CA411-3 SVA LO FROM ACCESS 2 3 4929
5976 CA411-2 SVML LO FROM ACCESS 2 4 5990 4930

SVMR
SVML 59108
59107 CA411-5 SVMR LO FROM ACCESS 2 5
6 59108 4931 4931
SVMR

5910
4929
4930
7
8 HYD MOTOR
SPEED ENCODER
CA415 SVA
23 ECR8
708 CA411-26 +5V FROM ACCESS 2 1 RED +5V
23

5990
4930
4931
526 CA411-7 BNEG ACCESS 2 593 BLK BNEG
SP1 23 2 M2
025 CA411-31 CH A TO ACCESS 2 3 BLU CH A
23
026 CA411-32 CH B TO ACCESS 2 4 WHT CH B
SVML
3 594 23 5 BLK 3
102 CA411-8 HYD MOTOR TEMP TO ACCESS 2 6 WHT
TS2 HYD MOTOR
T°
MAINFRAME
CA416 TEMP SENSOR
HYDRAULIC
CTS
4918 CA411-10 CTS TO ACCESS 2 1 BLK BLOCK
COMM NO
29159 CA205-2 +48V (KYS) FROM FU7 2 WHT TF MAST ONLY
RES6
4922 CA206-11 +BV (KYS) FROM FU8 3 ORG
CTS HEATER 2
561 (CA411) EMS2 BNEG 59106 4 GRN
TS4
2 5
6
4919 CA411-22 CHS7 TO ACCESS 2
29160 CA205-2 +48v (KYS) FROM FU7 TT MAST ONLY
CA801 SLACK CHS5
CA416
NOTES:
1 BLK 1
1 PVML LOCATED IN PUMP CHS6
4 2 WHT 2 4
2 OPTIONAL C/C THERMOSTAT
OPEN > 15.5° C (60° F) 3 3
CLOSED < 4.5° C (40° F) BREAK CHS7
4 4
5 RED
CHS8
6 GRN

A B C

149686 C 1 of 2

Crown 2011 PF25259-18 TSP 7000 SERIES DIA-1970-018

647
SCHEMATIC DIAGRAMS
PS3, PS4, CAN PORT

PS3, PS4, CAN Port

A B C

1 1

CA417
064 CA201-12 CAN H TO DISTRIBUTION PANEL 1
065 CA201-6 CAN L TO DISTRIBUTION PANEL 2
3 PC CAN PORT
4
5
6

2 2

CA418 PS3
409 CA406 +BV TO K3+ 4
5112 CA406 BNEG 3 FU22
210 CA406 +48V TO K2+ 2
+24V 1

29142
CA419 PS4
410 CA406 +BV TO K3+ 4
5114 CA406 BNEG 3 FU23
+24V 2
5113 CA406 BNEG 1
3 3

CA426 CA422 TS5

122
122 CA411-16 SIGNAL FROM TS5 1 1 BLK
2 608 2 BLK +t
608 CA411-18 NEG TO TS5

NOTE:
CA422 AND TS5 OPTIONAL
(FREEZER CONDITION)
4 4

A B C

149686 C 2 of 2

DIA-1970-019 TSP 7000 SERIES Crown 2011 PF25259-19

648
 SCHEMATIC DIAGRAMS
ACCESS 8 (OCM)

ACCESS 8 (OCM)

A B C
NOTES:
1 CA501(GRAY) ACCESS 8
1 OPTIONAL GRN TDS 1 TILT DOWN SW IN (OPT)
RED
2 JUMPER WITHOUT
WIRE GUIDANCE GRN TBS 1 WHT 2 TILT BACK SW IN (OPT)
3 C/C TRUCKS EDS HEATER
ORG HPSR
RH VIO 3 RIGHT OPTICAL EMITTER
PRESENCE
FORWARD BLK 4 RIGHT OPTICAL COLLECTOR
1 OPTICAL 1
SWITCH
SWITCH GRN VIO 5 HORN SW IN CA501
RED GRN BLU HNS THRU
BLK WHT
GRN 6 LED OPTIC — CA504
VIO 7 +5V TO FS & RS 12 1
GRN 8 FS & RS COMM
OPTICAL SW BD
WHT 9 REV SW IN
7 6
BLK 10 FWD SW IN
RED GRN BLU GRN RSS
BLK WHT BLK 11 SEAT RELEASE SW IN
GRN GUS 1
REVERSE WHT 12 WIRE GUIDANCE SW IN (OPT)
OPTICAL
SWITCH
SWITCH 2 CA502(BLK)
3 RED 1 TRACTION POT1 +
CA505
549 CA507-8 POT1 2 2 TRACTION CMD IN
TRACT WHT
583 CA318-4 1 1
582 CA318-5 BLK 3 TRACTION CMD —
577 (CA318) SES N.O. 1 RED 4 TRAVEL POT4 +
POT4 2
5 TRAVEL CMD IN
CA506 TRAVEL WHT
2 5945 CA507-4 HND LED 1 ORG 3 BLK 6 TRAVEL CMD — 2
5944 CA509-1 2 WHT 7 C/C DRIVER (LOW SIDE)
RES7 3
29101 CA509-2 3 WHT 8 C/C DRIVER (+V TO HTRS)
2970 CA318-3 +48V C/C 4 2971 9 C/C DRIVER (+48V TO ACCESS 8)
1 RED 10 MAIN R/L CMD IN
2967 CA318-1 +48V
EDS POT2 2 WHT
11 MAIN R/L POT2 +
EDS MAIN R/L 3
2968 CA318-2 +48V BLK 12 MAIN R/L POT2 .
12
CA503(GRN)
11 SPARE SW INPUT
5939 (CA318) SEAT SWITCH IN 2 OPERATOR SEATED SW IN
5941 CA507-10 FROM APS 3 AUTO PIVOT SWITCH IN
5940 CA507-9 FROM ORS1 4 OVERRIDE SW IN
7
710 CA508-8 +5V TO ECR2 5 STEER CMD ECR2 +5V
7
521 CA508-6 BNEG TO ECR2 6 STEER CMD ECR2 COMM
7
3 038 CA508-5 CH A FROM ECR2 7 STEER CMD ECR2 CH A 3
7 8 STEER CMD ECR2 CH B
039 CA508-7 CH B FROM ECR2
8
711 CA508-4 +5V TO ECR1 9 +5V TO STEER ECR1
8
542 CA508-2 BNEG TO ECR1 10 BNEG TO STEER ECR1
8
030 CA508-1 CH A FROM ECR1 11 STEER CMD ECR1 CH A
8 12 STEER CMD ECR1 CH B
031 CA508-3 CH B FROM ECR1
CA504(BRN)
2995 CA318-6 +48V (KYS) 1 +48V IN
520 2 BNEG IN
057 CA318-8 CAN H FROM DISTRIBUTION PNL 3 CAN H
056 CA318-7 CAN L FROM DISTRIBUTION PNL 4 CAN L
2965 CA507-2 5 LEFT OPTICAL COLLECTOR
2966 CA507-1 6 LEFT OPTICAL EMITTER
9
713 CA507-5 +5V TO POT3 7 AUX R/L POT +
4 9 4
105 CA507-6 SIG FROM POT3 8 AUX R/L CMD IN
9
544 CA507-7 BNEG TO POT3 9 AUX R/L POT —
2964 CA507-3 10 LED OPTIC +
5942 CA507-11 FROM PLS 11 PIVOT LEFT SW IN
5943 CA507-12 FROM PRS 12 PIVOT RIGHT SW IN
A B C
149696 B

Crown 2011 PF25259-20 TSP 7000 SERIES DIA-1970-020

649
SCHEMATIC DIAGRAMS
LEFT ARMREST - PLATFORM

Left Armrest - Platform

A B C

NOTES:
1 LH PRESENCE
NO HAND = OUTPUT PWM'D
HAND PRESENT = HIGH

1 1
CA507 HPSL 1

2966 CA504-6 +48V TO ACCESS 8 1 VIO

2965 CA504-5 +48V FROM ACCESS 8 2 BLK
2964 CA504-10 +V FROM ACCESS 8 3 ORG
5945 CA506-1 TO RH PRESENCE LED 4 GRN
9 1
713 CA504-7 +5V FROM ACCESS 8 5 RED
9 2 POT3
105 CA504-8 AUX R/L SIG TO ACCESS 8 6 WHT AUX R/L
9 3
544 CA504-9 BNEG FROM ACCESS 8 7 BLK
549 CA505 BNEG 8 GRN
ORS1 TERMINAL
5940 CA503-4 ORS1 TO ACCESS 8 9 VIO GRN 062007-113
APS
5941 CA503-3 APS TO ACCESS 8 10 BLK GRN
2 PLS
2
5942 CA504-11 PLS TO ACCESS 8 11 RED GRN
PRS
5943 CA504-12 PRS TO ACCESS 8 12 WHT GRN

CA508
7
030 CA503-11 CH A TO ACCESS 8 1 WHT CH A ECR1
7
542 CA503-10 BNEG FROM ACCESS 8 2 BLK BNEG
7 STEER
031 CA503-12 CH B TO ACCESS 8 3 BLU CH B COMMAND
7 ENCODER
711 CA503-9 +5V FROM ACCESS 8 4 RED +5V
8
038 CA503-7 CH A TO ACCESS 8 5 WHT CH A
8 ECR2
521 CA503-6 BNEG FROM ACCESS 8 6 BLK BNEG
3 8 STEER 3
039 CA503-8 CH B TO ACCESS 8 7 BLU CH B COMMAND
8 ENCODER
710 CA503-5 +5V FROM ACCESS 8 8 RED +5V

CA509
5944 CA506-2 1
29101 CA506-3 2

4 4

A B C
149697 B

DIA-1970-021 TSP 7000 SERIES Crown 2011 PF25259-21

650
 SCHEMATIC DIAGRAMS
ACCESS 6 (EAC/GCM)

ACCESS 6 (EAC/GCM)

A B C
CA601 ACCESS 6
2905 CA205-4 +48V (KYS) FROM FU7 1 +48V AK
CA601
507 (CA406) BNEG 2 BNEG 5 4

3 CAN COMM 1 3
14 2
1 011 CA201-11 CAN H FROM DISTRIBUTION PNL
14
4 CAN H 1
012 CA201-5 CAN L FROM DISTRIBUTION PNL 5 CAN L
CA602
10
1 20

EAC EAC NOTES:

SENSOR SENSOR
B1 A1 1 EU WIRE COLOR
9
5 5 19 28
CA608
CA605 CA606 1 CA602
26
2 314 1 EAC SENSORS +12V
26
CA607 575 2 EAC SENSORS BNEG
27
1 901 3 EAC A1 TEST
27
2 109 4 EAC A1 ANALOG
27
3 052 5 EAC A1 DIGITAL
27
4 902 6 EAC A2 TEST
EAC 27
DISTRIBUTION PANEL 5 110 7 EAC A2 ANALOG
27
2 6 053 8 EAC A2 DIGITAL 2
28
7 903 9 EAC B1 TEST
28
8 111 10 EAC B1 ANALOG
28
9 054 11 EAC B1 DIGITAL
28
10 904 12 EAC B2 TEST
28
11 112 13 EAC B2 ANALOG
28
CA610 CA609 12 055 14 EAC B2 DIGITAL
24
5 5 BLU 1 717 15 STEER WHL GUIDE BAR +5V
24
YEL 1 576 16 STEER WHL GUIDE BAR BNEG
EAC EAC 24
SENSOR SENSOR BRN 1 113 17 STEER WHL GUIDE BAR COIL 4
B2 A2 24
RED 1 114 18 STEER WHL GUIDE BAR COIL 3
24
BLK 1 115 19 STEER WHL GUIDE BAR COIL 2
24
CA603 GRN 1 116 20 STEER WHL GUIDE BAR COIL 1
24
GS1 COIL 1 1 116 ORG 1 905 21 STEER WHL GUIDE BAR COIL TST
25
3 COIL 2 2 115 718 22 LOAD WHL GUIDE BAR +5V 3
25
BNEG 3 576 577 23 LOAD WHL GUIDE BAR BNEG
25
STEER WHEEL 4 24 LOAD WHL GUIDE BAR COIL 4
SENSOR BAR 118 25
+5V 5 717 25 LOAD WHL GUIDE BAR COIL 3
BLU 1

119 25
SLF TST 6 905 26 LOAD WHL GUIDE BAR COIL 2
120 25
YEL 1

COIL 3 7 114 27 LOAD WHL GUIDE BAR COIL 1

25
COIL 4 8 113 28 LOAD WHL GUIDE BAR COIL TST
117
9
GRN 1
1

STEER WHEEL SENSOR BAR

BLK

906 C4 C3 C2 C1
1

CA604
RED 1

GS2 COIL 1 1 120

ORG 1

COIL 2 2 119
BRN 1

BNEG 3 577
LOAD WHEEL 4
4 SENSOR BAR 4
+5V 5 718
LOAD WHEEL
SLF TST 6 906 SENSOR BAR
COIL 3 7 118 C4 C3 C2 C1
COIL 4 8 117
B1 A1 A2 B2
9

A B C
149687 B

Crown 2011 PF25259-22 TSP 7000 SERIES DIA-1970-022

651
 4
3
2
1

652
407 CA205-13 +BV FROM FU3 CA611
5101 (CA406) NEGATIVE BUS BAR 1 +BV INPUT
59102 CA403-5 BRAKE REQ TO ACCESS 5 2

DIA-1970-023
29127 CA401-9 BRAKE REQ TO ACCESS 3
3 BNEG INPUT

A
A
29128 CA401-24 CREEP REQ TO ACCESS 3
5999 CA401-3 GUIDANCE ACTIVE FROM ACCESS 3 4 PDS BRAKE REQ2 LOW = RELEASE
59101 CA401-6 TRUCK EAC ACTIVE FROM ACCESS 3 5 PDS BRAKE REQ1 LOW = APPLY
PDS, FSB1, FSB2 (Optional)

002 CA403-4 CH A TO ACCESS 5 6 PDS CREEP REQ LOW = CREEP SPD

001 CA403-3 CH B TO ACCESS 5
7 TRUCK GUIDE STAT LOW = ACTIVE
511 CA403-22 BNEG FROM ACCESS 5
702 CA403-21 +5V FROM ACCESS 5 8 TRUCK EAC STAT LOW = ACTIVE
CA408 1 CA613 1 723 9 +5V TO FSB2

2 511 2 5103 10 TRACTION ENCODER CH B INPUT

3 001 3 062 11 TRACTION ENCODER CH A INPUT

SCHEMATIC DIAGRAMS

4 002 4 063 12 BNEG TO FSB3

CA409 CA614
PDS, FSB1, FSB2 (OPTIONAL)

RED 1 5 726 1 5 724

ECR7
BLK 2 6 5102 2 6 5104
TRACTION FSB1 FSB2
MTR SPD/DIR BLU 3 7 060 3 7 009
ENCODER
WHT 4 8 061 4 8 010

BLK 5 9 103 5 9 PDS

TS1

B
B

WHT 6 10 595 6 10
TRACTION
MOTOR TEMP
SENSOR 11 11

12 12

TSP 7000 SERIES

103 CA401-8 T SENSE TO ACCESS 3
010 CA401-32 CH A TO ACCESS 3
009 CA401-31 CH B TO ACCESS 3 CA612
SP3
514 CA401-7 BNEG 5104 1 CAB LWRD STAT LOW = CAB UP
SP4 2 QUIT BUTTON INPUT
706 CA401-26 +5V 724
59103 CA401-19 PLATFORM LWRD FROM ACCESS 3 3 PDS ALARM REQUEST
59104 CA401-20 QUIT BUTTON FROM ACCESS 3 4 PDS ACTIVE OUTPUT
29123 CA401-22 PDS ALARM ACCESS 3
29124 CA401-33 PDS ACTIVE ACCESS 3 5
4927 CA205-1 +BV (KYS) FROM FU8 6 +BV INPUT

4928 CA205-1 +BV (KYS) FROM FU8 7 +BV INPUT

Crown 2011 PF25259-23

9

C
C

10

725 CA401-26 +5V FROM ACCESS 3 11 +5V FROM ACCESS 3

5105 CA401-7 BNEG FROM ACCESS 3 12 BNEG FROM ACCESS 3

4
3
2
1

149706 B
 SCHEMATIC DIAGRAMS
ACCESS 7 (ACM)

ACCESS 7 (ACM)

A B C
NOTES:
1 FHSL & FSHR ONLY ON TRUCKS WITH TELESCOPIC FORKS ACCESS 7
2 PART OF WIRE HARNESS
CA702(GRAY)
PVAR
2976 2979 5958 1 AUX RAISE PROPOR VALVE DR
PVAL
2978
2983
5959 2 AUX LOWER PROPOR VALVE DR
1 2984
5960 3 TRAVERSE PROPOR VALVE 2 DR
1
2984 PVT2
2977
5961 4 TRAVERSE PROPOR VALVE 1 DR
PVT1
2979 5962 5 AUX MAST LOWER VALVE DR
29106 PVLH 5989 6 LOAD HANDLER PROPOR VALVE
2980
5963 7 PIVOT VALVE 2 DR (PVP)
PVP2
PVP2
2981
5964 8 PIVOT VALVE 1 DR (PVP)
PVP1
2982
PVF1 5966 9 EXT FORKS PROPOR VALVE 1 DR
2981 5965
5965 10 EXT FORKS PROPOR VALVE 2 DR
PVF2
PVF2
2976 11 +48V & SUPP TO PVAR VALVE
2977 12 +48V & SUPP TO VALVES
CA703(BLK)
TB709 CA707 059 1 CAN H
HGTRS2
1 RED A 5967 2 AUX HEIGHT RESET SW INPUT
1 FHSL
2 WHT B 5968 3 FORK HOME SW INPUT
1 FHSR
2 3 BLK C 598 048 4 AUX HEIGHT ENCODER CH B 2
059

4
4 049 5 AUX HEIGHT ENCODER CH A
CA711 CA708 715 6 AUX HEIGHT ENCODER +5V
LOAD SENSE BLK BLK 1 121 2974 7 +48V INPUT
PRESSURE
TRANSDUCER
LS RED WHT 2 401 569 8 BNEG INPUT

RED 3 2978 565 9 AUX HEIGHT ENCODER BNEG

SVAL 2975 10 +48V INPUT
CA710 GRN 4 5962
AUX HEIGHT
RED +5V 1 ORGORG 5 715 566 11 BNEG
ENCODER
058 12
GRN CHB 2 BLU 6 048 CAN L
ECR3 PVT PVF PVP
WHT CHA 3 BRN 7 049 2984
2977
2983
2982
2981
2980
1 1 1
CA702 5961 5966 5964
BLK NEG 4 YEL 8 565 2983 2982 2980
THRU 2984 2 2981 2 29106 2
CA701 CA704 5960 5965 5963
LOADHANDLER
BLK CA105-1 BNEG 1 569 12 1 MANIFOLD BLOCK
3 WHT CA105-2 +48V (KYS) 2 2974 2978
2979
2976 3
PVAL PVAR
RED CA105-3 +48V (KYS) 3 2975
7 6
5959 5958
GRN CA105-4 BNEG 4 5989
SP2 PVLH
ORG CA105-5 BNEG 5 599 29106
2979
BLU CA105-6 EMS1 6 5995
5995
BRN CA106-6 CAN L 7 046 058 CA704(GRY)
2 RES3
YEL CA106-7 CAN H 8 047 5995 1 TRAVERSE OVERRIDE INPUT
27
121 2 LOAD SENSE INPUT
27
401 3 LOAD SENSER +14V
13
CA706 716 4 TRAVEL POS ENCODER +5V
TVRS
A 570 RED 5 TRAVEL RESET SW INPUT
PIVOT 722 TVRS RESET
POT5 B BLK 6 BNEG
12
PIVOT C 107
POSITION 7 PIVOT POS POT INPUT
4 SENSE
12
12 4
CA705 722 8 PIVOT POS POT +5V
12
12
RED +5V 1 716 570 9 PIVOT POS POT BNEG
13
TRAVERSE BLU CHB 2 050 10 TRAVEL POS ENCODER CH B
POSITION ECR4 13
ENCODER 3 051
WHT CHA 11 TRAVEL POS ENCODER CH A
13
BLK NEG 4 571 12 TRAVEL POS ENCODER BNEG

A B C
149698 B

Crown 2011 PF25259-24 TSP 7000 SERIES DIA-1970-024

653
 4
3
2
1

654
1

Power Cables
1
— — TO NEGATIVE BUS BAR

DIA-1970-025
+ 17 + 2 TO ED1

A
A
BATTERY CONNECTOR BATTERY CONNECTOR
NEGATIVE BUS
— 1
POWER CABLES

+ 2
BATTERY CONNECTOR
ED1

PS3 4
FU22 3
2 9 M2
1 (HYDRAULIC MOTOR)
PS4 4
SCHEMATIC DIAGRAMS

3 FU13 FU11 FU12 10

FU23
2 W1
1 11

ACCESS 2 V1
6 7 8 16

U V W U1
ACCESS 3 K2 K3 15

B
B

B+ B-

U V W
NOTES:
14

TSP 7000 SERIES

1 DUAL BATTERY CONFIGURATION
B+ B-

12
13
5
M1 A1 A2
(TRACTION MOTOR)
A1 B+ A2 B- 4

C
C

Crown 2011 PF25259-25

W1 V1 U1
M3
3 (STEER
ACCESS 5
MOTOR)

4
3
2
1

149688 E 1 of 2
 4
3
2
1
SINGLE BATTERY CONFIGURATION DUAL BATTERY CONFIGURATION
ITEM CABLE P/N BATTERY CONNECTOR ITEM CABLE P/N BATTERY CONNECTOR
COMP'T COMP'T
137636-001 A ANSI 137636-060 D ANSI
Power Cables P/N’s

137636-002 A EU 137636-068 C ANSI

A
1
137636-083 A DIN 137636-074 B ANSI A
137636-053 B/C/D ANSI 137636-063 D EU
137636-055 B/C/D EU 1 137636-070 C EU
137636-057 B/C/D DIN 137636-076 B EU
137636-058 A ANSI 137636-066 D DIN
137636-085 A EU 137636-072 C DIN
A 137636-078 B DIN

Crown 2011 PF25259-26

2 137636-086 DIN
137636-052 B/C/D ANSI 137636-058 B/C/D ANSI
137636-087 B/C/D EU 2 137636-085 B/C/D EU
137636-088 B/C/D DIN 137636-086 B/C/D DIN
084571-289 A/B/C/D ANSI 084571-289 B/C/D ANSI
3 3
139255-001 A/B/C/D EU/DIN 139255-001 B/C/D EU/DIN
084571-288 A/B/C/D ANSI 084571-288 B/C/D ANSI
4 4
139255-001 A/B/C/D EU/DIN 139255-001 B/C/D EU/DIN
084571-290 A/B/C/D ANSI 084571-290 B/C/D ANSI
5 5
139255-001 A/B/C/D EU/DIN 139255-001 B/C/D EU/DIN
6 090963-042 A/B/C/D ANSI/EU/DIN 6 090963-042 B/C/D ANSI/EU/DIN

B
B

7 084572-283 A/B/C/D ANSI/EU/DIN 7 084572-283 B/C/D ANSI/EU/DIN

8 137636-003 A/B/C/D ANSI/EU/DIN 8 137636-003 B/C/D ANSI/EU/DIN
9 084572-284 A/B/C/D ANSI/EU/DIN 9 084572-284 B/C/D ANSI/EU/DIN

TSP 7000 SERIES

10 090963-046 A/B/C/D ANSI/EU/DIN 10 090963-046 B/C/D ANSI/EU/DIN
11 137636-004 A/B/C/D ANSI/EU/DIN 11 137636-004 B/C/D ANSI/EU/DIN
12 090963-044 A/B/C/D ANSI/EU/DIN 12 090963-044 B/C/D ANSI/EU/DIN
13 090963-045 A/B/C/D ANSI/EU/DIN 13 090963-045 B/C/D ANSI/EU/DIN
084572-291 A ANSI 084572-323 B/C/D ANSI
14
084572-323 B/C/D ANSI 138917-002 B/C/D EU/DIN
14
138917-001 A EU/DIN 084572-322 B/C/D ANSI
15
138917-002 B/C/D EU/DIN 138917-002 B/C/D EU/DIN
084572-290 A ANSI 084572-321 B/C/D ANSI
16
084572-322 B/C/D ANSI 138917-002 B/C/D EU/DIN
15
138917-001 A EU/DIN 137636-059 D ANSI
138917-002 B/C/D EU/DIN 137636-067 C ANSI
084572-289 A ANSI 137636-073 B ANSI

C
C

084572-321 B/C/D ANSI 137636-062 D EU

16
138917-001 A EU/DIN 17 137636-069 C EU
138917-002 B/C/D EU/DIN 137636-075 B EU
137636-065 D DIN
137636-071 C DIN
137636-077 B DIN

4
3
2
1

DIA-1970-026
149688 E 2 of 2
POWER CABLES P/N’S
SCHEMATIC DIAGRAMS

655
SCHEMATIC DIAGRAMS
WIRE HARNESSES

Wire Harnesses

Wire Harness Chart

Wire Harness
Components Connected By:
Part Number
132562-001 Battery Retainer & Rail Guide Harness:JC404, BRES, LRGS, RRGS
132562-002 Rail Guide Harness: JC404, LRGS, RRGS
132562-003 Battery Retainer Harness: JC404, BRES
132563 EAC Harness(1): JC602, PC607, PC608
132564 Guidance Harness(1): JC602, PC603, PC604
132565 EAC/Guidance Harness(1): JC602, PC603, PC604, PC607, PC608
132716 Chain Slack Switch Harness: JC309, Includes Switches CHS1, CHS2, CHS3, CHS4
132718 Seat Position Switch: JC316, SLS, SPS Includes Solenoid (EML)
132720-001 RH Armrest Harness: Includes RRS
132729 RH Armrest Traverse Harness: POT4
132730 RH Armrest Harness: POT1
132731 RH Armrest R/L Harness: POT2
132735-001 LH Hand Presence Sensor Harness: Includes HPSL
132735-002 RH Hand Presence Harness: Includes HPSR
132770-001 RH Armrest Handle W/Thumbwheel Standard Harness:
132770-002 RH Armrest Handle W/Thumbwheel Tilt Harness:
132771 LH Armrest Handle W/Thumbwheel Standard Harness
132783 RH Armrest Harness C/C
132989-001 LH Armrest Harness: Includes APS, ORS1, PLS, PRS
133380-001 8 Conductor Cable: Coiled Under Seat
133864-001 Wire Hose Gang Harness: PC105, PC701
132990 LH Armrest R/L Harness
134217 Auxiliary Mast Harness: PC708, PC710, SVAL
134219 Strobe Harness
134322 Accessory Cable Harness(1)
135141 Fork Plate Harness: JC707

Auxiliary Hydraulic Harness, 864 - 1397 mm (34 - 55 in) Load Handler(1): PC702, PC703,
136766 PC704, PC705, PC706, PC707, JC701, JC708, PVAR, PVAL, PVLH, PVP1, PVP2, PVF1,
PVF2, PVT1, PVT2, Includes Resistor RES3

Auxiliary Hydraulic Harness 584 - 838 mm (23 - 33 in) Load Handler(1): PC702, PC703, PC704,
136767 PC705, PC706, PC707, JC701, JC708, PVAR, PVAL, PVLH, PVP1, PVP2, PVF1, PVF2, PVT1,
PVT2, Includes Resistor RES3
(1) Optional

DIA-1970-027 TSP 7000 SERIES Crown 2011 PF25259-27 Rev. 6/12

02 Rev. 6/12
656
 SCHEMATIC DIAGRAMS
WIRE HARNESSES

Wire Harness Chart

Wire Harness
Components Connected By:
Part Number
136796 DT/DTM Adaptor Harness: PC409, JC409
138434 1.0 Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
138773 1.0 EAC Harness: JC602, PC607, PC608
138932 EU Guidance Harness: JC602, PC603, PC604
138953 EU EAC Harness: JC602, PC603, PC604, PC607, PC608
140290-001 InfoLink® CAN Breakout Harness: CAN, PROG, SHOCK, RS232, Module, Current, Alarm
Power Unit Harness: PC201(CAN BUS), PC205, PC206, PC207, PC401 (TCM), PC402 (SCM),
PC404 (BRES), PC405 (STROBE), PC406 (CURRENT SENSE), PC408 (SPLITTER BLOCK),
143205 PC411 (HCM), PC412, PC413, PC414, PC416 (CTS), PC417 (CAN), PC426, PC601 (GCM),
JC403 (SCM), JC407 (BRAKE), JC410 (ENCODER), JC415, ALARM, B - BUS, ED Coil 1, ED
Coil 2, EMS2, HORN, K2 Coil, K3 Coil, SB41
143758 InfoLink® Harness: CAN, BYPASS, CA103-11, CA104-4, CA104-12, CA106-4, CA106-11
144518-001 TT Mast Switch Harness: JC416, PC801; Harness Length 3890 mm (153 in)
144518-002 TT Mast Switch Harness: JC416, PC801; Harness Length 4400 mm (173 in)
144518-003 TT Mast Switch Harness: JC416, PC801; Harness Length 4910 mm (193 in)
144518-004 TT Mast Switch Harness: JC416, PC801; Harness Length 5420 mm (213 in)
144518-005 TT Mast Switch Harness: JC416, PC801; Harness Length 5930 mm (233.5 in)
144518-006 TT Mast Switch Harness: JC416, PC801; Harness Length 6440 mm (253.5 in)
144518-007 TT Mast Switch Harness: JC416, PC801; Harness Length 6950 mm (273.6 in)
144518-008 TT Mast Switch Harness: JC416, PC801; Harness Length 7460 mm (293.7 in)
145762 OHG LED Light Harness: PC510, PC511, PC512, PC513
149438 Contactor Panel Harness: PC204, ED, K2, K3
149489 Power Supply Harness: PC418 (PS3), PC419 (PS4), B-, K2, K3
Platform Harness: PC101, PC103, PC104, PC106 (CAN BUS), PC304 (DISPLAY), PC305
(KYS), PC306 (ACC), PC307 (RS232), PC309 (CHS1, CHS2, CHS3, CHS4), PC310 (EN-
CODER), PC311, PC312, PC313, PC314, PC316 (EML), PC316 (EML), JC317 (SEAT), JC319
149518 (RIGHT FRONT PRESENCE), JC320 (LEFT FRONT PRESENCE), JC321 (LEFT REAR
PRESENCE), JC322 (RIGHT BRAKE), JC323 (LEFT BRAKE), Dome Lights, EMS1, FAN, FAN
Suppressor, FNS, HGTRS, LGS1, LGS2, LGS3, LGTS, Power Point, RGTS, RES8, Spot
Lights, TS3, Work Lights, ZSS, +48V Supply (B+, B-,+IV, I-)
149661 Main Manifold Harness: JC414, PVML, SVA, SVML, SVMR
Power Unit Harness W/PDS: PC201(CAN BUS), PC205, PC206, PC207, PC401 (TCM),
PC402 (SCM), PC404 (BRES), PC405 (STROBE), PC406 (CURRENT SENSE), PC408
(SPLITTER BLOCK), PC411 (HCM), PC412, PC413, PC414, PC416 (CTS), PC417 (CAN),
149798
PC426, PC601 (GCM), JC403 (SCM), JC407 (BRAKE), JC410 (ENCODER), JC415, JC611,
JC612, PC613, PC614, ALARM, B - BUS, ED Coil 1, ED Coil 2, EMS2, HORN, K2 Coil, K3 Coil,
SB41, TS4

Crown 2011 PF25259-28 Rev. 6/12 TSP 7000 SERIES DIA-1970-028

02 Rev. 6/12
657
SCHEMATIC DIAGRAMS
WIRE HARNESSES

Wire Harness Chart

Wire Harness
Components Connected By:
Part Number
151488 Temperature Sensor Harness, F/C: PC422, JC426
151489 Auxiliary Mast Harness, F/C: PC708, PC710, SVAL
151519 Fork Plate Harness, F/C: JC707
152626 Seat Position Switch (1): JC316, SLS, SPS Includes Solenoid (EML)
(1) EE Trucks, Optional

DIA-1970-029 TSP 7000 SERIES Crown 2011 PF25259-29 Rev. 6/12

02 Rev. 6/12
658
HYDRAULIC SCHEMATIC
659
Notes:

660
 HYDRAULIC SCHEMATIC
HYDRAULIC SCHEMATIC

Hydraulic Schematic

Main Lift - SVMR energized, lift motor M 1 TN Lift Cylinder 68.1 l/m, 20.7 MPa
drives Pump P1 at variable speed 2 Velocity Fuse

Main (regen) lower - PVML and SVML en- 3 Velocity Fuse

ergized, P1 drives motor (reverse rotation) at 4 Velocity Fuse Free Lift
variable speed
5 TF Lift Cylinder 71.9 l/m, 20.7 MPa
LH function - SVA energized, lift motor M 6 Velocity Fuse Free Lift
drives Pump P1 at reduced variable speed 7 TT Lift Cylinder 80.9 l/m, 20.7 MPa
8 Velocity Fuse
9 Velocity Fuse
10 Mainframe Manifold Block
11 Tank Top Filter Assembly 5 Micron Element
12 Inner Mesh Screen, 100 Mesh
13 Hydraulic Reservoir 48.5 Liters (12.8 Gallons)
14 Filler-Breather-Dipstick Assembly
15 RV1 Pre-Set to 24.8 MPa
16 22 cc High Performance Lift Regenerative Pump Assembly - 48 V trucks
28 cc High Performance Lift Regenerative Pump Assembly - 72/80 V trucks

Figure 25439

Crown 2011 PF25281-1 TSP 7000 SERIES HYD-1970-001

661
HYDRAULIC SCHEMATIC
HYDRAULIC SCHEMATIC

LH Function Movement 1 Auxiliary Hoist 22.7 l/m, 24.1 MPa

S1 = Top Coil, S2 = Lower Coil
Pivot CW = S1 Energized, R2 Pressurized
Pivot CCW = S2 Energized, R1 Pressurized
Fork Extend = S1 Energized, F2 Pressurized
Fork Retract = S2 Energized, F1 Pressurized
Traverse Right = S1 Energized, T1 Pressurized to “A”
Motor Port
Traverse Left = S2 Energized, T2 Pressurized to “B”
Motor Port
2 Load Sense Pressure Transducer
3 Traverse 9.4 l/m, 16.5 MPa
4 CBV1, CBV2 Set to 17.25 MPa
5 Fork Extend 9.4 l/m, 9.6 MPa
6 Pivot 3.8 l/m, 9.6 MPa
7 Load Handler Manifold Block
8 CBV3, CBV4 Set to 9.6 MPa
9 PR1 Set to 16.5 MPa
10 PR2 Set to 9.6 MPa

Figure 25440

HYD-1970-002 TSP 7000 SERIES Crown 2011 PF25281-2

662
 HYDRAULIC SCHEMATIC
HYDRAULIC SCHEMATIC

LH Function Movement 1 Auxiliary Hoist 22.7 l/m, 24.1 MPa

S1 = Top Coil, S2 = Lower Coil
Pivot CW = S1 Energized, R2 Pressurized
Pivot CCW = S2 Energized, R1 Pressurized
Tilt Up = S2 Energized, F1 Pressurized
Tilt Down = S1 Energized, F2 Pressurized
Traverse Right = S1 Energized, T1 Pressurized to
“A” Motor Port
Traverse Left = S2 Energized, T2 Pressurized to
“B” Motor Port
2 Load Sense Pressure Transducer
3 Traverse 9.4 l/m, 16.5 MPa
4 CBV1, CBV2 Set to 17.25 MPa
5 Pivot 3.8 l/m, 9.6 MPa
6 Load Handler Manifold Block
7 CBV3, CBV4 Set to 9.6 MPa
8 PR1 Set to 16.5 MPa
9 PR2 Set to 9.6 MPa
10 Tilting Forks 9.6 MPa

Figure 25447

Crown 2011 PF25281-3 TSP 7000 SERIES HYD-1970-003

663
Notes:

664