Old SC4200 Pre Service Info

Hazardous Energy
SAFETY
Control of Hazardous Energy
Control of Hazardous Energy Battery Care

In the interest of safety and to ensure compliance with
OSHA Regulations, (Standards - 29 CFR), The control CAUTION
of hazardous energy (lockout/tagout) - 1910.147,
Crown has developed guidelines for proper energy • Only qualified and experienced personnel should
control when performing service and maintenance on perform maintenance and repair on batteries.
the SC 4500. Before performing any service or mainte-
nance on this truck, review the appropriate sections in • Make certain the charger being used matches the
this service manual for additional procedures to be fol- voltage and amperage of the truck battery. This
lowed. voltage is listed on the truck serial plate.
In addition, Crown recommends that all mechanics • Before disconnecting or connecting batteries to a
wear appropriate protective items, such as safety
charger, make sure the charger is "OFF". If an at-
glasses, work gloves, and steel toed shoes, whenever
tempt is made to do this while the charger is "ON",
performing service or maintenance work on Crown
serious injury to you, the battery and charger could
equipment.
result.
Battery • Never use a match or lighter. Battery fumes are ex-

plosive.
Safety Rules • Make certain battery used meets weight, size and
voltage requirements of truck (refer to serial plate).
• Wear protective clothing, such as, rubber apron, NEVER operate truck with an undersized battery.
gloves, boots and full-face shield when performing
any maintenance on batteries. Do not allow elec-
Charging
trolyte to come in contact with eyes, skin, clothing
or floor. If electrolyte comes in contact with eyes,
flush immediately and thoroughly with clean water. CAUTION
Obtain medical attention immediately. Should elec-
trolyte be spilled on skin, rinse promptly with clean Never smoke or bring flame near the battery. Gas
water and wash with soap. A baking soda solution formed during charging is highly explosive and can
(one pound to one gallon of water) will neutralize cause serious injury.
acid spilled on clothing, floor or any other surface. Consult the charger manufacturer's manual covering
Apply solution until bubbling stops and rinse with your charger for hints on operation and maintenance.
clean water.
• Keep vent plugs firmly in place at all times except

when adding water or taking hydrometer readings.
• Do not bring any type of flame, spark, etc., near the

battery. Gas formed while the battery is charging,
is highly explosive. This gas remains in the cells
long after charging has stopped.
• Do not lay metallic or conductive objects on bat-

tery. Arcing will result.
• Do not allow dirt, cleaning solution or other foreign

material to enter cells. Impurities in electrolyte has
a neutralizing effect reducing available charge.
• If battery repair is planned, follow the battery man-

ufacturer's instructions concerning repair practices
and procedures.
Crown 2006 PF15538-1 Rev. 11/06 MA-1145-100

02 Rev. 11/06
7
SAFETY
Battery Removal
CAUTION
Make certain battery used meets weight, size and volt-
CAUTION age requirements of truck (refer to serial plate).
When removing the battery, move truck to area in- NEVER operate truck with an undersized battery.
tended for battery care. Floor must be level. Turn key-
switch or toggle switch to "off" position and remove Lockout - Tagout
key. Disconnect battery and lockout or tagout truck as
described in Battery - Lockout/Tagout in this section. Always turn key switch to "off", remove key and apply
Never move battery partially from truck without roller tag to steering wheel with cable tie warning others truck
stand in place. Lower load engaging means com- is being serviced.
pletely. If battery is removed with load engaging means
raised, use hoist attached to mast to provide tip over
protection. Don’t allow any metallic object to come in
contact with the top of the battery cells. This may cause
a short circuit when removing, transporting the battery.
Use an insulator (such as plywood) to cover the top of
the battery before and during removal.
Figure 8346
When maintenance is to be performed and the battery

will be left in the truck, disconnect battery, remove the
main power fuses and install a commercially available
lockout device on the battery connector.
When maintenance is performed and the battery is re-
moved from the truck, remove the main power fuses,
install a lockout device on the trucks battery connector
if possible, or if possible install a tag with a cable tie on
the trucks battery connector so it cannot be removed
easily warning that the truck is not available for opera-
tion.
Figure 8251
Battery Installation
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 Battery -
Lockout/Tagout in this section. If battery was removed
with load engaging means raised, use hoist attached to
mast to provide tip over protection. Don’t allow any me-
tallic object to come in contact with the top of the bat-
tery cells. This may cause a short circuit when trans-
porting or installing the battery. Use an insulator (such
as plywood) to cover the top of the battery before and
during installation.
MA-1145-101 Crown 2006 PF15538-2 Rev. 11/06
01 Rev. 11/06
8
SAFETY
Capacitance 3. Disconnecting the battery for a minimum of 10 min-

utes will discharge the capacitors that are inside
Due to capacitance voltage present in the traction mo- the Traction Control Module ACCESS 3. Two addi-
tor controller, whenever performing maintenance which tional methods of discharging these capacitors are
may permit contact with the bus bars and associated to disconnect the battery, place a jumper from top
power cables, discharge the capacitors. stud of line contactor to fuse bus bar and then hold
the key switch in the START position for 10 sec-
1. Move truck to a secure non traffic maintenance
onds, or disconnect the battery and connect a 100
area with a level floor.
ohm 2 watt resistor between the positive and neg-
2. Lockout or tagout truck as described in Battery - ative terminals on the controller, ACCESS 3.
Lockout/Tagout in this section.
Access 3 - Traction Control Module
Figure 14944
Crown 2006 PF15538-3 Rev. 11/06 MA-1145-102

02 Rev. 11/06
9
SAFETY
Brake
It is necessary to release the electric brakes before
towing a SC 4500 truck PC605 (Drive)
WARNING
Extreme care must be taken when using any of the fol-
lowing procedures to release the truck brakes. The
brake pedal in the operator compartment and the truck
brakes will not function when using any of the following
procedures. The brakes can only be applied when the
truck is returned to its original configuration.
During any procedure, lockout and tagout the truck as
described in Battery Lockout/Tagout in this manual
section.
Remove load from truck before releasing the brakes
and towing.
Always perform brake release procedure on a level
surface to prevent the truck from rolling. Chock drive
wheels or make sure truck is secure before releasing
brakes. PC606 (Tow)
When towing the truck, make sure all operators know
that truck does not have braking capability. Figure 14980
Move truck to a maintenance area and secure on a
level surface. • Raise seat deck, locate and disconnect JC405
If the truck is not returned to normal braking configura- from PC405. They are the "Drive/Tow connectors"
tion after towing, it must remain in a Lockout/Tagout and are located near the Traction Control Module.
condition. Route the female end of the plug between the seat
deck and rear counterweight, so it can be ac-
Releasing Brakes cessed from the rear of the truck. Be careful not to
pinch the wires.
When releasing the truck brakes use extreme caution
and follow one of the following procedures. Choose the • Using Brake Release Harness (139956-001
procedure that best fits the situation. 24 volt, or 139956-002 36/48 volt), connect an
auxiliary power source to the plug. This will release
Releasing Brakes by Switching Connec- the brakes.
tors & Using an External Power Source • Tow truck to Maintenance area, secure truck in po-
• Turn key switch to OFF position, disconnect bat- sition, disconnect power supply, and return con-
nectors to original configuration. NOTE: Leaving a
tery (if present) and remove left side operator floor
power source ON and connected to the truck brake
plate.
coils could over heat and damage the brakes. If the
• Refer to Figure 14980. Disconnect Plug JC605 truck is not returned to normal braking configura-
from PC605 (labeled "Drive") located near battery tion then it must remain in Lockout/Tagout condi-
disconnect. Connect plug JC605 and PC606 (la- tion.
beled "Tow"). Install floor plate.
MA-1145-103 Crown 2006 PF15538-4 Rev. 11/06
01 Rev. 11/06
10
SAFETY
Releasing Brakes by Switching Connec- • When in Tow-Mode, if operator is "present" (in the
tors & Using On Board Truck Battery seat) and either drive wheel moves, there is no au-
dible alarm.
• With truck key switch turned OFF, disconnect bat-
tery and remove left side operator floor plate. • Tow the truck to Maintenance area and apply
brakes using the display to key truck "OFF". If truck
• Refer to Figure 14980. Disconnect Plug JC605 is not returned to normal braking configuration then
from PC605 (labeled "Drive") located near battery it must remain in Lockout/Tagout condition.
disconnect. Connect plug JC605 and PC606 (la-
beled "Tow"). Install floor plate.
Releasing Brakes Using Screws
• If brakes do not release, locate "Drive/Tow connec-
• With the truck key switch in the OFF position and
tors" JC405 and PC405 in the rear of the truck near
the mast raised and blocked, insert two M6 screws
the Traction Control Module, and make sure that
45 mm (1.75 in) long, into the brake assembly as
they are connected.
shown in Figure 14981. Tighten both screws
• Tow truck to Maintenance area, secure truck in po- equally until the brake is released. Repeat the pro-
sition and return connectors to original configura- cedure on the opposite brake.
tion. NOTE: Leaving this power source connected
to the truck brake coils could over heat and dam-
age the brakes. If the truck is not returned to nor-
mal braking configuration then it must remain in
Lockout/Tagout condition.
Releasing Brakes by Using the Crown

Operator Display and Truck Battery is
Present
• Turn key switch ON and navigate through display
menus to release brakes.
• The Tow-Mode feature is only available in Service Figure 14981

Menu Level 3, Analyzer menu level 4.7 (A4.7), a
password is required. At this level all Traction is in-
hibited and the steer pump will be active if operator
is present.
• When in Tow-Mode, there is a five minute window

that the brakes are in the released state. If addi-
tional time is required the release can be reacti-
vated for additional five minute periods.
• When in Tow-Mode, the message "TOW? Y" "5

Minute BRAKES RELEASED" is displayed. Press
enter key to release brakes.
• If the brakes are released in Tow-Mode, and need

be applied, the action can be cancelled by pressing
the down arrow key and then answering "TOW? N"
or keying truck "OFF".
• When in Tow-Mode, if operator is not "present" (out

of seat) and either drive wheel moves, an audible
alarm will sound.
Crown 2006 PF15538-5 Rev. 11/06 MA-1145-104

01 Rev. 11/06
11
SAFETY
Hydraulic
When maintenance is to be performed on the hydraulic
system, to make sure the hydraulic system is not under
WARNING pressure:
AVOID HIGH PRESSURE FLUIDS—Escaping fluid 1. Move truck to a secure non traffic maintenance
under pressure can penetrate the skin causing serious area with a level floor.
injury. Relieve pressure before disconnecting hydraulic 2. No load on forks.
lines. Tighten all connections before applying pres-
sure. Keep hands and body away from pin holes which 3. Completely lower load engaging means (mast) or,
eject fluids under high pressure. Use a piece of card- if required for maintenance, block mast sections at
board or paper to search for leaks. Do not use your appropriate height as described in Mast of this sec-
hand. tion.
Any fluid injected into the skin under high pressure 4. Lockout or tagout truck as described in Battery -
should be considered as a serious medical emergency Lockout/Tagout in this section.
despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage 5. Operate the hydraulic levers to remove any hy-
may occur. Medical attention should be sought imme- draulic pressure that may be present.
diately by a specialist who has had experience with this
type of injury.
Lower forks
completely
No load
on forks
Figure 8347-02
MA-1145-105 Crown 2006 PF15538-6 Rev. 11/06
01 Rev. 11/06
12
SAFETY
Lifting and Blocking
SIDE
Lower Forks and

Move Toward Center
of Truck if Required
Hard Wood Block

One Side of
Truck Only
Figure 8348-02

area with a level floor. WARNING
2. No load on forks. Truck stability decreases dramatically if truck skirt is
raised more than 140 mm (5.5 inch). Attach sling and
3. Lockout or tagout truck as described in Battery - overhead lifting device to all cross members of the
Lockout/Tagout in this section. mast to prevent truck from tipping over when raising
NOTES: the side of the truck.
• Hydraulic Jack - Capacity 3620 kg (8000 lbs)
• Crown part number: 122599
• Collapsed height minimum: 60 mm (2.25 in)
• Raised height maximum: 400 mm (16 in)
• Jack Stand - capacity 4500 kg (10,000 lbs) Com-

mercially available.
NOTE
When raising rear of truck, raise one side 25 to 38 mm
(1 to 1 1/2 in) and block. Raise opposite side 25 to
38 mm (1 to 1 1/2 in) and block. Continue alternating
sides until required height not to exceed 400 mm
(16 in).
Crown 2006 PF15538-7 Rev. 11/06 MA-1145-106

01 Rev. 11/06
13
SAFETY
Steer Wheel
Raise Forks
75 to 150 mm
(3 to 6 in)
from Floor
Wheel Chock
Both Drive Wheels
Set Jack Stand

Height as Required
Hardwood Blocks Not to Exceed
Refer to Note 400 mm (16 in)
Figure 8349-03
NOTE
When raising rear of truck, raise one side 25 to 38 mm
(1 to 1 1/2 in) and block. Raise opposite side 25 to
38 mm (1 to 1 1/2 in) and block. Continue alternating
sides until required height not to exceed 400 mm
(16 in).
MA-1145-107 Crown 2006 PF15538-8 Rev. 11/06
02 Rev. 11/06
14
SAFETY
Mast 4. Raise forks and position blocks under second

stage mast as shown.
Blocking Masts 5. Using a clamp or ratchet tie down, secure blocks to

mast channel as shown.
Use 100 mm (4 inch) by 100 mm (4 inch), 50 mm
(2 inch) by 100 mm (4 inch) or bigger hardwood blocks 6. Lower mast and position appropriate length blocks
of appropriate length for supporting mast channels. under third stage mast as shown.
Block both mast rails of each stage to maintain truck 7. Lower mast and position appropriate length blocks
stability. under fourth stage mast (or inner) on quad mast
Remove any carriage mounted accessory (e.g. carton trucks as shown.
clamp, etc.) except sideshifters before blocking masts. 8. Using a clamp or ratchet tie down, secure blocks to
These accessories add significant weight to the mast. mast channel or second stage block as shown.
1. Move truck to a secure non traffic maintenance 9. Lower fork carriage until carriage rests on stops or
area with a level floor. place blocks under carriage and lower until weight
2. Chock wheels of truck. Refer to Lifting and Block- rests on blocks.
ing in this section. 10. Lockout or tagout truck as described in Battery -
3. Connect battery. Lockout/Tagout in this section.
Quad Mast
TT Mast
Fourth Stage
Mast (or Inner)
Fork Carriage
(shown raised slightly
for clarity)
Third Stage Mast

Second Stage Mast
First Stage Mast Third Stage

(or mainframe) Mast
First Stage Mast

(or Outer Mast)
Second Stage Mast
Figure 14948
Crown 2006 PF15538-9 Rev. 11/06 MA-1145-108

01 Rev. 11/06
15
SAFETY
Fork Carriage TT Mast
Third Stage
Second Stage
FirstStage
(or mainframe)
Quad Mast
Fork Carriage
Fourth Stage
(or Inner Mast)
Third Stage
Second Stage
FirstStage
(or Outer Mast)
Figure 14949
MA-1145-109 Crown 2006 PF15538-10 Rev. 11/06
01 Rev. 11/06
16
SAFETY
Disconnecting Tilt Cylinder

When the tilt cylinders are disconnected from the hy-
draulic system or from the mounting brackets, the mast
must be secured to keep the mast from pivoting to-
ward, or away from the truck.
2. Lower load engaging means (mast) completely. No
load on forks.
3. Lockout or tagout truck as described in Battery -
4. Chock wheels. Refer to Lifting and Blocking in this
section.
5. Attach a sling and lifting device to all mast top
cross braces so movement will be minimal when tilt
cylinders are disconnected.
Attach Lifting Device to All

Top Cross Braces and
Center to Maintain Balance
Wheel Chocks
Figure 8350-01
Crown 2006 PF15538-11 Rev. 11/06 MA-1145-110

01 Rev. 11/06
17
SAFETY
Removing Mast
1. Move truck to a secure non traffic maintenance Mast
Shim
3. Remove battery.
4. Remove forks.
5. Cycle all hydraulic levers to remove any hydraulic Power
pressure in the system. Unit
6. Disconnect lift cylinder hydraulic lines, accessory

Figure 8352-01
cables and accessory hydraulic lines between
power unit and mast if present. Use container to
catch hydraulic oil.
7. Disconnect wiring between mast and power unit.
8. Support mast as described in Disconnecting Tilt
Cylinders in this section.
9. Chain mast sections together at the upper cross-
braces. Chain fork carriage to lower mast cross-
brace. This will keep carriage and mast sections
from moving when the mast is laid down.
10. Remove pins connecting tilt cylinders to the mast.
Figure 8351
11. Remove pivot block mounting bolts. If pivot blocks

are to be removed, note number and location of
shims between pivot blocks and mast.
12. Move mast away from truck and lay mast on level
floor with the truck side of the mast on the floor.
MA-1145-111 Crown 2006 PF15538-12 Rev. 11/06
01 Rev. 11/06
18
SAFETY
Removing Counterweight
2. Lockout or tagout truck described in Battery - Lock-
out/Tagout in this section.
3. Remove battery.
4. Attach a sling and lifting device to all top cross
braces of the mast, to prevent tipover.
5. Attach a sling and lifting device to the rear of the
overhead guard to support the guard when the
guard mounting bolts are removed.
Figure 8354
WARNING
After mounting bolts holding the counterweight to the
truck are removed, the counterweight will be balanced
on the pallet truck forks. Use extreme care when mov-
ing counterweight to maintain balance.
8. Remove counter weight mounting bolts.
9. Carefully move the counterweight away from truck.
Overhead Guard
Mounting Bolts
Counterweight
Mounting Bolts
Figure 8353-01
6. Remove overhead guard mounting bolts from the

counterweight.
7. Position a pallet truck or other similar lifting device
under the counter weight from the rear of the truck
and raise to support the weight of the counter
weight when the mounting bolts are removed.
Crown 2006 PF15538-13 Rev. 11/06 MA-1145-112

01 Rev. 11/06
19
SAFETY
Hose Reel
Hose reels have a minimum of 3 revolutions of prewind
and up to 16 revolutions maximum. When performing
maintenance to these units, use the following steps to
remove the spring prewind.
2. Position the forks to provide the shortest distance
between the carriage mounted junction block and
the hose reel. Block the carriage at this height as
described in Mast of this section.
4. Remove battery.
5. Cycle the hydraulic control levers repeatedly to re-
move any hydraulic pressure that may be present.
6. Clean oil and residue from hose(s) exterior.
7. Disconnect the hose(s) from the carriage mounted
junction block while maintaining a tight grip on the
hose(s).
8. Slowly allow hose(s) to coil up on the reel and care-
fully remove prewind by grasping reel and slowly Figure 8320
allowing the reel to rotate.
MA-1145-113 Crown 2006 PF15538-14 Rev. 11/06
01 Rev. 11/06
20
Brakes
BRAKE
Brake
Brake Brake Assembly Removal

1. Move truck to service area on level floor.
Checking Brake Air Gap 2. Raise and block mast so that lower crossbrace of
second stage mast is 914 mm (36 in) off the floor.
To check the brake air gap, insert a feeler gage into
slots in dust cover. Gap will be checked between mag- 3. Turn key switch off, chock wheels, and disconnect
net body & coil and armature (See Figure 14939). Air the battery.
gap should measure between 1.4 mm (0.056 in) maxi-
4. Insert two 44.45 mm (1.75 in) long M6 Hex Head
mum at 212 degrees Fahrenheit and 0.2 mm (0.008 in)
Cap Screws in the non-used holes in the Magnet &
minimum. If the gap measures outside this range, the
Coil Body (11) (See Figure 14940). Tighten the
friction disc(s) will need to be replaced.
screws to compress the springs and release the
If friction discs need to be replaced, the brake assem- brake.
blies must be removed from the truck. In that case, fol-
low the procedure outlined under “Brake Assembly Re-
moval”.
Armature (under Spacer)
Install M6 screws in these holes
14940
5. Disconnect wiring to brake assembly being re-

moved (CA627 – LH Brake, CA628 – RH Brake).
6. Remove three M8 Hex Head Cap Screws (12).
Feeler Gage Magnet & Coil Body 7. Loosen, but do not completely remove, three M8
Socket Head Cap Screws (13). See Figure 14941.
14939 8. Remove M10 Hex Head Cap Screw (4). See Fig-
ure 14941.
9. Remove brake assembly including hub (1) from
drive unit shaft. See Figure 14941.
Crown 2006 PF15535-1 M5.0-1145-001
223
BRAKE
Brake
Part of
Left Hand
Drive Unit
Brake Assembly
Part of
Drive Unit
Right Hand
Brake Assembly
14941
M5.0-1145-002 Crown 2006 PF15535-2
224
BRAKE
Brake
Brake Disassembly 4. Install M10 Hex Head Cap Screw (4) and tighten
securely.
(Ref. Figure 14941)
5. Connect wiring to brake assembly (CA627 – LH
1. Remove hub (1) from brake assembly. Brake, CA628 – RH Brake).
2. Remove three M8 Socket Head Cap Screws (13) 6. Remove the two 44.45 mm (1.75 in) long M6 Hex
that were previously loosened. Head Cap Screws from the Magnet & Coil Body
that were used to compress the springs.
3. Remove two M6 Hex Head Cap Screws that were
previously installed to release the brake. Mark the
location of these screws for future reference.
4. Disassemble brake assembly and discard worn
friction disc(s).
NOTE
The right hand brake assembly contains two friction
discs. When the brake air gap measures outside the
specified range, both friction discs must be replaced.
Brake Assembly
(Ref. Figure 14941)
1. Assemble brake components as shown on the
“Brake Parts” page in the Service and Operating
Manual. Use care to properly orient slots used to
check air gap.
2. Install three M8 Socket Head Cap Screws (13) to
hold assembly together. Tighten screws securely.
3. Install two 44.45 mm (1.75 in) long M6 Hex Head
Cap Screws in the previously marked holes (during
disassembly) in the Magnet & Coil Body (11).
Tighten the screws to compress the springs.
4. Install hub (1) into assembly and line up splines
with friction plate.
5. Install three M8 Hex Head Cap Screws (12) in the
remaining holes in the Magnet & Coil Body (11).
These screws must be installed prior to installing
assembly on truck.
Brake Assembly Installation

(Ref. Figure 14941)
1. Position brake assembly in truck with wire harness
to the top.
2. Rotate assembly slightly to align hub (1) with drive
unit input shaft.
3. Align M8 Hex Head Cap Screws (12) with threaded
holes in drive unit and tighten screws securely.
Crown 2006 PF15535-3 M5.0-1145-003
225
Steering
STEERING
Steering
Steering
Your truck is equipped with a hydraulic steering sys- Steer
tem. A hydrostatic steering control unit, located in the Unit
control column, is coupled via hydraulic tubes and
hoses to the steering axle, mounted near the back of
the power unit, used to actuate the steering.
Part of
Power Unit
Hydrostatic Steering Unit
Clamps
The hydrostatic steering unit (open center non-reac-
tion) mounts in the control column below the steering
wheel. The non-reaction unit maintains the steered po-
sition when the operator releases the steering wheel.
The cylinder ports are blocked in the neutral valve po-
sition. The operator must steer the drive wheel back to
the straight ahead position.
The steering unit meters a proportional amount of oil to
the steering motor when the wheel is rotated. This
pressurized oil is supplied by the PS pump, and is sup- Figure 15138
plied to the appropriate side of the steering motor by
the direction of rotation of the steer control unit via the
steering wheel. When the steering wheel rotation is WARNING
stopped, the steer motor ports are blocked to hold the The steering on your truck can be reversed by incor-
steering in that position. In the event that pump flow is rectly connecting the hydraulic hoses. Care should be
stopped, the steer unit can be manually rotated to exercised when maintenance is performed on the
"pump" flow to the appropriate steer actuator port by steering system. Prior to disassembly, mark hose and
turning the steering wheel in the desired direction, thus tube locations so they can more easily be properly as-
allowing emergency steering. sembled.
Steer circuit relief pressure is non-adjusting and preset After completing maintenance, always check to be
to 8273 - 8618 kPa (1200 - 1250 psi). Normal steering sure steering system is functioning properly.
pressures are 2758 - 5516 kPa (400 - 800 psi).
NOTE
The clamps shown at the right secure steer unit hy-
draulic tubes to the power unit and must be securely in
place to prevent fluid leakage.
Crown 2006 PF15569-1 M6.0-1145-001
229
STEERING
Steering
Steering Column Assembly

Refer to the following procedures and specifications Brush
when assembling the steering column. Holder
Brush
Upper
Directional Shaft
Control
Steering Lower
Wheel Shaft
Column
Gas
Cylinder Column
O-Ring
Mounting
Bracket
Figure 15153
Steer • Refer to Figure 15154. Apply 1.5 to 2 turns of black

Unit electrical tape around upper shaft at positions
where wires enter tube, covering solder area on
contact ring and wire entering tube.
Figure 15149
Column
NOTE
Before removing shaft assembly from column, remove Electrical Solder
the brush holder and brushes or they will be destroyed. Tape Area
Upper
Contact
Insulator Shaft
Ring
Figure 15154
• Apply a small amount of 063001-002 oil to outside

of o-ring at bottom of lower shaft. Refer to Figure
15153.
M6.0-1145-002 Crown 2006 PF15569-2
230
STEERING
Steering
Gas Cylinder
Release
Lever Forward
Retaining Switch
Ring
Roll Pin Cam Lever Reverse
Switch
Gas Cylinder
Release
Head Part of
Power Unit
Bracket
Part of
Column
Figure 15157
Figure 15155
• Screw gas cylinder threaded shaft into threaded

• When installing cam lever into bracket, be sure to
orient handle in correct position. Refer to Figure
hole in release head until plunger pin on gas cylin-
15158.
der contacts bottom edge of release lever. Refer to
Figure 15156.
Orient cam lever as shown for North
American trucks. Orient cam lever on
other side (rotate 180 degrees) for
Jam Gas European trucks.
Nut Cylinder
Release Roll Pin
Lever
Cam Lever
Release Pin Contacts
Head Release Lever
Bracket
Figure 15156
• Continue to screw the gas cylinder into head until

release lever moves to its maximum position and Figure 15158
lever is not "loose" within head. Screw gas cylinder
another 1/4 rotation and lock in position by tighten-
ing jam nut.
• Rotate gas cylinder body until lower mounting tab

is parallel with release head.
Directional Control
• Apply a small amount of grease (063002-007) to
cam lever mounting bracket bores.
Crown 2006 PF15569-3 M6.0-1145-003
231
STEERING
Steering
Steering Wheel Removal 7. Use either bolt, 050007-022, trucks manufactured

from April 30, 2001 (M8 x 70) or bolt, 060063-009,
1. Disconnect battery and chock wheels. trucks manufactured from September 9, 1999 to
2. Position steering column in convenient position to April 30, 2001 (M8 x 85) depending upon date of
allow for steering wheel removal. manufacture of truck with wheel puller, 129256.
Refer to Figure 15161.
3. Remove horn button. Refer to Figure 15159.
8. Turn each bolt equally to prevent steering wheel
from binding.
9. Remove steering wheel from steering shaft.
Remove
Horn NOTE
Button
The use of a rubber mallet may be needed to initially
loosen the steering wheel from the steering shaft by
striking upwards on the bottomof the steering wheel
base.
Bolt, 050007-022 NOTE

Figure 15159 (Trucks Manufactured Turn Each Bolt
to May 7, 2001) Equally to Prevent
4. Disconnect wires from horn contact rings. OR Steering Wheel
Bolt, 060063-009 from Binding During
NOTE (Trucks Manufactured Removal
Horn contact rings do not need to be removed from the from May 7, 2001) Wheel Puller,
steering wheel. 129256
Insert Horn
5. Remove jam nut. Refer to Figure 15160. Wires Here
to Prevent
Pinching of
Wires
Remove
Jam Nut
Disconnect Horn Wires

From Contact Rings
Figure 15161
Figure 15160
6. Position horn wires in wheel puller, 129256, notch.

NOTE
Wires must be positioned inside of puller as they could
be pinched during the removal of the steering wheel.
M6.0-1145-004 Crown 2006 PF15569-4
232
STEERING
Steering
Steering Wheel Final Assembly

• The two notches on the upper horn switch contact, 1. Apply a small amount of anti-seize compound
which are directly opposite of each other, must be (065005-003) on tapered area of steering shaft
aligned with the two brass inserts in the steering prior to installing steering wheel. Do Not get any on
wheel. the threaded portion of the shaft. This will make
wheel removal easier.
2. When installing steering wheel on shaft, align
Upper Contact splines and push down until taper in steering wheel
seats with taper on shaft. Secure with jam nut. Do
Not over tighten - torque to 36 Nm (27 ft lbs).
3. Apply a small amount of grease (063002-007) on
the O.D. of tilt pin and install release head (with gas
cylinder included). Secure with retaining ring. Re-
Steering lease head (with gas cylinder) must rotate freely on
Wheel the tilt pin, without excessive free movement;
Notches in Upper 0.025 mm (0.001 in) maximum movement.
Contact Must Align
Insert 4. Apply a small amount of grease (063002-007) to
with Inserts
gas cylinder lower end mounting pin (included with
power unit frame) and position gas cylinder and
column assembly onto frame. The fit of the gas cyl-
Figure 15162 inder to its mounting pin must be held and must not
have excessive free movement 0.050 mm
(0.002 in) maximum.
5. After steering column assembly is mounted to
frame, check tilting and locking functions for proper
operation. Check the "full up" and "full back" posi-
tions. The full up (forward) position should be 16°
± 2° and the full back should be 40° ± 2° from ver-
tical.
Crown 2006 PF15569-5 M6.0-1145-005
233
STEERING
Steering
Steer Axle Assembly

Yoke
Cylinders Shaft
Axle
Metallic
Seal
Steer Wheel
Housing Assembly
Cotter
Pin
Flatwasher
Yoke
Shaft Nut
Bearing
(Cup & Cone) Tabbed
Grease
Washer Cap
Figure 15164
Metallic Grease 1st Bearing Cup

Steer Wheel
AV Outer Ring Seal
Assembly 2nd Bearing Cup
Figure 15163 Bearing Cone

Flatwasher
Steer Tire
Axle
When replacing the steer tire, make sure the composi-
tion and size are such that maneuverability, stability Grease Cap
and braking requirements are maintained. Both steer Cotter Pin
tires should be replaced at the same time to maintain
equal tire circumference. Nut
Yoke Shaft Tabbed Washer
The steer tire is a "press-on" type; press the old tire off
the hub and press new tire on. The outside of the hub
Steer Wheel Assembly
must be pressed flush with the outside edge of the tire.
Figure 15165
M6.0-1145-006 Crown 2006 PF15569-6
234
STEERING
Steering
Hub
1. Refer to Figure 15164 and 15165. The steer wheel
hub is sealed by two types of metallic grease seals;
an outer ring metallic grease seal and grease cap.
2. Prior to assembly, pack tapered roller bearings and
fill hub bearing bore cavities with grease
(063002-034).
3. Apply a light coating of lubricant to steer axle bear-
ing diameters and install outer ring metallic grease
seal and bearing cone on steer axle (1st bearing
cup area).
4. Install both bearing cups into steer wheel hub and
install steer wheel hub over steer axle. Pack
grease (063002-034) into bearing/steer wheel hub
cavity.
5. Install bearing cone into 2nd bearing cup. Add flat-
washer, tabbed washer and nut. Torque nut to
170 Nm (125 ft lbs). Rotate the hub a minimum of
three turns in each direction while torquing. Then
loosen nut until free. The wheel bearing setting as
adjusted must not be disturbed. Retighten nuts to
34 Nm (25 ft lbs) of torque. Further tighten the nuts
until next slot in nut and hole in end of the steer
axle are aligned.
6. Insert new cotter pin and bend. Do not reuse old
cotter pin.
7. After installing the special nuts and applying the
torque requirements listed in step 5, pack
(063002-034) grease into bearing/cap cavity. Also
fill the grease cap half way with grease.
8. Install the grease caps. Repeat steps 1 thru 8 for
other wheel assembly.
Crown 2006 PF15569-7 M6.0-1145-007
235
STEERING
Steering
Housing and Yoke Shaft
Locknut
Lockwasher
Locknut Outer Ring Metallic
Lockwasher Grease Seal Top Cap
Top Cap Bearing Cone
Outer Ring Metallic 2nd Bearing
Grease Seal Cup Inner Ring
Bearing Metallic
(Cup & Cone) Grease Seal
Inner Ring Metallic Rack
Grease Seal
Housing
1st Bearing
Housing Cup
Outer Ring Metallic
Bearing Cone Grease Seal
Inner Ring Metallic Yoke Shaft
Inner Ring Metallic Grease Seal
Grease Seal
Bearing Figure 15167
(Cup & Cone) 2. Prior to assembly, pack tapered roller bearings and
fill housing bearing bore cavities with grease
Outer Ring Metallic (063002-034).
Grease Seal
3. Apply a light coating of lubricant to yoke shaft bear-
ing diameters. Pack grease (063002-034) into
yoke shaft gear cavities. Install outer ring metallic
Yoke grease seal and bearing cone on yoke shaft (1st
Shaft bearing cup area).
4. Install inner ring metallic grease seal and 1st bear-
ing cup into bottom of housing.
5. Pack grease (063002-034) into gear cavities on
rack. Install yoke shaft into housing. Install and
time rack with yoke shaft using identification marks
Figure 15166 stamped on both components.
1. Refer to Figure 15166 and 15167. The housing is 6. Fill (as much as possible) yoke shaft/housing cav-
sealed by two types of metallic grease seals; outer ity with grease (063002-034). Install inner ring me-
ring and inner ring metallic grease seals. tallic grease seal and 2nd bearing cup into "top of"
housing. Install bearing cone into 2nd bearing cup
(over the yoke shaft).
7. Install outer ring metallic grease seal on yoke
shaft.
8. Install top cap, lockwasher and locknut on yoke
shaft. Torque locknut 170 Nm (125 ft lbs). Rotate
yoke shaft to its maximum in both directions a min-
imum of three times while torquing. Then loosen
locknut until free. The bearing settings as adjusted
must not be disturbed. Retighten locknut to 34 Nm
(25 ft lbs) of torque. Further tighten locknut until
one slot in locknut and tab on washer are aligned.
9. Install tab and bend.
M6.0-1145-008 Crown 2006 PF15569-8
236
STEERING
Steering
Housing, Rack, Pistons and Cylinders

1. Apply a light coating of lubricant to machined areas
in housing and flanged bushings. Housing
9.46 mm (0.37 in)

Cylinder Yoke Both Sides
Piston Shaft
Seal
Slide Ring
Rack Cylinder
Rack
O-Ring
Slide Ring
Flanged
Piston Bushing Flanged
Flanged Piston Asm
Piston Bushing
Bushing
Slide Ring O-Ring
Housing
Slide Ring
Figure 15169
Piston
Seal
Cylinder
Yoke
Shaft
Figure 15168
2. Install flanged bushings and o-rings in housing.

3. Before installing pistons, be sure cylinders are
clean. Apply a light coating of lubricant to pistons
and install pistons into cylinders.
4. Install rack and yoke shaft into housing. Time rack
with yoke shaft using stamped identification marks
on both components. Be sure rack does not shift,
reference dimension 9.46 mm (0.37 in) refer to
Figure 15169. If rack shifts, check timing.
5. Install cylinder into the housing.
Crown 2006 PF15569-9 M6.0-1145-009
237
STEERING
Steering
Steer Cylinders Seal Replacement

1. Lower mast and forks completely and chock
wheels. Steer Cylinder
2. Disconnect battery. O-Ring Piston
3. Tilt steering wheel up and raise battery cover. Assembly
4. Remove hydraulic lines to steer axle cylinder and Steer
Housing
cap hydraulic lines to prevent leakage and contam- Cylinder
ination. Refer to Figure 15170.
Yoke Flanged
Shaft Bearing
Remove Steer
Remove Hydraulic Axle Cylinders
Lines
Figure 15173
Remove
8. Remove piston assembly from steering cylinder.
Steering Hydraulic
Potentiometer Lines 9. Remove existing slide ring (2 ea.) and seal (1 ea.)
(STR) from piston.
10. Apply a thin coating of lubricant to replacement
Steering slide rings, 124475 and install in the outer grooves
Housing of the piston. Refer to Figure 15175.
11. Apply a thin coating of lubricant to replacement
seal, 064216-015 (yellow).
12. Using seal loading tool, 127521, install seal,
064216-015 (yellow) into middle groove of piston.
13. Clean the interior of the steer cylinders prior to in-
stalling piston assembly.
14. Apply a thin coating of lubricant to piston assembly
Figure 15170
and insert into piston loading tool.
5. Remove steer axle cylinder using spanner wrench.
15. Evenly press piston assembly into steer cylinder.
6. Remove flanged bushing from steering housing.
CAUTION
7. Remove existing o-ring from steering housing as-
sembly. Piston assembly must be evenly pressed into steer cyl-
inder, if not seals could possibly twist resulting in fluid
leakage. Do Not use hammers or other similar devices
to install piston assembly.
16. Remove piston loading tool.
17. Apply a thin coat of lubrication to replacement o-
ring, 064019-096 and flanged bushing.
18. Install replacement o-ring into steering housing.
19. Install flanged bushing into steering housing.
M6.0-1145-010 Crown 2006 PF15569-10
238
STEERING
Steering
Replacement
O-Ring - 064019-096
Steer Cylinder
with Piston Assembly
Housing
Flanged
Bearing
Clean Steering Housing and Apply

a Thin Coating of Lubricant Prior to
Installing O-Ring and Flanged Bushing.
Figure 15174
20. Install steer cylinder into steering housing.

21. Connect hydraulic lines to steer cylinder.
22. Repeat process for other steer cylinder.
23. Refer to Service Manual Section M2.0 or M6.0 for
bleeding procedures on steering circuit.
24. Connect battery and turn truck on. Check for leaks
at steer cylinder(s) and check steering operation
through full range, lock-to-lock.
Crown 2006 PF15569-11 M6.0-1145-011
239
STEERING
Steering
Replacement Piston
Slide Ring, 124475
Piston with Replacement

Slide Rings Installed
Replacement
Piston Seal, 064216-015
Replacement
Slide Ring, 124475
Piston Assembly Loading

Tool, 127522
Piston Seal Loading
Piston Assembly Tool, 127521
MUST be Pressed
Evenly into Steer Cylinder
Apply a Thin Coating of
Lubricant to ALL Components
Prior to Installation.
Steer Cylinder
Piston With Replacement

Slide Rings and
Piston Seal Installed
Clean Steer Cylinder

Prior to Installing
Piston Assembly
Figure 15175
M6.0-1145-012 Crown 2006 PF15569-12
240
STEERING
Steering
Circuit Bleeding
Air can be introduced into the steering system when
removing the steering unit, disconnecting hoses, etc.
and must be bled from the system before the truck is
returned to operation. To bleed circuit:
CAUTION
Do not attempt to bleed a line by cracking an o-ring
face seal fitting. This will result in damaging the o-ring
which then must be replaced to prevent hydraulic fluid
leakage.
• Power up truck and rotate steering wheel 10 revo-

lutions or more to the right (clockwise) at 60 rpm or
higher.
• Rotate steering wheel 10 revolutions or more to the

left (counter clockwise) at 60 rpm or higher.
• Check steering for an equal number of revolutions

lock to lock in both directions. There should be 6
revolutions, but not more than 6 revolutions.
• If there are more than 6 revolutions lock to lock in

either direction, repeat the procedure.
Crown 2006 PF15569-13 M6.0-1145-013
241
Menue & Failure Codes
SC4200 Operator Menus Operstor Menu Structure_V1.1
XXXXXX-001-01 updated: 25. June ´07
Message Mode Timer Stop Message Mode Menus

Allows the user to select what is displayed in
message mode if no higher priority items are
active. Also allows the user to control the trip
meter and timer. Only the appropriate menus
Start will be made visible based on the "Default
Message" feature item.
Message Mode Priority

Reset 1. PM Due (if enabled)
2. User Code (if enabled)
3. Return throttle to neutral
4. Default message
Trip Reset
in [miles] or [kph]
These buttom are MODE KEYS

Bdi
to select individual modes or functions
Hours These buttom are CURSOR KEYS

to move the cursor around in the
actual mode or function
Odometer Streckenzähler: zurückgelegte

Wegstrecke in [miles] oder [kph]
This buttom is the DATA INPUT KEY
(ENTER) to activate or save a
function
Hour H1 Runtime 1=Value Value
H2 Runtime 2=Value Value
DISPLAY
H3 Access 1=Value Value
PUMP Controller
Traction Controller
H6 Odometer=Value Value in [miles] or [kph]

To Page 2
June 25, 2007 Page 1 of 2

SC4200 Operator Menus
XXXXXX-001-01
From Page 1
Events Last Ev=Value Value
Last-1 Ev=Value Value
Last-3 Ev-Value Value
Service Level 2 Password

Note: For
time beings,
level 2 & 3
password are
the same !
Level 3 Password
Performance =
P1 Performance menu only
value
visible when selected in the
service menu.
P2
P3
June 25, 2007 Page 2 of 2

SC4200 Service Menus Service Menu Structure_V1.4
From Page 11 XXXXXX-001-01 updated: 25. June ´07
Displays text & value Displays only the value
Analyzer A1 Status A1.1 Lift = Value Value
A1.2 Brake = Value Value
A1.3 Assist = Value Value
DISPLAY
A2 Inputs A2.1 Access1 Inputs To Page 8
PUMP Controller
A2.2 Access2 Inputs To Page 4
Traction Controller
A2.3 Access3 Inputs To Page 3
DISPLAY
A3 Outputs A3.1 Access1 Outputs To Page 11
PUMP Controller
A3.2 Access2 Outputs To Page 11
Traction Controller
A3.3 Access3 Outputs To Page 11
A4 Test Outputs A4.1 Lamp Test ON/OFF
Service Level
3 only A4.2 Buzzer ON/OFF
Brake
A4.3 BRK1 ON/OFF
L will only work if

Main contactor = OFF,
For example: Brake
In failure A4.4 BRK2 ON/OFF
TOW MODE will release

the park brake for 5 A4.5 TOW MODE TOW? Y/N
To Page 2 minutes to allow through
the display to tow a
disabled vehicle.
During TOW MODE if thr A4.6 L ON/OFF

truck moves the display
will beep to notify that the
parking brakes are not Controller Fans
set.
A4.7 FAN1 & FAN2 ON/OFF
Motor compartment Fan (feature)

FAN3 is only visable
when FAN3 feature is A4.8 FAN3 ON/OFF
enabled
ALM2 is only visable Travel Alarm (feature)

when travel alarm feature A4.9 ALM2 ON/OFF
is enabled
06-25-2007 Page 1 of 12
SC4200 Service Menus
XXXXXX-001-01
From Page 1
Press ACCEL and

Calibration C1 Prg VACC C1.1 Dir Switch FWD
Release
Max Volts Value Min Volts Value
Press ACCEL and

Dir Switch REV Min Volts Value
Release
Save? N/Y Max Volts
Brake Pedal ACQ BRAKE

C2 Brake Pot C2.1 C2.1.1 Value
RELEASED POT MIN
Save? N/Y
Depress Brake ACQ BRAKE

C2.2 C2.2.1 Value
Pedal Fully POT MAX
Save? N/Y
Center Steering ACQ Steer

To Page 4 C3 Steer POT C3.1 C3.1.1 Value
Wheel Pot Center
Save? N/Y
Turn Steering Wheel ACQ Steer Pot

C3.2 C3.2.1 Value
Full Right Full Right
Save? N/Y
Turn Steering ACQ Steer Pot

C3.3 C3.3.1 Value
WheelFull Left Full Left
Save? N/Y
Lift Lever ACQ Lift Pot

C4 Lift Pot C4.1 C4.1.1 Value
RELEASED MIN
Save? N/Y
Pull Back Lift ACQ Lift Pot

C4.2 C4.2.1 Value
Lever Fully MAX
Save? N/Y
C5 ADJ BATT C4.1 ADJ Volts Volt Value Value
Save? N/Y
06-25-2007 Page 2 of 12
TRACTION CONTROLLER
ACCESS 3 INPUTS currently
XXXXXX-001-01 A.2.2.x in software version V 7
Value 0 = OFF
From Page 1 A2.3.1 FS=Value Value
Value 1 = ON
Value 0 = OFF
A2.3.2 RS=Value Value
Value 1 = ON
Switch logic and Pedal

Percent
A2.3.3 BRKS1=Value Value
0 : 0%
Value 0 = OFF
A2.3.4 SES=Value Value
Value 1 = ON
Value 0 = OFF
A2.3.5 HGTS1=Value Value
Value 1 = ON
Value 0 = OFF
A2.3.6 ACS=Value Value
Value 1 = ON
Steer Pot
A2.3.8 POT1=Value Value %
-90 to +90 degrees
A2.3.9 POT2=Value Value Volts Brake Pot
A2.3.10 POT3=Value Value Volts Accel Pot
A2.3.11 M1SpeedRPM=Value Value RPM
A2.3.13 MPH=Value Value MPH
A2.3.14 BDI=Value Value %
Access3 Temp
A2.3.15 Value C
=Value
A2.3.16 M2_TEMP Value C
A2.3.18 M1_Current Value Amps
A2.3.19 M2_Current Value Amps
A2.3.20 Bat V = Value Value Volt
Dynamic Brake
A2.3.21 Value Counts
Count = Value
06-25-2007 Page 3 of 12
PUMP CONTROLLER
XXXXXX-001-01 ACCESS 2 INPUTS
Tilt switch
Value 0 = OFF
From Page 1 A2.2.1 TLT=Value Value
Value 1 = ON
Sideshift SS
Aux switch 1
Value 0 = OFF
A2.2.2 AXS1=Value Value
Value 1 = ON
4th. function
Aux switch 2
Value 0 = OFF
A2.2.3 AXS2=Value Value
Value 1 = ON
Seat switch
Value 0 = OFF
A2.2.4 SES=Value Value
Value 1 = ON
A2.2.5 POT4=Value Value Volts Lift Pot
Controller Temp.
Access2 Temp
A2.2.6 Value C
=Value
Motor M3
Motor M3
Motor M3
A2.2.9 M3_Currnet Value amps
Battery Voltage
From Page 1 A2.2.10 Bat V = Value Value Volts
Features F1 Language=Value English
Selectable
between
[kph] & [mph] German
F2 Metric=Value Disable
French
Alarm 2
F3 Travel Alarm=Value OFF
Italian
FORWARD
Dutch
REVERSE
Spanish
BOTH
11 Others
F4 Hour Meter=Value Mode 1
Mode 1: counts only operating

To Page 7 hours in H1 (Runtime 1)
Mode 2: counts operating hours
Mode 2
in H1 & H2 (Runtime 1 & 2)
To Page 5
06-25-2007 Page 4 of 12
XXXXXX-001-01
From Page 4
F5 Message Mode=Value BDI
Hours
Odometer
Trip
Timer
All
F6 User Performance=Value Disable Default = Disable
Enable
F7 User Codes=Value Disable Default = Disable
Enable To Page 6
F8 & F9 will provide flow

Aux function 1 adjustment for accessories
(Sideshift SS) from x to x lpm.
F8 Accy 1=Value Disable
F8 & F9 default = Disable. F9

only visable if F8 has been
enabled. Enable Value=LPM Value
Save? N/Y
Aux function 2
(4th. Function) Select / adjust the oil flow to
F9 Accy 2=Value Disable calculate LPM for accessories
Default = 10 LPM
Range: 3 – 30 LPM
Enable Value=LPM Value
Save? N/Y
F10 default = Disable. F10 FAN3=Value Disable
Enable
06-25-2007 Page 5 of 12
XXXXXX-001-01
From Page 5 F7.1 View Codes Entry 1 1111 P1
View Codes
"Entry ##" is displayed on
screen for the initial 0.5
Entry 2 2222 P2
seconds. Then the code and
performance level are
displayed.
Entry 25 3333 P3
F7.2 Add Codes PIN 0001
Perf Level P1
P2
Modify Codes
performance level are P3
displayed as shown below:
1234 P1
F7.3 Modify Code Entry 1 PIN 0001
Entry 2 Perf Level P1
Entry 25 P2
P3
F7.4 Delete Code Entry 1 1111 P1
Delete Codes
Entry 2 2222 P2
performance level are
displayed.
Entry 25 3333 P3
F7.5 Timeout=Value Disable
Enable Value=min Value
Save? N/Y
06-25-2007 Page 6 of 12
From Page 4 SC4200 Service Menus
XXXXXX-001-01
Value in [kph] Value in [mph]
Performance P1 Setup P1 P1.1 Forward=Value Edit 0.0-15.0 kph
Default Value = 15.0 9.3
P1.2 Reverse=Value Edit 0.0-15.0 kph
P1.3 Accel=Value Edit 0-9
Default Value = 9
P1.4 Power=Value Hi, Med, Low
Default Value = Hi.
P1.5 Ld Speed=Value Edit 0.00-13.5 kph

Aux function 1
Accessory1
P1.6 Edit 0-9
=Value
Default Value = 9
Aux function 2
Accessory2
P1.7 Edit 0-9
=Value
Default Value = 9
P2 Setup P2 P2.1 Forward=Value Edit 0.0-15.0 kph
Default Value = 7
P2.4 Power=Value Hi, Med, Low
Default Value = Med.

Aux function 1
Accessory1
P2.6 Edit 0-9
=Value
Default Value = 9
Aux function 2
To Page 9 Accessory2
P2.7 Edit 0-9
=Value
Default Value = 9
P3 Setup P3 P3.1 Forward=Value Edit 0.0-15.0 kph
Default Value = 7
To Page 8 P3.4 Power=Value Hi, Med, Low
Default Value = Low.

ACCESSORY1 and ACCESSORY2 is only
visable when Accy1 and Accy2 features are Default Value = 12.0 7.5
enabled Aux function 1
Accessory1
P3.6 Edit 0-9
ACCESSORY1 3rd. Hydraulic function =Value
Default Value = 9
ACCESSORY2 4th. Hydraulic function
Aux function 2
Accessory2
P3.7 Edit 0-9
=Value
Default Value = 9
06-25-2007 Page 7 of 12
XXXXXX-001-01
ACCESS 1 INPUTS
Seat switch
Value 0 = OFF
From Page 1 A2.1.1 SES=Value Value 0:1 Value 1 = ON
Height switch
Value 0 = OFF
A2.1.2 HGTS1 = Value Value 0:1 Value 1 = ON
Brake switch
Value 0 = OFF
A2.1.3 BRKS1 = Value Value 0:1
Value 1 = ON
Load Sens
Transducer
A2.1.4 Value = AD converter value
PT1=Value Count
[0 – 1024]
On- Demand
Steer Encoder
A2.1.4 ECR4=Value Count
From Page 7
P4 BDI Edit 0-9
Default Value = 2
9 = max. Setting
P5 Plug Edit 0-9
0 = min. Setting
Default Value = 6
Edit 0-9 0 = max. Setting

P6 Coast
9 = min. Setting
Default Value = 5
ZAPI: Parameter REL BRAK GAIN = 50%
P7 Perf > Free lift P7.1 Forward=Value Edit 0.0-6.5 kph
Default Value = 5.6
Default Value = 5.6
Default Value = 5
P7.4 Plug=Value Edit 0-9
Default Value = 5
Aux function 1
Accessory1
P7.5 Edit 0-9
=Value
Default Value = 5
Aux function 2
Accessory2
P7.6 Edit 0-9
=Value
Default Value = 5
P99 Factory Defaults Y/N ACCESSORY1 and

ACCESSORY2 is only
visable when Accy1 and
Accy2 features are
enabled
06-25-2007 Page 8 of 12
From Page 7
XXXXXX-001-01
Level2: View only

Level3: Increase only
Hour H1 Runtime1=Value Edit Value
Level2: View only

H2 Runtime2 H2.1 Runtime2=

Level 3 after changes are made
answer Y/N
H2.2 Timeout=
Remark: Runtime2 = Runtime1 + additional time delay (Timeout),

[0 – 15 min.]
Level2: View only

DISPLAY Level3: Increase only
H3 Access1=Value Value
Level2: View only

PUMP Controller Level3: View only
H4 Access2=Value Edit Value
Level2: View only

Traction Controller Level3: View only
H5 Access3=Value Edit Value
Level2: View only

H6 Odometer=Value Edit Value
Level2: View only
H7 PM Timer H7.1 Tag=Value H1
Level2: View only

H2
PM Timer:
Message „PM Due“
displays if the hours H3
+ intervall time is up
H4
To Page 10
H5
H6
Level2: View only
H7.2 Interval=Value Edit Value
06-25-2007 Page 9 of 12
From Page 9
XXXXXX-001-01
Events E1 Chron History E1.1 Last Ev=Value Value
Hour=Value Value
Soc=Value Value
To Page 11 E1.2 Last-1 Ev=Value Value
Hour=Value Value
Soc=Value Value
E1.16 Last-15 EV=Value Value
Hour=Value Value
Soc=Value Value
Event X
E2 Accum History occurrences=Value Value
Event Y
occurrences=Value Value
Event Z
occurrences=Value Value
Clear
E3 Clear History E3.1 No
Chronological
Yes
E3.2 Clear All No
Yes
06-25-2007 Page 10 of 12
From Page 10 XXXXXX-001-01
U1 Scroll Part U1.1.1 Scroll

Utilities U1.1 Scroll Access1 Value
Numbers Module=Value
DISPLAY
U1.1.2
Value
Software
U1.2.1
U1.2 Scroll Access2 Value
Module=Value
PUMP Controller
U1.2.2
Value
Software
U1.3.1
U1.3 Scroll Access3 Value
To Page 1 Module=Value
Traction Controller
U1.3.2
Value
Software
From Page 1 A3.1.1 BRK1=Value Value Value 0 = OFF

Value 1 = ON
DISPLAY
ACCESS 1 OUTPUTS A3.1.2 BRK2=Value Value Value 0 = OFF
Value 1 = ON
A3.1.3 Buzzer=Value Value Value 0 = OFF

Value 1 = ON
From Page 1 A3.2.1 FAN3=Value Value Value 0 = OFF

Value 1 = ON
PUMP CONTROLLER
ACCESS 2 OUTPUTS A3.2.3 M3=Value Value=Amps
From Page 1 A3.3.1 L=Value Value Value 0 = OFF

Value 1 = ON
TRACTION
CONTROLLER A3.3.2 FAN1&FAN2=Value Value Value 0 = OFF
Value 1 = ON
ACCESS 3 OUTPUTS
A3.3.2 M1=Value Value=Amps
A3.3.3 M2=Value Value=Amps
A3.3.4 ALM2=Value Value Value 0 = OFF

Value 1 = ON
06-25-2007 Page 11 of 12
SC4200 ACCESS 2 (HCM PUMP- CONTROLLER) FAULT
DESCRIPTIONS
Err=200 (Zapi Code 6010h) (Similar to 300 on Traction)

EVNT_HCM_WATCHDOG
ZAPI Description: Fault in the microcontroller watchdog circuit. This fault could
happen at startup, standby, or dynamically and is most likely a hardware problem in the
Access 2 module.
Corrective Action
1. Ensure Access 2 power connections are tight and functional.
2. Check the CAN High and Low wires for opens/shorts.
3. If prevalent, replace Access 2 module.
Action: Disable ED

EVNT_LOGICFAILURE1
ZAPI Description: This alarm signals that an undervoltage or overvoltage situation
has occurred. This fault can happen at startup or in standby. It could mean a real
undervoltage or overvoltage situation has occurred, or could be a fault internal to the
Access 2 module.
Corrective Action
1. Check power connections for Access 2 module, especially B-.
2. Check pump contactor for pitting of the tips, check Power Fuse.
3. Measure voltage of Access 2 Power Fuse at time of fault.
4. Could be bad battery in truck (open cell)
5. If prevalent and voltages look good, replace Access 2.
Action: Disable ED

EVNT_VMNLOW
ZAPI Description: Motor voltage output low. This diagnostic is performed at power
up and in standby. This alarm signals a problem with the motor connections or motor
power circuit in the controller.
Corrective Action
1. Measure voltage of U, V and W phases. Should be xx –xx V with no
command. Check integrity of cabling at controller and motor.
2. Check FU2, check for +BV on power cables at Access 2 with P closed.
3. Check U,V and W for shorts to frame and B-, especially B-.
4. Could be failure in the module.
Action: Disable ED
DESCRIPTIONS
EVNT_VMNHIGH
ZAPI Description: Motor voltage output high. This diagnostic is performed at power
Corrective Action
1. Measure voltage of U, V and W phases. Should be xx-xxV with no
command.
2. Check U,V and W for shorts to frame and B+.
3. Check integrity of power cable connections to Access 2 and motor.
Action: Disable ED
Err=204 (Zapi Code FF31h)

EVNT_IOEVER
ZAPI Description: This diagnostic is only carried out when the motor is running and
signals that the sensor used to measure the motor current is reading something near 0
when the motor is running. Incorrect current feedback reading and a fault is thrown.
Corrective Action
1. This fault can happen at power up or dynamically if the P contactor wiring is
not in tact.
2. If all P contactor wiring is proven good, most likely a problem in the current
sensor internal to Access 2, replace module.
3. We have also seen this fault thrown with a bad battery (cell opening) during
operation while the pump is running (pump runs during traction).
Action: Disable ED

EVNT_STBYIHIGH
ZAPI Description: This diagnostic is a check to see if the motor current is 0 in
standby. If it is greater than 0 in standby the fault is thrown.
Corrective Action
1. Most likely a defect in the current sensor internal to Access 2, replace
module.
2. Could also be incorrect wiring of power cables, if work has recently been
done in this area verify wiring is correct.
Action: Disable ED
DESCRIPTIONS
EVNT_DRIVERSHORTED
ZAPI Description: Driver for the Optional Traction Motor Compartment Fan is
shorted.
Corrective Action
1. Check that the Optional Traction Motor Compartment Fan is not shorted,
especially the negative wire being shorted to B-.
2. Check resistance of Optional Traction Motor Compartment Fan for short.
3. If no short found the driver is shorted internal to Access 2, replace module.
Action: None
Err=207 (Zapi Code 3221h)

EVNT_CONTACTORDRIVER
ZAPI Description: The driver of the Optional Traction Motor Compartment Fan.
Corrective Action
1. The MOSFET in the Optional Traction Motor Compartment Fan driver
circuit is damaged internal to Access 2, replace module.
Action: Disable ED

EVNT_COILSHORTED
ZAPI Description: Access 2 has detected a short circuit in the Optional Traction
Motor Compartment Fan circuit.
Corrective Action
1. Check integrity of Optional Traction Motor Compartment Fan wiring for
pinches/shorts.
a. Check negative wire for short to +BV.
2. Check resistance of Optional Traction Motor Compartment Fan for short.
3. If no shorts are found the problem is internal to Access 2, replace module.
Action: Disable ED
DESCRIPTIONS
EVNT_WRONGSETBATTERY
ZAPI Description: At power up the Access 2 module performs a diagnostic of the
battery voltage. If this voltage is too high or low the fault is thrown.
Corrective Action
1. Could be wrong voltage battery in truck
2. Could be a bad battery in truck (open cell)
3. Could need battery voltage adjusted, check what this parameter is reading
compared to what a voltmeter reads the battery to be. Adjust as necessary.
4. Measure voltage powering Access 2 logic board to ensure it is +BV.
Action: Disable ED

EVNT_CANBUSKO
ZAPI Description: This alarm signals that the Access 2 module did not receive any
CAN messages.
Corrective Action
1. Check integrity of CAN wiring and termination.
2. If all wiring is functional problem is most likely in Access 2, replace module.
Action: Disable ED

EVNT_CURRENTSENSKO
ZAPI Description: This alarm signals that the current transducer output is out of
range.
Corrective Action
1. If the problem occurs permanently replace Access 2 module.
Action: Disable ED
DESCRIPTIONS
EVNT_MOTOR_STALLED
ZAPI Description: This fault is thrown when the speed set point of the hydraulic
motor is not equal to the speed read back from the hydraulic motor encoder.
Corrective Action
1. Problem could be in the pump encoder, pump controller, or wiring.
a. Check encoder wiring for opens and shorts.
b. Check for power and ground at the sensor bearing.
c. Replace with working encoder and plug into main harness connector
and watch analyzer as encoder is spun with the hand. If there is no
change and the encoder is known to be good, the problem is in the
controller. If there is now a change, the problem is in the encoder or
encoder side of wiring.
Action: Disable ED
Err=219 (Zapi Code FF12h) (Similar to 302 on Traction)

EVNT_LOGICFAILURE2
ZAPI Description: Failure in the U,V,W voltage feedback circuit, most likely a failure
in the Access 2 AC module.
Corrective Action
1. Ensure motor cables are not shorted together.
2. Ensure line contactor coil is connected.
3. Ensure line contactor tips are good and not hung up.
Action: Disable ED
Err=220 (Zapi Code FF11h) (Similar to 301 on Traction)

EVNT_LOGICFAILURE3
ZAPI Description: Fault in the hardware which manages the hardware current
protection.
Corrective Action
1. Check power cable integrity, B-, +BV, U, V, W.
2. Most likely a fault internal to Access 2 logic card, replace module.
Action: Disable ED
DESCRIPTIONS
EVNT_CAP_CHARGE
ZAPI Description: Power capacitor does not increase at the required rate when the
key is turned on or when going attended.
Corrective Action
1. Check for motor leakage to frame, and power cabling integrity.
2. If permanent failure replace Access 2.
Action: Disable ED

EVNT_ENCODER_ERROR
ZAPI Description: Motor speed sensor not working properly. This diagnostic is only
carried out dynamically so the motor must be spinning for this fault to occur.
Corrective Action
1. Since this fault only happens dynamically it will probably never be an issue.
Action: Disable ED
SC4200 ACCESS 1 (DCM DISPLAY) FAULT DESCRIPTIONS
Err=110
Communication Error
Check voltage at Access 1 CA630-17 (+) and CA630-4 (-). Should be battery volts. If
battery voltage is present then follow event code 300 procedures for loss of CAN
communication between Access 3 and Access 1.
Action: Disable All Traction
Err=111
EV_LOST_TCM_PDO
This fault will happen when the TCM loses power but the ACM is still powered. This
fault can happen any time. At power up if this fault is present will get a single flashing
BDI LED, fault 108 will be in the event log.
1. Check FU5
2. Check power at TCM
3. Check TCM CAN wiring
Err=112
EV_DCM_BRAKE_OFF_TEST_FAIL
According to the software engineer this fault will never happen. If it does happen it and
is prevalent follow 105 and 106 brake open fault instructions. If prevalent and 105/106
descriptions do not find problem replace Access 1 module.
Err=113
EV_SPI_READBACK_ERROR
This error is most likely generated from an internal problem in the display. Check
display power and ground. Re-key the truck, if persistent replace Access 1 module.

Err=114
EV_BRK2_SHORT
This error detects a short in the left hand brake coil. Fault can be generated at power
up, when traction is requested or when going to park. This fault cannot be detected
dynamically.
1. Check for pinched/shorted wires.
2. Check brake coil resistance, should be between 2 and 9 ohms.
Err=115
EV_BRK1_SHORT
This error detects a short in the right hand brake coil. Fault can be generated at power
dynamically.
1. Check for pinched/shorted wires.
Err=116
EV_BRAKE_SHORT_TEST_FAILED
This fault is an odd one; it is actually a diagnostic of the brake short diagnostic.
According to the software engineer this should never/rarely happen. If it does happen
and is prevalent follow the 102 and 103 brake short fault instructions. If prevalent and
102/103 descriptions do not find problem replace Access 1 module.
Err=118
EV_BRK2_OPEN
This error detects an open in the left hand brake coil. Fault can be generated at power
dynamically.
1. Check integrity of wiring for opens.

Err=117
EV_BRK1_OPEN
This error detects an open in the right hand brake coil. Fault can be generated at power
dynamically.
1. Check integrity of wiring for opens.
Err=121
EVNT_SES_CROSSCHECK
The seat switch is wired into the TCM and DCM. This fault represents a mismatch;
one module is reading the switch as being closed and the other module reading it open.
1. Read voltages at TCM and DCM SES inputs and compare.
Err=122
EVNT_HGTS1_CROSSCHECK
The height switch (staging) is wired into the TCM and DCM. This fault represents a
mismatch; one module is reading the switch as being closed and the other module
reading it open.
1. Read voltages at TCM and DCM HGTS1 inputs and compare.
Action: Disable Full Traction (speed cutback)
Err=123
EVNT_BRKS_CROSSCHECK
The brake switch is wired into the TCM and DCM. This fault represents a mismatch;
one module is reading the switch as being closed and the other module reading it open.
2. Read voltages at TCM and DCM BRKS inputs and compare.

Err=124
Display Initialization Error
Note: This code may occur after software has been downloaded.
If event occurred after downloading software then re-load software.
If event occurs any other time, rekey truck. If event clears monitor truck. If event does
not clear then replace Access 1.
Err=162
EVNT_LOAD_SENSE_RANGE
Description: The pressure transducer input (PT1), CA232-2 is reading out of range
from the expected values.
Corrective Action:
1. Check pressure transducer counts using Analyzer menu A2.1.1. Should read
less than 10 counts with forks empty and carriage fully lowered.
2. Check connections at pressure sensor (PT1) and Access 1 display module
CA604-13 and 21.
3. Check voltage to pressure sensor (PT1) at Access 1 CA604-13 (+) to battery
negative. Should be 15 volts.
4. Check voltage at pressure sensor (PT1) CA61-2 (+) to battery negative.
Should be 15 volts.
5. Check pressure sensor (PT1) at Access 1 CA604-21 (+) to battery negative.
Should be between 0 and 5 VDC.
6. Check resistance of wiring between pressure sensor (PT1) and Access 1.
Action: None, goes to maximum load speeds.
Err=199
Compatibility Error
Undefined error detected. This could be caused by incompatible software. Perhaps
contact Crown factory?

SC4200 ACCESS 3 (TCM TRACTION- CONTROLLER) FAULT
DESCRIPTIONS
Err=300 (Zapi Code 6010h) (Similar to 200 on Access 2)

EV_TCM_WATCHDOG
ZAPI Description: Fault in the microcontroller watchdog circuit between the master
and slave microcontrollers. This fault could happen at startup, standby, or dynamically
and is most likely a hardware problem in the Access 3 module. Could be a caused by a
problem with the CAN bus as well.
Corrective Action
1. Ensure Access 3 power connections are tight and functional.
2. Check the CAN High and Low wires for shorts (frame, b-) and opens.
3. If prevalent, replace Access 3 module.
Err=301 (Zapi Code FF11h) (Similar to 220 on Access 2)

EV_TCM_LOGIC_FAILURE3
ZAPI Description: Fault in the hardware which manages the hardware current
protection
Corrective Action
1. Check power cable integrity, B-, +BV, U, V, W.
2. Most likely a fault internal to Access 3 logic card, replace module.
Err=302 (Zapi Code FF12h) (Similar to 219 on Access 2)

ZAPI Description: Failure in the U,V,W voltage feedback circuit, most likely a failure
in the Access 3 module
Corrective Action
1. Ensure motor cables are not shorted together.
2. Ensure line contactor coil is connected.
3. Ensure line contactor tips are good and not hung up.

DESCRIPTIONS
ZAPI Description: This alarm signals that an undervoltage or overvoltage situation
has occurred. This fault can happen at startup or in standby. It could mean a real
undervoltage or overvoltage situation has occurred, or could be a fault internal to the
Access 3 module.
Corrective Action
1. Check power connections for Access 3 module, especially B-.
2. Check line contactor for pitting of the tips, check FU1.
3. Measure voltage of Access 3 power (FU5) at time of fault.
4. Could be bad battery in truck (open cell)
5. If prevalent and voltages look good, replace Access 3.

EV_TCM_VMN_LOW
ZAPI Description: Motor voltage output low. This diagnostic is performed at power
Corrective Action
1. Measure voltage of U, V and W phases of master and slave motors. Should
be 15-18V with no command. Check integrity of cabling at controller and
motors.
2. Check FU1, check for +BV on power cables at Access 3 with L closed.
3. Check U,V and W for shorts to frame and B-, especially B-.

DESCRIPTIONS
EV_TCM_VMN_HI
ZAPI Description: Motor voltage output high. This diagnostic is performed at power
Corrective Action
1. Measure voltage of U, V and W phases of master and slave motors. Should
be 15-18V with no command.
2. Check U,V and W for shorts to frame and B+.
3. Check integrity of power cable connections to Access 3 and motor.

EV_TCM_LC_CLOSED
ZAPI Description: Before closing the L contactor, Access 3 performs a diagnostic to
ensure the contactor is open prior to closing.
Corrective Action
1. Check that the L contactor is not welded shut, stuck, or binding.
2. Check for mis-wire of L contactor power cabling.
3. Check that +BV is not getting to controller from something other than L.

EV_TCM_LC_OPEN
ZAPI Description: The L contactor coil has been commanded to close but the contacts
did not pull in, at least Access 3 does not think they did.
Corrective Action
1. Check that the L contactor is not stuck or binding
2. Check the tips for pitting
3. Could be a blown fuse, check FU1 and that cabling is tight
4. Check the L contactor coil wiring from controller to coil

DESCRIPTIONS
EV_TCM_STBY_HI
ZAPI Description: This diagnostic is a check to see if the motor current is 0 in
standby. If it is greater than 0 in standby the fault is thrown.
Corrective Action
1. Most likely a defect in the current sensor internal to Access 2, replace
module.
2. Could also be incorrect wiring of power cables, if work has recently been
done in this area verify wiring is correct.

EV_TCM_CAP_VOLT
ZAPI Description: Power capacitor does not increase at the required rate when the
key is turned on or when going attended.
Corrective Action
1. Check for motor leakage to frame, and power cabling integrity.
2. Check U, V and W for short to B-.
3. If permanent failure replace Access 2.

EV_TCM_CAN_BUS_KO
ZAPI Description: This alarm signals that the Access 3 module did not receive any
CAN messages.
Corrective Action
2. Check that all modules are powered, especially Access 7.
3. If all wiring is functional and Access 7 powered problem is most likely in
Access 3, replace module

DESCRIPTIONS
EV_LCD_SHORT
ZAPI Description: Access 3 has detected the L contactor driver to be shorted. This
diagnostic is carried out only at power up.
Corrective Action
1. Check that the L contactor is not shorted with an ohm check.
2. Check that the negative wire to L is not shorted to B- or frame.
3. If all checks out ok, the problem is internal to Access 3, replace module.

EV_TCM_LCD_OPEN
ZAPI Description: Access 3 has detected the L contactor driver to be open. The L
contactor has been commanded by Access 3 to close, but it did not happen.
Corrective Action
1. Check integrity of L contactor wiring from contactor to module.
2. If wiring is ok then the problem is most likely internal to Access 3.
Err=313 (Zapi Code 2250h) (208 on Access 2)

EV_TCM_LC_SHORT
ZAPI Description: Access 3 has detected the L contactor to be shorted. This
diagnostic is carried out at power up, in standby and dynamically.
Corrective Action
1. Check that the L contactor is not shorted with an ohm check.
2. Check that the negative wire to L is not shorted to +BV or frame.
3. If all checks out ok, the problem is internal to Access 3, replace module.

DESCRIPTIONS
EV_TCM_ENCODER_MA
ZAPI Description: Access 3 has detected an encoder error in the master or slave
motor. If an encoder failure were to happen dynamically the fault would be thrown and
logged only once. Once re-keyed the truck will no longer detect an encoder error, but
when trying traction will only get a “creep” speed.
Corrective Action
1. Check encoder wiring and power/ground.
2. In analyzer watch master and slave encoders for counts. Slave or master will
most likely not show any counts. Can turn the steer pot to -70 degrees or
+70 degrees to make only 1 wheel move.
3. Once it is determined to be master or slave, would be nice to take a known
working encoder and hook to encoder connector. In analyzer watch for
counts as the encoder is rotated by hand. This will determine if the problem
is in the encoder or controller. Repair as necessary.
Err=315 (Zapi Code FFF5h) (Similar to 209 on Access 2)

EV_TCM_WRONGBAT
ZAPI Description: At power up the Access 3 module performs a diagnostic of the
battery voltage. If this voltage is too high or low the fault is thrown.
Corrective Action
1. Could be wrong voltage battery in truck
2. Could be a bad battery in truck (open cell)
3. Could need battery voltage adjusted, check what this parameter is reading
compared to what a voltmeter reads the battery to be. Adjust as necessary.
4. Measure voltage powering Access 3 logic board to ensure it is +BV.
Err=316 (Zapi Code FFF6h)

EV_TCM_SLAVE_MASTER_KO
ZAPI Description: The master and slave microcontrollers internal to Access 3
perform a cross check to verify each is functioning as expected. If one or the other is
acting irregular, the fault is thrown.
Corrective Action
2. If failure is permanent replace Access 3 module.

DESCRIPTIONS

EV_TCM_STEER_SENSOR_KO
ZAPI Description: Access 3 has detected the steer pot voltage to be out of range from
the calibrated values (mechanically impossible).
Corrective Action
1. In analyzer watch the steer pot voltage while turning.
2. Check for power/ground at steer pot, should be +11.3V. Everything
powered from Access 3 with the +11.3V is tied together internal. If this is
being pulled low will have to determine where a short to B- is.
3. If power and ground ok (+11.3V), read the wiper. Make sure the pot is
stroking and going into the Access 3 input.
4. If wiper voltage going into Access 3, could be a problem with module.
5. Repair/Replace components as necessary and recalibrate the steer pot.
Err=317 (Zapi Code FFF0h)

EV_TCM_BRK_PEDAL_ERR
Description: This diagnostic is on the brake pedal and can be caused from several
scenarios, including:
• It can be caused by the brake sensor (RPS1) being out of range from the
calibrated values (mechanically impossible).
• It can be caused by the brake switch not toggling within 5-50% of brake
pedal stroke.
• It can be caused if the brake switch toggles but no stroke on the brake
sensor.
Corrective Action
1. Use analyzer menu that shows brake switch status vs. brake sensor %.
Should see 0% with pedal down, 100% with pedal up. Watching this menu
will help determine if the problem is in the brake sensor or switch.
2. If the pedal is stroking but not from 0-100% then something has most likely
slipped. Fix mechanically and recalibrate.
3. If the pedal is being moved but see no change of percent then either:
a. The sensor is not rotating, slipping mechanically
b. Problem with wiring, sensor, or controller, follow similar steps to
318 steer pot error. Only difference is the brake sensor shares power
with the accelerator pot (+11.3V) and is dropped to +5V on the
distribution panel. If not reading +5V at sensor then check that
+11.3V is going to the distribution panel. If not reading +11.3V then
something powered from the +11.3V from Access 3 is being shorted
low.

DESCRIPTIONS
Err=399
EV_TCM_UNDEFINED
Description: This fault should never happen and if it does is most likely caused by
incompatible software. If Access 3 throws a fault that the Crown software does not
recognize, this fault is thrown. All current Access 3 faults are built in to be understood
by Crown software.
Corrective Action
1. Contact the Crown service factory.

Diagrams
ACCESS 2
HCM
CA208-2
+
POT4 CA208-1
LIFT
CA208-3
CA208-4
TLT
CA208-6 CA209-5
AXS2 CA209-11
CA208-7
CA209-6
P_
T HERM
CA209-7
CA209-12
AXS1 N_
T HERM
CA209-10
WS WS
CA209-2
PUMP
+ 1 VS VS M3 NEG MOTOR
CA209-8 B
FAN3 US US P A
TS3
AXS3 CA208-5 CA207-1 ECR3
1
CA206-3 CA207-3
SV2 CA207-5
CA207-2
5TH CA206-1
FUNCTION
CA209-1
FU2
+BV B-NEG
300A LGS1 FRONT WORKLIGHTS
LGT1
1 REAR LGT5 1 LGT6 1
LGS2 LGT2 WORKLIGHT 1
TAIL BRAKE BACK-UP TAIL BRAKE BACK-UP
LGT3
LGT4
STROBE
1
1 BRKS2
FNS FAN4 1
ACCESS 3
TCM
SES
CA203-5
FS
CA203-6
RS
CA203-7
BRKS1
CA203-9 CA203-17
HGTS1 POT1
CA203-16 + STR
CA203-10
CA405 CA203-15
1 CA203-18
2 PC606
+
POT2
3 1 BRK
4 2 TOW CA203-19
8 14 15 5 3 PLUG
6 4 CA203-21
ACCESS 1 5 POT3
DCM CA203-33 +
CA605 6 ACC
CA630 C+ CA203-20
16 1 BRK2
C-
1 2 LH CA203-35
CA602 CA203-34
N_
T HERM P_
T HERM
COMMON 1 12
ECR4 CH A 2 5 C+ WS WS
STEER 9 3 BRK1 LEFT
+5V 3 10 C-
ENCODER 2 4 RH VS VS M2 MOTOR
1 OPTIONAL FEATURE
CH B 4 11 NEG
B
US US P A
TS2
CA604 ACS
5 CA203-8 CA203-11 ECR2
OUTPUT 1 21 FU5 CA203-22
PT1 6 CA203-3
LOAD + 2 13 6A CA203-23
3 N/C CAN_H CA203-12
SENSE 19 CA201-1
NOTES
4 N/C
FU4
ALM1 CAN_
L CA203-25
15A
18 CA201-6
CA201-2 CA203-24
TR1 17 4 N_
T HERM P_
T HERM
START
FU3 ACC
IGN
-T
+ FAN1 WM WM
CA201-4 M1 RIGHT
15A
K1 CA203-31
VM VM NEG MOTOR
OFF
B
KYS + UM UM P A
FAN2 TS1
CA203-1 ECR1
K1 CA203-30 CA203-13
CA203-14
CA203-2 1
HN1 + L CA203-26 +
HNS CA203-29 ALM2
CA203-28 TRAVEL
CA203-27
FU1 +BV B-NEG
140213xf
500A
48V
L +
CA201 (A) ACCESS 3
002 CA404-3 CAN H 1 CAN_
H TCM
2 CANT_
H
011 3 120
4 CAN_
L_O UT AC
001 CA404-6 CAN L
5
6 CAN_
L
TRACTION
7 CONTROLLER
8
CA201 CA203 CA202 (B)

1
1 3 1 12 2
4 5 13 23 3
6 8 24 35
HANDSET 4
5
6
7
NOTE: WIRE SIDE OF CONNECTOR SHOWN 8
CA203 (C)
312 CA413-3 ECR1 POS (11.3V) 1 RH MTR ECR1 POS
(11.3V)
515 CA413-6 ECR1 NEG (0.2V) 2 RH MTR ECR1 NEG
(0.2V)
2959 (CA409) +BV(K1) SHORTING PLUG KEYSWITCH (KYS)
3 (+BV =CLOSED, 0V =OPEN)
4
2911 (CA406) +BV SES N.O. 5 SEAT SWITCH (SES)
(+BV =CLOSED, 0V =OPEN)
2908 CA408-6 +BV(K1) FS N.O. 6 FORWARD SWITCH (FS)
2907 CA408-5 +BV(K1) RS N.O. 7 REVERSE SWITCH (RS)
2950 CA616-C +BV(K1) ACS N.O. 8 ACCELERATOR SWITCH (ACS)
2968 (CA609) +BV(KYS) BRKS1 N.O. 9 BRAKE SWITCH (BRKS1)
2946 (CA613) +BV(K1) HGTS1 N.O. 10 HEIGHT SWITCH (HGTS1)
311 CA412-3 ECR2 POS (11.3V) 11 LH MTR ECR2 POS
(11.3V)
514 CA412-6 ECR2 NEG (0.2V) LH MTR ECR2 NEG
12 (0.2V)
007 CA413-5 ECR1 CHA (0.2-11.3V) 13 RH MTR ECR1 CHA
(0.2-11.3V)
008 CA413-4 ECR1 CHB (0.2-11.3V) 14 RH MTR ECR1 CHB
(0.2-11.3V)
521 CA410-B STR POT1 NEG (0.2V) 15 POT1 (STEER) NEG
(0.2V)
310 CA410-A STR POT1 POS (11.3V) 16 POT1 (STEER) POS
(11.3V)
110 CA410-C STR POT1 WIPER (0.2-11.3V) 17 POT1 (STEER) WIPER
(0.2-11.3V)
113 CA611-B BRK POT2 WIPER (0.2-11.3V) 18 POT2 (BRAKE) WIPER
(0.2-11.3V)
567 CA611-C BRK POT2 NEG (0.2V) 19 POT2 (BRAKE) NEG
(0.2V)
309 CA617-A ACC POT3 POS (11.3V)
520 CA617-C ACC POT3 NEG (0.2V) 20 POT3 (ACCELERATOR) NEG
(0.2V)
109 CA617-B ACC POT3 WIPER (0.2-11.3V) 21 POT3 (ACCELERATOR) WIPER
(0.2-11.3V)
009 CA412-5 ECR2 CHA (0.2-11.3V) 22 LH MTR ECR2 CHA
(0.2-11.3V)
010 CA412-4 ECR2 CHB (0.2-11.3V) 23 LH MTR ECR2 CHB
(0.2-11.3V)
106 CA413-2 RH MTR TS1 NEG (0.2V) 24 RH MTR TS1 NEG
(0.2V)
1 OPTIONAL FEATURE
107 CA413-1 RH MTR TS1 SIGNAL (0.2-11.3V) RH MTR TS1 SIGNAL

25 (0.2-11.3V)
5907 CA210-8 LINE COIL NEG 26 LINE CONTACTOR NEG
(0.2V)
2958 CA210-7 LINE COIL POS 27 LINE CONTACTOR POS
(24V)
5919
NOTES
POST FARTHEST 1 ALM2 (TRAVEL) NEG

ALM2
28 (0.2V)
FROM MOUNTING
PLATE IS POS (+) (TRAVEL)
2990 ALM2 (TRAVEL) POS
+ 29 (48V)
FAN1&2 POS OFF <45 C
2964 CA210-11 FAN1 & FAN2 POS 30 (48V) ON >65 C
5908 CA210-12 FAN1 & FAN2 NEG FAN1&2 NEG
31 (0.2V)
32 BATT NEG
BARREL
302 CA611-A BRK POT2 POS (11.3V) 308 POT2&3 (BRAKE/ACCELERATOR)
33 POS (11.3V)
104 CA412-2 LH MTR TS2 NEG (0.2V) 34 LH MTR TS2 NEG
(0.2V)
105 CA412-1 LH MTR TS2 SIGNAL (0.2-11.3V) 35 LH MTR TS2 SIGNAL 140214xf
(0.2-11.3V)
CA204 (A)
1
2 ACCESS 2
3
4
HCM
HANDSET 5
6
7
8 AC
HYDRAULIC
CA205 (B) CONTROLLER
1
2
CA206 (C)
014 CA404-5 CAN H 1 CAN_
L
2
013 CA404-2 CAN L 3 CAN_
H
4
ECR3 CA207 (D)
RED/WHT
CA401 313 HYD MTR ECR3 POS
1 1 (11.3V)
TS3 BROWN 532 HYD MTR ECR3 NEG
+t
2 2 (0.2V)
HYDRAULIC +12V RED 019
3 3 HYD MTR ECR3 CHA
MOTOR BLUE
CHA 4 4
(M3) WHITE 020
CHB 5 5 HYD MTR ECR3 CHB
B- BLACK
6 6
CA208 (E)
POT4 (LIFT) WIPER
108 CA631-2 LIFT POT4 WIPER (0.2-11.3V) 1 (0.2 - 11.3V)
POT4 (LIFT) POS
307 CA631-1 LIFT POT4 POS (11.3V) 2 (11.3V)
POT4 (LIFT) NEG
527 CA631-3 LIFT POT4 NEG (0.2V) 3 (0.2V)
2934 CA632-1 +BV(K1) TLT 4 COMMON TO HYDRAULIC LEVERS
2912 (CA406) +BV(K1) SES N.O. HYDRAULIC ENABLE INPUT

5 (+BV=
C LOSED, 0V=
O PEN)
2936 CA632-C +BV(K1) TLT N.O. 6 1ST SPEED INPUT (TILT)
(+BV=
C LOSED, 0V=
O PEN)
2944 CA634-C +BV(K1) AXS2 N.O. 7 3RD SPEED INPUT (AXS2)
(+BV=
C LOSED, 0V=
O PEN)
8
9
10
11
12
13
14
CA209 (F)
KEYSWITCH (KYS)
2974 (CA409) +BV(K1) SHORTING PLUG 1 (+BV =CLOSED, 0V =OPEN) 1 OPTIONAL FEATURE
+ 2995 1 2994 2 FAN3 POS
5901 2 5906 3
FAN3 MOTOR COMP 4
525
NOTES
1
5 SAFTEY INPUT
115 HYD MTR TS3 SIGNAL
6 (0.2-11.3V)
2940 (CA633) +BV(K1) TO AXS1 & AXS2 7 COMMON TO HYDRAULIC LEVERS
8 FAN3 NEG
9
2942 CA633-C +BV(K1) AXS1 N.O. 10 2ND SPEED INPUT (AXS1)
(+BV=
C LOSED, 0V=
O PEN)
11 BATT NEG
112 HYD MTR TS3 NEG
12 (0.2)
BATT NEG PWR TERMINAL 140215xf

554 CA812-1 B-NEG FREEZ
E R BOARD
217 CA812-4 +BV FREEZ
E R BOARD
CA210 FU3
BATTERY
POSITIVE
203 C408-1 B+(FU3) KYS & HNS 202 201
1
212 15A + TERMINAL
LINE
221 CA407-4 B+(FU4) CAN ACCESS 2 CONTACTOR
208 C641-2 B+(FU4) LGS1 213 FU4 211
3
214 15A
220 CA405-3 B+(FU4) BRK1 & BRK2 TOW 4 BATTERY
502 NEGATIVE
504 CA405-6 BNEG BRK1 & BRK2 TOW 5 TERMINAL
503 TRACTION
505 CA403-1 BNEG SHORTING PLUG 6 CONTROLLER
7 2960 L
2958 CA203-27 LINE POS
8 5909
5907 CA203-26 LINE NEG
9
10
2964 CA203-30 FAN1&2 POS 11 2965 2966
5908 CA203-31 FAN1&2 NEG 12 5912
FAN1 FAN2
CA402 5913
2904 (CA409) +BV(K1) K1 N.O. 1
2905 CA408-4 +BV(K1) FS & RS COMM 2
BATTERY POSITIVE
2906 CA609-A +BV(K1) BRKS1 COMM 3
AFTER K1
2909 CA406-1 +BV(K1) SES COMM 4
SHORTING PLUG
2915 CA605-5 +BV(K1) ACS COMM 5
LOCATED UNDER FLOORBOARD
2919 CA651-1 +BV(K1) TAIL & STROBE 6
29103 CA812-5 +BV(K1) FREEZ
E R BOARD 7
2967 CA411-6 +BV(K1) DISPLAY 8
2913 CA613-1 +BV(K1) HGTS1 COMM 9
2988 CA618-1 +BV(K1) AXS3 COMM 10
2987 CA610-A +BV(K1) BRKS2 COMM 11
29113 CA407-5 +BV(K1) CAN ACCESS 12
CA403
505 CA210-6 BATT NEGATIVE TERMINAL 1
530 CA407-3 BNEG CAN ACCESS 2
508 (CA408) BNEG HN1 3
BATTERY NEGATIVE
522 CA411-2 BNEG DISPLAY 4 SHORTING PLUG
517 CA409-4 BNEG K1 5 LOCATED UNDER FLOORBOARD
513 CA651-6 BNEG LGT1 AND LGT2 6
579 CA651-7 BNEG LGT3 REAR WORK LGT 7
510 CA651-8 BNEG LGT4 STROBE 8
507 CA642-1 BNEG FAN4 9
10
528 CA619-1 BNEG SV2 11
512 CA641-1 BNEG ACCY CABLE 12
CA404
003 CA411-8 CAN H DISP 1
004 CA411-7 CAN L DISP 2 CAN DISTRIBUTION PLUG
013 CA206-3 CAN H HYD 3 LOCATED UNDER FLOORBOARD
014 CA206-1 CAN L HYD 4
002 CA201-1 CAN H TRAC 5
001 CA201-6 CAN L TRAC 6
016 CA407-1 CAN H CAN 7
015 CA407-2 CAN L CAN 8
9
10
11
12 140216xg
CA405
SHIPPING HARNESS
SEE BRAKE PICTORIAL
CA406 SES
GRN WHT (NOT USED)
2909 CA402-4 +BV(K1) SHORTING PLUG 1
BARREL
2911 CA203-5 +BV(K1) SES INPUT 2910 BRW
2
2912 CA208-5 +BV(K1) SES INPUT
2939 CA411-3 +BV(K1) SES INPUT
CA407
016 CA404-10 CAN H 1
015 CA404-7 CAN L 2 CAN ACCESS
530 CA403-2 BATT NEG SHORTING PLUG CONNECTOR
3
221 CA210-2 +BV(FU4) LOCATED UNDER FLOORBOARD
4
29113 CA402-12 +BV(K1) 5
6
CA408 CA601
203 CA210-1 +BV(FU3) 204 BARREL 210 RED KYS
1 A
2902 CA409-1 +BV(KYS) TO K1 2922 RED START
2 B ACC
BATT
2903 CA409-2 +BV(KYS) IGN K1 COMM 2923 RED
3 C IGN
OFF
2905 CA402-2 +BV(K1) SHORTING PLUG 2924

4 LEFT RIGHT
2907 CA203-7 +BV(K1) RS INPUT 2926
5 RS
2927 LEFT RIGHT 2925
2908 CA203-6 +BV(K1) FS INPUT 6
OUT IN 2914 2928 205 FS
508 CA403-3 B- HORN 7
HN1
1 HNS
FIL BRUSH/SLIP BRUSH/SLIP
CA621 RING RING
2918 CA651-2 +BV(K1) BACKUP LIGHTS
2901 CA641-3 +BV(K1) LGS2 COMM 2930 2929
8
BARREL 2961
2917 (CA642) +BV(K1) FNS COMM 9
10
11
12
CA602
509 CA603-4 ECR4 (STEER) NEG 1
2
COMMON
CHANNEL A
ECR4
025 CA603-2 ECR4 (STEER) CHA 3 5V STEER
4 CHANNEL B ENCODER
303 CA603-1 ECR4 (STEER) POS +5V
026 CA603-3 ECR4 (STEER) CHB
RELAY MODULE
CA409 CR3
2902 CA408-2 +BV(KYS) KYS START 2991 E1 TR1
1 -T
CR2
2903 CA408-3 +BV(KYS) KYS IGN 2992 E2 COM N.O.
BARREL
2
2904 CA402-1 +BV(K1) TO SHORTING PLUG 2985 2993 E3 K1
3 K1
2959 CA203-3 +BV(K1) TCM KEY INPUT 2984 CR1
FU5
2974 CA209-1 +BV(K1) HCM KEY INPUT 6A
517 CA403-5 BATT NEG SHORTING PLUG 584 E4
4
CA410
310 CA203-16 POT1 (STEER) POS (11.3V) A POT1 STEER
521 CA203-15 POT1 (STEER) NEG (0.2V) B 5K POT
110 CA203-17 POT1 (STEER) WIPER (0.2-11.3V) C
140217xh
ACCESS 1
DCM
NOTES
* 1) APPLIED =
0V (REFERENCED TO +BV)
RELEASED =
1 8V (REFERENCED TO +BV OR BRK +BV)
* 2) APPLIED =
1 8V (REFERENCED TO B-)
RELEASED =3 6V (REFERENCED TO B-)
5930 PC605-2 BRK2 NEG

2955 PC605-1 BRK2 POS CA630
2954 PC605-3 BRK1 POS 1 BRK2 LO (LH) SEE NOTE 1
5931 PC605-4 BRK1 NEG CA411 2 BRK1 LO (RH) SEE NOTE 1
1 3
522 CA403-4 BATT NEG 524
2 4 DISPLAY BNEG
023
5 ECR4 (STEER) CHA
6
7
2939 (CA406) +BV(K1) SES 2970
3 8 SES INPUT (SEAT SWITCH)
(+BV=C LOSED, 0V=
O PEN)
2954 BRK1 +BV (RH)
CA603 9 SEE NOTE 2
301
303 (CA408) ECR4 1 10 ECR4 (STEER) POS 5V
024
025 (CA408) ECR4 2 11 ECR4 (STEER) CHB
542
026 (CA408) ECR4 3 12 ECR4 NEG
314
509 (CA408) ECR4 4 13 PS1 (LOAD SENSE) +15V
2971
2975 (CA609) +BV(K1) BRKS1 4 14 BRS1 INPUT(BRAKE SW)
(+BV=
C LOSED, 0V=
O PEN)
2949 (CA613) +BV(K1) HGTS1 2972
5 15 HGTS1 INPUT (HEIGHT SWITCH)
2955
16 BRK2 +BV (LH)
SEE NOTE 2
2967 CA402-8 +BV(K1) KYS 2973
6 17 DISPLAY +BV(K1)
004 CA404-4 CAN L 005
7 18 CAN_
L
003 CA404-1 CAN H 006
8 19 CAN_
H
20
114
21 PS1 INPUT (LOAD SENSE)
22
23
CA604
PT1 114 1 8
OUTPUT 1 9 15
LOAD +15V 2 16 23
SENSE 3 314
4
140218xf
LEFT
CA412 MOTOR
105 CA203-35 LH MTR TS2 SIGNAL (0.2-11.3V) BROWN
1
104 CA203-34 LH MTR TS2 NEG (0.2V) BLACK TS2
2 +t
311 CA203-11 ECR2 POS (11.3V) RED
3 +12V
010 CA203-23 ECR2 CHB 4 BLUE
CHB
M2
WHITE
009 CA203-22 ECR2 CHA 5 CHA ECR2
514 CA203-12 ECR2 NEG (0.2V) BLACK B-
6
RIGHT
CA413 MOTOR
107 CA203-25 RH MTR TS1 SIGNAL (0.2-11.3V) BROWN
1
106 CA203-24 RH MTR TS1 NEG (0.2V) BLACK TS1
2 +t
312 CA203-1 ECR1 POS (11.3V) RED
3 +12V
008 CA203-14 ECR1 CHB 4
BLUE
CHB
M1
WHITE
007 CA203-13 ECR1 CHA 5 CHA ECR1
515 CA203-2 ECR1 NEG (0.2V) BLACK B-
6
PC605 JC605
CA607 BRK2
2955 CA630-16 +BY(KYS) 1/3 BRK 2956 BLUE
1 1 C+
5904 BLUE LH
5930 CA630-1 B- 1/3 BRK 2 2 C-
CA608 BRK1
2954 CA630-9 +BV(KYS) 2/3 BRK 2957 BLUE
3 A C+
5931 CA630-2 B- 2/3 BRK 5905 BLUE RH

4 B C-
C
5 2915 CA402-5 +BV(K1)
2963 6 2945 CA616-A +BV(K1) ACS
PC405/JC405
1
2 PC606 NOTE:
220 CA210-4 +BV(FU4) BRK1 3 222 TO TOW TRUCK WHEN TRUCK
1
4 593 BATTERY IS PRESENT.
2
2962 5 223 3 - REMOVE PC605 FROM JC605
504 CA210-5 B- BRK2 6 594 4 CONNECTORS LOCATED
UNDER FLOOR BOARD COVERS
5
- PLUG PC606 INTO JC605
6 - VERIFY PC405 IS
PLUGGED INTO JC405
SHIPPING NOTE:
- HARNESS USED TO RELEASE BRAKES
- REMOVE PC605 FROM JC605
- PLUG PC606 INTO JC605
- REMOVE PC405 FROM JC405
- HANG JC405 OUT BACK OF TRUCK
- PLUG A VOLTAGE SOURCE INTO JC405
ACCORDING TO THE 24V OR 36/48V
WIRING DIAGRAM SHOWN BELOW
PC605-A PC605-B
24V SHIPPING METHOD 36V/48V SHIPPING METHOD
SERVICE PART: 139956-001 1 SERVICE PART: 139956-002 1
2 2
15A 15A
24V BATT 3 36V OR 48V 3
BATTERY
4 4
5 5
BATT NEG 6 BATT NEG 6
140219xg
CA609
2906 CA402-3 +BV(K1) SHORTING PLUG BLK
A
RED N.C.
COMM
B
BARREL 2976 BLU
2968 CA203-9 BRKS1 INPUT C N.O. BRKS1
2975 CA411-4 BRKS1 INPUT
CA610
2987 CA402-11 +BV(K1) SHORTING PLUG BLK
A
2916 CA651-5 +BV BRAKE LIGHT RED N.C.
COMM
B
BLU N.O.
C BRKS2
BRKS2 PRESENT ONLY
WITH TAIL LIGHT OPTION
CA611
302 (CA203) POT2 (BRAKE) POS (11.3V) A

113 CA203-18 POT2 (BRAKE) WIPER (0.2-11.3V) B
POT2 BRAKE PEDAL
5K POTENTIOMETER
567 CA203-19 POT2 (BRAKE) NEG (0.2V) C
CA612 / CA613 / CA614 / CA615

SHOWN ON MAST & HYDRAULIC PICTORIAL
CA616
2945 CA605-6 +BV(K1) BLK
A
RED N.C.
COMM
B
2950 CA203-8 +BV ACS INPUT BLU N.O.
C ACS
CA617
309 (CA203) POT3 (ACC) POS (11.3V) A
POT3 ACCELERATOR
109 CA203-21 POT3 (ACC) WIPER (0.2 - 11.3V) B 5K POTENTIOMETER
520 CA203-20 POT3 (ACC) NEG (0.2V) C
140220xf
CA613 CA614
C3-BLACK
2913 CA402-9 +BV(K1) SHORTING PLUG 1 1
BARREL 2977 C3-WHITE HGTS1
2946 CA203-10 +BV(K1) TRACTION 2 2
2949 CA411-5 +BV(K1) DISPLAY SB80
C3
1
3
CA618 AXS3 CA615 2
29110 29111 C5-BLACK
2988 CA402-10 +BV(K1) 1 1 +
506 C5-WHITE SV2 3
528 CA403-11 BNEG SHORTING PLUG 1 2
4
+
CA619 C5
5
5TH FUNCTION
3
CA631
GREEN POT4
307 CA208-2 POT4 (LIFT) POS (11.3V) 1
415
108 CA208-1 POT4 (LIFT) WIPER (0.2-11.3V) 2 RED
3.32K
2.5K LIFT
527 CA208-3 POT4 (LIFT) NEG (0.2V) 3 YELLOW
415
POTENTIOMETER
4
CA632
BLACK
2934 CA208-4 +BV(K1) A
RED
B
BLUE TLT
2936 CA208-6 +BV(K1) 1ST SPEED C
BARREL CA633
2941 BLACK
2940 CA209-7 +BV(K1) A
RED
B
BLUE AXS1
2942 CA209-10 +BV(K1) 2ND SPEED C
CA634
2943 BLACK
A
RED
B
BLUE AXS2
2944 CA208-7 +BV(K1) 3RD SPEED C
CA642 3
207 1 +BV
CA641 ACCESSORY
516
512 CA403-12 BATT NEG 1 2 CABLE
206 LGS1
208 CA210-3 +BV(FU4) LGS1 2 1
2901 (CA408) +BV(K1) RS 2931 LGS2
3
2920 CA651-3 +BV FRONT LIGHTS 2932
4
2921 CA651-4 +BV REAR LIGHT 2933
5
6
CA666
LOW
CA665 FAN4 1
557 RED
OPERATOR COOLING FAN 1 CA667
3 BLACK HIGH
CA662 1
BLUE
CA661 1
519 CA663
507 CA403-9 BATT NEG A DIODE ASM
29140 129900
2917 CA408-9 +BV(K1) RS NO B 2947 FNS 1
29141 29142
C CA664
2948 2
1
29143
NOTES
1 LGS1 IS CENTER SLOT ON DASH
LGS2 IS RIGHT SLOT ON DASH
2 FNS IS LEFT SLOT ON DASH
IF NO FAN THEN JUMPER 2986 BETWEEN PINS B & C 10221xg
3 OPTIONAL FEATURE
LEFT SIDE DIRECTION OF TRUCK
OVERHEAD GUARD WITH TAIL LIGHT PACKAGE
TAIL
DISTRIBUTION
PANEL
CA807
1
STROBE RED 2
STROBE BV
LGT4 STROBE NEG
3
BLACK 4
JC801 5
PC801 RED
1 REAR
2X
PC802
24V/70W LGT3
1 JC802 BLACK
CA651 PC803 JC803

CA808 1
2978 1 2
2919 CA402-6 +BV(K1) 29178
1 3
2979 PC804 JC804 5140 4
2918 (CA408) +BV(RS) 2 1 5
2980 6
2920 CA641-4 +BV(LGS1) 3 PC805 7
1 JC804 29179
2921 CA641-5 +BV(LGS2) 2981
4
2982 PC806 JC804 29182
2916 CA610-B BRKS NO 5 1
513 CA403-6 BATT NEG 538
6
539 LGT5 LGT6
579 CA403-7 BATT NEG 7 TAIL BRAKE BACK-UP TAIL BRAKE BACK-UP
510 CA403-8 BATT NEG 540

8
CA809
BLACK
BLACK 1
RED 2
WHITE 3
YELLOW 4
5
CA810
BLACK
1
BLACK
RED 2
WHITE 3
YELLOW 4
5
RIGHT SIDE DIRECTION OF TRUCK
FRONT WORKLIGHT LEFT

PC813 JC813
2980 1 RED
LGT1
PC814 JC814 BLACK 24V/70W
1
NOTE 1) FOR MAST MOUNTED WORKLIGHTS, WIRES 2980 AND FRONT WORKLIGHT RIGHT
538 IS REMOVED FROM CA651 AND A 2 WIRE CONDUCTOR 2983
IS RAN TO PC813 AND PC814 ON MAST WORKLIGHTS PC815 JC815
1 RED
LGT2
538 PC816 JC816 BLACK 24V/70W
1
OVERHEAD GUARD WITHOUT TAIL LIGHT PACKAGE

PC801 JC801 RED
1 REAR WORKLIGHT
PC802 LGT3
JC802 BLACK
1 2X 24V/70W
CA651
2978 PC803 JC803 RED
2919 CA402-6 +BV(K1) 1 1 STROBE
LGT4
2918 (CA408) +BV(RS) 2979
2 PC804 JC804 BLACK
1
2920 CA641-4 +BV(LGS1) 2980
3
2981 PC805
2921 CA641-5 +BV(LGS2) 4 NOT USED
2916 CA610-B BRKS2 N.O. 2982
5 PC806
513 CA403-6 BATT NEG 538 NOT USED
6
579 CA403-7 BATT NEG 539
7
510 CA403-8 BATT NEG 540 PC JC FRONT WORKLIGHT LEFT
8 2980 PC815 JC815 RED
1 LGT1
PC816 JC816 BLACK 24V/70W
1
2983 PC JC FRONT WORKLIGHT RIGHT

PC817 JC817 RED
1 LGT2
541 PC818 JC818 BLACK 24V/70W
1
140222xc
F/C DIST BRD
CA811
FU13 K12-B CA813 RES2
CA812 29100 29104 545
1 1
15A 543 545 F/R
554 (CA209) BATT NEG 1 2 2 RES3
29105 546
2 3 F/R
3 K12-A 4
FU14
217 (CA210) +BV 4 5
15A
29103 CA402-7 +BV(K1) 5 6
7
8
29101 29109 LOCATED
9 3 FRONT
29102 29110 THS1 COWEL
K11 10 4
29106 29111 LOCATED
11 5
R1 29107 29112 STEER
K11 12 6 THS2 COLUMN
K12
1) THS1 SHOWN AT AMBIENT OF 21 C (70 F)
< 4.5 C (40 F) = CLOSED
> 15.5 C (60 F) = OPEN
2) THS2 SHOWN AT AMBIENT OF 21 C (70 F)
< 49 C (120 F) = CLOSED
> 60 C (140 F) = OPEN
3) RES2 AND RES3 ARE 120 OHMS 25W
4) CA813 LOCATED BY BRAKE PEDAL
FU13 K12-B
15A RES2
FU3 KYS
K1
RES3
15A
THS1
+
K11
48V
THS2
K11 K12
FREEZER CONDITION SCHEMATIC
140223xb
ITEM 13
FU1 ITEM 12
500A
ITEM 11
TRACTION/PUMP FU2
LINE CONTACTOR 300A
TRACTION CONTROLLER V
W U
WS VS US WM VM UM M3
MOTOR
PUMP
W V U
ITEM 9
LIFT PUMP
CONTROLLER
ITEM 10
+BV BUS BAR
-BATT
BATT NEG BUS BAR

+BATT
ITEM 1 ITEM 3 ITEM 6
ITEM 2 ITEM 4 ITEM 7
ITEM 5 ITEM 8
BATTERY
CONNECTOR
V V
POS NEG W U W U
M2 M1
48V LEFT RIGHT
TRUCK TRAC TRAC
MOTOR MOTOR
BATTERY
630MM BATT BOX 522MM BATT BOX 414MM BATT BOX
ITEM PART NO. ITEM PART NO. ITEM PART NO.
BATTERY CABLES 3. 084570-266 3. 084570-260 3. 084570-254
TRK MODEL ITEM PART NO. 4. 084570-267 4. 084570-261 4. 084570-255
1 084572-327 5. 084570-268 5. 084570-262 5. 084570-256
SC4210-1.3 2 084572-328 6. 084570-269 6. 084570-263 6. 084570-257
SC4210-1.3H 7. 084570-270 7. 084570-264 7. 084570-258
1 084572-329 8. 084570-271 8. 084570-265 8. 084570-259
SC4220-1.3
SC4220-1.6 2 084572-330 9. 084572-335 9. 084572-335 9. 084572-335
SC4220-1.3H 10. 084572-336 10. 084572-336 10. 084572-336
1 084572-331 11. 084570-272 11. 084570-272 11. 084570-272
SC4220-1.6H
SC4240-1.8 2 084572-332 12. 084570-273 12. 084570-273 12. 084570-273
13. 084570-274 13. 084570-274 13. 084570-274
SC4240-1.6H 1 084572-333
SC4240-1.8H 2 084572-334
140224xd

Old SC4200 Pre Service Info

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Old SC4200 Pre Service Info

Uploaded by

Copyright:

Available Formats

Hazardous Energy

Control of Hazardous Energy Battery Care

Battery • Never use a match or lighter. Battery fumes are ex-

• Keep vent plugs firmly in place at all times except

• Do not bring any type of flame, spark, etc., near the

• Do not lay metallic or conductive objects on bat-

• Do not allow dirt, cleaning solution or other foreign

• If battery repair is planned, follow the battery man-

Crown 2006 PF15538-1 Rev. 11/06 MA-1145-100

When maintenance is to be performed and the battery

MA-1145-101 Crown 2006 PF15538-2 Rev. 11/06

Capacitance 3. Disconnecting the battery for a minimum of 10 min-

Access 3 - Traction Control Module

Crown 2006 PF15538-3 Rev. 11/06 MA-1145-102

MA-1145-103 Crown 2006 PF15538-4 Rev. 11/06

Releasing Brakes by Using the Crown

• The Tow-Mode feature is only available in Service Figure 14981

• When in Tow-Mode, there is a five minute window

• When in Tow-Mode, the message "TOW? Y" "5

• If the brakes are released in Tow-Mode, and need

• When in Tow-Mode, if operator is not "present" (out

Crown 2006 PF15538-5 Rev. 11/06 MA-1145-104

MA-1145-105 Crown 2006 PF15538-6 Rev. 11/06

Lifting and Blocking

Lower Forks and

Hard Wood Block

1. Move truck to a secure non traffic maintenance

• Hydraulic Jack - Capacity 3620 kg (8000 lbs)

• Crown part number: 122599

• Collapsed height minimum: 60 mm (2.25 in)

• Raised height maximum: 400 mm (16 in)

• Jack Stand - capacity 4500 kg (10,000 lbs) Com-

Crown 2006 PF15538-7 Rev. 11/06 MA-1145-106

Set Jack Stand

MA-1145-107 Crown 2006 PF15538-8 Rev. 11/06

Mast 4. Raise forks and position blocks under second

Blocking Masts 5. Using a clamp or ratchet tie down, secure blocks to

Third Stage Mast

First Stage Mast Third Stage

First Stage Mast

Crown 2006 PF15538-9 Rev. 11/06 MA-1145-108

Fork Carriage TT Mast

MA-1145-109 Crown 2006 PF15538-10 Rev. 11/06

Disconnecting Tilt Cylinder

Attach Lifting Device to All

Crown 2006 PF15538-11 Rev. 11/06 MA-1145-110

6. Disconnect lift cylinder hydraulic lines, accessory

11. Remove pivot block mounting bolts. If pivot blocks

MA-1145-111 Crown 2006 PF15538-12 Rev. 11/06

6. Remove overhead guard mounting bolts from the

Crown 2006 PF15538-13 Rev. 11/06 MA-1145-112

MA-1145-113 Crown 2006 PF15538-14 Rev. 11/06

Brake Brake Assembly Removal

Armature (under Spacer)

Install M6 screws in these holes

5. Disconnect wiring to brake assembly being re-

Crown 2006 PF15535-1 M5.0-1145-001

M5.0-1145-002 Crown 2006 PF15535-2

Brake Assembly Installation

Crown 2006 PF15535-3 M5.0-1145-003

Crown 2006 PF15569-1 M6.0-1145-001

Steering Column Assembly

Steer • Refer to Figure 15154. Apply 1.5 to 2 turns of black