Maintenance Manual

C
WAV 60 Series
Maintenance Manual
Order Number: 812616-001

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

– European Headquarters –
Philipp-Hauck-Str. 12
85622 Feldkirchen
Germany
Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 312
www.crown.com
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2020
Crown Equipment Corporation
TABLE OF CONTENTS
I
Notes:
II
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the vehicle with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the vehicle with a forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Loading the vehicle onto a pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Securing the Vehicle for Transport on a Truck Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lifting the vehicle and pulling it with another forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Releasing the brake and pushing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Jacking up the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Placing the Vehicle in Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Restoring the Vehicle to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Commission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Commissioning the Vehicle into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operator instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operator training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Vehicle data number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Lubricants, Aerosols and Service Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Platform and third stage mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SAE Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
III
TABLE OF CONTENTS
COMPONENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Componentry and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Access 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Access 3™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Access 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ALM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ALM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ANSI AC Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
BRK1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
BRK2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CB1 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CHSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CHS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Cord Reel Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
D1 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
D2 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D3 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D4 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D5 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D6 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D7 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D8 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
D9 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
D10 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
D11 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
D12 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
D13 (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DMSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DMSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EDS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EDS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EDS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EDS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ERLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
IV
TABLE OF CONTENTS
FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FU7 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FU8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
GCSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
GCSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
GOSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
GOSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HGTS20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HGTS84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HGTS118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
IEC 320 Inlet (Not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Impact Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
InfoLink® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
K3 Optional (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
K4 Optional (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
K6 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
L ................................................................................ 82
LED1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LED2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LED Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LGS Optional (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LGT1 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LGT2 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LMS1 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LMS2 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LTS Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
M4 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MCS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MCS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MCS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MCS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MOV1 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
PLSL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
PLSL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
RHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SB1 Optional (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
STR CMD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
SPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
TLTS (Only on EMEA Vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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TABLE OF CONTENTS
TS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
TXN CMD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintaining the hydraulic lines and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Drive Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Caster Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Wire designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Testing the encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Channel feedback overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Index voltage overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Pod Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Steer sensor (STR CMD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Steer linkage adjustment for the steer sensor (STR CMD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Traction sensor (TXN CMD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Access 1 2 3® Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Operator menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Messages and menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Operator menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Analyser menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Calibration menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Features menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Performance menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Utilities menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Hours menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Analyser Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Analyser menus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Analyser menus access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
A1 Inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
A2 Inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
A2.X Access 2/3 inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
A3 Inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
A3.X Access 3™ inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
A4 Inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
A4.X Access 4 inputs menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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TABLE OF CONTENTS
Calibration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Calibration menus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Calibration menus access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Feature Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Features menus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Features menus access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
F1 Language menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
F2 Units of measure menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
F3 User performance menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
F4 User codes menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
F5 Options menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Performance Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Performance menus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Performance menus access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
P1.X Travel speeds menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
P4.X Steering menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
P5.X Performance H menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
P6.X BDI menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
P7 Turtle mode menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
P8 Load factory default values menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Utilities Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Utilities menus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Utilities menus access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
U1 SW part numbers menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
U2 Tester menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
U3 Clear events menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
U4 Clear EEPROM menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Hour Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Hour menus overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Hour menus access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Servicing the line contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Battery indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Maintenance-free batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Charging requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
BDI information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Right and Left Traction Motors (M1 and M2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Lift Pump Motor (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Checking the current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
VII
TABLE OF CONTENTS
Event Code Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
No event code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
AC inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Indicator lights for the battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Push/Drive switch (DTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Emergency disconnect switch (EDS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Emergency raise and lower switch (ERLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Regenerative brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Mast reshimming (without removing the mast assembly from the vehicle) . . . . . . . . . . . . . . . . . . . . . . . 240
Mast disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Mast assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Planned maintenance for lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Cleaning and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Cleaning the lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Checking the lift chains for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Replacing the lift chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Removing the lift chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the secondary chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Disconnecting the leaf chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Load tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Load Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Powered load tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
VIII
TABLE OF CONTENTS
SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Introduction to Diagram Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Vehicle Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Platform, Access 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
InfoLink®, Motorised Load Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Access 2, ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Access 2, Access 3™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Chassis, M1, M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Wire Colour-Codes and Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Wire Colour-Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
IX
X
SAFETY
1
Notes:
2
SAFETY
General Maintenance Instructions
General Maintenance – Limit switches

– Protective devices
Instructions – Electrical conductors
If regular maintenance is not performed on the vehicle, – Connections
the vehicle will not be safe to operate. When perform-
• Make sure that the electrical insulation is in good
ing maintenance procedures or inspecting the vehicle,
condition.
follow these guidelines:
• Make sure that the service technicians are trained Hydraulic system
and authorised to maintain, repair, adjust and in- • Regularly inspect hydraulic components such as
spect the vehicle. cylinders and valves.
• Follow a scheduled planned maintenance, lubrica- Safety labels on the vehicle
tion and inspection system.
• Inspect the capacity, operation and maintenance in-
Preparing the vehicle for maintenance struction plates or decals for completeness and leg-
1. Make sure that the shop is well ventilated, clean ibility in accordance with planned maintenance
and dry. intervals.
2. Move the vehicle to a secure maintenance area • Immediately clean any dirty decals and replace
with a level floor. damaged or missing decals.
3. Block the load engaging means, inter masts or Vehicle modifications and additions
chassis. • Modifications or additions to the vehicle can only be
4. Raise the drive tyres off the floor or disconnect the performed with prior written approval from Crown.
power sources. In such cases, the vehicle data plate or capacity
5. Chock the wheels. plate must be changed accordingly.
• Make sure that all replacement parts are inter-
Preparing to leave the vehicle
changeable and of the same quality as the original
1. Stop the vehicle. parts.
2. Fully lower the platform. • Make sure that additions (terminal, fan, clip pad
3. Place the directional controls in neutral. etc.) do not obstruct the vision of the operator or
4. Use the battery disconnect to remove the power prevent safe operation of the vehicle.
from the vehicle. Returning the vehicle to operation after performing
5. Remove the key. maintenance
6. Block the wheels if the vehicle is on an incline. 1. Be in the operating position.
Safety precautions 2. Place the directional controls in neutral.
• Avoid fire hazards and have fire protection equip- 3. Test the vehicle operation in an open area where
ment present. Do not use an open flame to check there are no people or obstacles. In particular, test
level, or for leakage of electrolyte and fluids or oil. the following functions for successful operation:
Do not use open pans of fuel or flammable cleaning • Brakes
fluids for cleaning parts. • Speed controls
• Keep the vehicle clean to minimise fire hazards and • Directional controls
make it easier to locate any loose or defective parts.
• Steering controls
Vehicle inspection • Warning devices
• Regularly inspect all parts of the lifting mecha- • Lifting mechanism
nisms.
• Make sure that the following components are regu-
larly inspected and maintained:
– Batteries
– Motors
– Controllers
Crown 2016 PF27593 MA-2360-001
3
SAFETY
Cleaning of Material Handling Equipment
Cleaning of Material Handling Note: Steam cleaning can remove anti-corrosion

agents, lubricants and paint from surfaces (including
Equipment hydraulic lines, terminal strips and linkages) for freezer
and corrosive environments. Avoid steam cleaning with
Preparing the vehicle for cleaning a cleaning agent.
Before you clean the vehicle, complete the following 3. If necessary, steam clean the component.
procedures.
4. If a cleaning agent has been used, rinse the com-
ponents with clear water.
Note: Oxidation and corrosion can result from mineral
WARNING and chemical residue left on or in components (such as
Malfunctions when restarting the vehicle can circuit boards, contactors, encoders, switches and po-
cause serious injury. tentiometers) after washing. Make sure that all mineral
Water can penetrate electrical components after steam and chemical residue is removed from the component.
cleaning or power washing. Water penetration can ac- 5. Allow the component to dry thoroughly.
cidentally trigger certain functions when the vehicle 6. Lubricate, paint, or apply anti-corrosion agent to
starts again. the components as required.
 Do not steam clean or wash the vehicle with a hose 7. Install the component on the vehicle.
or power washer.
Cleaning the surface of the vehicle
1. Park the vehicle in an area with an oil separator. Note: If dry cleaning cannot remove local contamina-
tion, use a damp cloth and a neutral cleaning agent,
2. Follow all instructions in Preparing the vehicle for such as a non-butanyl cleaner/degreaser (P/N 063009-
maintenance. 005). Make sure that water and cleaning agents do not
Cleaning electrical components get into electrical components or bearings.
1. Clean electrical components only with weak, dry 1. Dry clean the vehicle with cloths, soft brushes (not
compressed air and a dry cloth. metal brushes) and weak, dry compressed air.
Cleaning removed components After cleaning the vehicle
Except for lift chains, bearings and electrical compo- 1. Wipe down the vehicle.
nents, most components that have been removed from 2. Repair any paint damage.
the vehicle can be steam cleaned. 3. Add anti-corrosion agent where necessary.
CAUTION
There is a risk of vehicle damage.
Steam cleaning can damage electrical components
and bearings.
 Nuisance fault logging, intermittent operation or im-
mediate failure can result from steam cleaning. Me-
chanical components can only be steam cleaned if
no electrical components (such as connectors, ter-
minal boards and wiring) or bearings are affected.
Cleaning mechanical components

1. Remove the component from the vehicle.
2. Clean the component by hand, preferably with
warm water and a mild, neutral cleaning agent.
MA-2360-050 Crown 2016 PF27594
4
SAFETY
Cleaning of Material Handling Equipment
Returning the vehicle to operation after cleaning

Normally, no special procedures are required to return
the vehicle to operation after cleaning. If there is a pos-
sibility that moisture has penetrated electrical compo-
nents, proceed as follows:
1. Clean the vehicle with weak, dry compressed air
and a dry cloth.
2. Allow the vehicle to stand for at least 30 min in a
dry environment.
3. Insert the batteries, but do not connect the batter-
ies yet.
4. Jack up the vehicle so that the drive tyres are off
the ground.
5. Connect the batteries.
WARNING
Malfunctions when restarting vehicle can cause
serious injury.
Water or cleaning agent residue in electrical compo-
nents can cause malfunctions when the vehicle is
turned on.
 Be prepared to turn off the vehicle immediately with
the emergency disconnect when the batteries are
connected and the vehicle is turned on.
 Make sure that components accidentally starting up
cannot injure anyone.
6. Turn on the vehicle.

• If a function automatically starts, immediately apply
the emergency disconnect, or disconnect the bat-
teries, and then continue to step 7.
• If the start-up is normal, continue to step 8.
7. Apply compressed air to the respective compo-
nent. Repeat steps 1 to 6.
8. Check all vehicle functions.
9. If the vehicle functions normally, return the vehicle
to operation.
Crown 2016 PF27594 MA-2360-051
5
SAFETY
Control of Hazardous Energy
Control of Hazardous Energy • Make sure that the battery charger being used
matches the voltage and amperage of the battery
on the vehicle. This voltage is listed on the serial
Lockout/Tagout plate.
In the interests of safety and to ensure compliance with • Before disconnecting or connecting batteries to a
the OSHA Regulations, (Standards - 29 CFR), control battery charger, make sure that the battery charger
of hazardous energy (lockout/tagout) - 1910.147, is turned off. Connecting the battery to the battery
Crown has developed guidelines for proper energy charger while the charger is turned on can result in
control when performing service and maintenance on serious injury to you and damage the battery and
the vehicle. Before performing any service or mainte- charger.
nance, review the appropriate sections in this service
• Never use a match or lighter. Battery fumes are ex-
manual for additional procedures to be followed.
plosive.
In addition, Crown recommends that all service techni-
• Make sure that the battery used meets weight, size
cians wear the appropriate protective items, such as
and requirements of the vehicle (refer to the data
eye protection, work gloves and safety-toe shoes,
plate). Never operate the vehicle with an under-
whenever performing service or maintenance work on
sized battery.
Crown equipment.
Charging
Battery
Safety rules
• Wear protective clothing, such as a rubber apron,
WARNING
gloves, boots and a full face shield when performing Risk of gas explosion.
any maintenance on batteries. Do not allow electro- Battery gases are explosive. An injury or death could
lyte to come in contact with the eyes, skin, clothing occur if the battery gas explodes.
or floor. If electrolyte comes in contact with the
 Do not smoke, use an open flame, or make an arc
eyes, flush immediately and thoroughly with clean
or sparks around the battery.
water. Seek medical assistance immediately. If
electrolyte is spilled on the skin, rinse promptly with  Do not use a source of ignition (for example, a cig-
clean water and wash with soap. A baking soda arette, lighter or grinder) near the battery or battery
solution (one pound to one gallon of water) neu- charging area.
tralises acid spilled on clothing, the floor or any  Make sure that the area where you charge the bat-
other surface. Apply the solution until the bubbling tery is correctly vented.
stops and rinse with clean water.  Use designated areas for charging batteries if they
• Always keep vent plugs in place except when add- are available.
ing water or taking hydrometer readings.
• Keep any type of flame or spark away from the bat- Consult the manual of the battery charger manufac-
tery. Gas formed while the battery is charging is turer for hints on operation and maintenance.
highly explosive. This gas remains in the cells long
after charging has stopped.
• Do not lay metallic or conductive objects on the bat-
tery. Arcing results.
• Do not allow dirt, cleaning solution or other foreign
material to enter cells. Impurities in electrolyte have
a neutralising effect, reducing available charge.
• If a battery repair is planned, follow the instructions
of the battery manufacturer concerning repair prac-
tices and procedures.
Battery care
• Only qualified and experienced personnel can per-
form maintenance and repair on batteries.
MA-2360-100 Crown 2016 PF27592
6
SAFETY
Battery removal
CAUTION
CAUTION Make sure that the battery used meets the weight, size
and voltage requirements of the vehicle (refer to the
When removing a battery, move the vehicle to an area data plate). Never operate the vehicle with an under-
intended for battery care. The floor must be level. Turn sized battery.
the key switch or toggle switch to the off position and
remove the key. Disconnect the battery and lockout or
tagout vehicle as described in the Lockout/tagout sec- Lockout/tagout
tion. Fully lower the load engaging means. Do not allow Always turn the key switch to off, remove the key and
any metallic objects to come in contact with the top of apply a tag to the steering pod with a cable tie to warn
the battery cells. This can cause a short circuit when others that the vehicle is being serviced. When mainte-
removing or transporting a battery. Use an insulator nance is to be performed and the batteries are left in
(such as plywood, plastic caps) to cover the top of bat- the vehicle, disconnect the batteries, remove the main
tery posts before and during removal. power fuses and install a commercially available lock-
out device on the battery connector.
1 2
1
Fig. 1 (30726)
1 Wet cell battery
2 Maintenance-free battery Fig. 2 (30727)
1 Remove the key
Battery installation
When maintenance is performed and the batteries are
removed from the vehicle, remove the main power
CAUTION fuses and install a lockout or tagout device on the bat-
tery connector to warn others that the vehicle is not
When installing a battery, move the vehicle to an area available for operation.
intended for battery care. The floor must be level. Turn
the key switch or toggle switch to the off position and
remove the key. Lockout or tagout vehicle as described
in the Lockout/tagout section. Do not allow any metallic
objects to come in contact with the top of the battery
cells. This can cause a short circuit when transporting
or installing a battery. Use an insulator (such as ply-
wood, plastic caps) to cover the top of the battery posts
before and during installation.
Crown 2016 PF27592 MA-2360-101
7
SAFETY
Hydraulic
WARNING
Avoid High-Pressure Fluids.
High-pressure fluids can go through the skin and cause
severe injury. High-pressure fluid that goes into the
skin can become a severe medical emergency even
when the skin looks normal. There is a delayed start of
pain and severe tissue damage may occur.
 Release the pressure before you disconnect the hy-
draulic plumbing.
 Tighten all connections before you apply hydraulic
pressure.
 Keep your hands away from pin-holes which eject
high-pressure fluids.
 You must immediately get medical aid from a spe-
cialist who has experience with this type of injury.
When maintenance is to be performed on the hydraulic

system, make sure that the hydraulic system is not un-
der pressure:
1. Move the vehicle to a secure non-traffic mainte-
nance area with a level floor.
2. Make sure that the load tray and load deck are
empty.
3. Fully lower the load engaging means or, if required
for maintenance, block the vehicle at an appropri-
ate height as described in Lifting and Blocking in
this section.
4. Actuate the hydraulic switch to remove any hy-
draulic pressure that may be present.
5. Lockout or tagout vehicle as described in the Lock-
out/tagout section.
MA-2360-102 Crown 2016 PF27592
8
SAFETY
Fig. 3 (30728)
1 No load on tray
• Make sure that the vehicle can be safely stopped
during movement by manually stopping it.
2 Platform is completely lowered
• Moving this vehicle does not require an operator.
Towing a Disabled Vehicle Do not move the truck with an operator on the plat-
form.
Preparing the vehicle for moving • Make sure that the floor is level and flat without rub-
• Read and understand the Push/Drive Switch-DTS bish or debris in the towing path.
section (M4.8-Service Panel) of the service manual • Remove all loads from the load deck and load tray
before moving the vehicle. before towing the vehicle.
• Reference the data plate for information about the • Fully lower the platform before towing the vehicle.
gross weight of the vehicle. Include the battery
weight if it is in the vehicle during towing.
• Turn the key switch to off and disconnect the bat-
tery.
Crown 2016 PF27592 MA-2360-103
9
SAFETY
Moving the vehicle by manually pushing

• Release the brakes by actuating the Push/Drive
Switch (DTS) on the service panel of the vehicle.
• Push vehicle at the low points of the platform or
chassis.
• Manually push the vehicle at a speed limited to a
maximum of 3.2 km/h (2 mph).
• Make sure that the vehicle can be steered safely
during moving by manually pushing the front end in
the desired travel direction.
Moving by lifting the entire vehicle
WARNING
Towing vehicles can be dangerous.
Severe injury or death can result.
 Do not lift the vehicle higher than 51 mm (2 in) off
the floor. The vehicle must always maintain three
(3) contact points with the floor or towing device.
 Do not travel more than 3.2 km/h (2 mph) while
moving the vehicle. 1
 Do not make sharp turns when lifting and moving
this vehicle. Fig. 4 (30729)
1 Lift the entire vehicle by lifting at the bottom in the positions
shown
Lifting device requirements
Lifting and Blocking
CAUTION 1. Move the vehicle to a secure non-traffic mainte-
• The lifting device must have a capacity greater than 2. Make sure that the load tray and the load deck are
the gross vehicle weight. Make sure that all lifting de- empty.
vice capacities are not exceeded while lifting, travel- 3. Lower the platform completely.
ling, accelerating or braking. Refer to the lifting device
4. Lockout or tagout the vehicle as described in the
manufacturer if there is any doubt as to whether this
Lockout/tagout section.
device can lift or carry the disabled vehicle.
5. See Figure 5. Use a hydraulic jack to raise the ve-
• The lifting device must not damage the underside of
hicle as shown. Do not raise the vehicle more than
the towed vehicle.
380 mm (15 in) from the floor.
6. Block the wheels with hardwood or composite
Preparing the vehicle for moving blocks.
• Remove the load from the tray or deck.
Recommended tools and equipment:
Lifting and moving guidelines • Hydraulic jack
See Figure 4. Lift the entire vehicle by lifting at the bot- – Capacity 3,620 kg (8,000 lb)
tom of the vehicle as shown.
– Crown part number: 122599
• Do not lift the vehicle higher than 51 mm (2 in) off
– Collapsed height minimum: 60 mm (2.25 in)
the floor.
– Raised height maximum: 400 mm (16 in)
• Make sure that the lifted vehicle does not uncouple
from the towing device during towing. Secure the • Composite or hardwood blocks
vehicle with straps or clamps. – 100 x 100 x 762 mm (4 x 4 x 30 in)
MA-2360-104 Crown 2016 PF27592
10
SAFETY
3
2
Fig. 5 (30730)
1 Hydraulic jack
2 Hardwood blocks
3 Do not raise more than 380 mm (15 in) from the floor
Mast
Block the mast and the platform using the appropriate
length and size of composite or hardwood blocks, ei-
ther 100 x 100 mm (4 x 4 in) or 50 x 100 mm (2 x 4 in).
2. Raise the platform to the necessary height and
clamp the composite or hardwood blocks to the
chassis. Lower the platform.
3. Disconnect the electrical and chain connections
necessary to remove the platform and mast
stages.
4. Remove the guides and shims necessary to re-
move the platform and mast stages.
5. Insert the lifting tool into the top of the third stage
mast to help with removing the third stage.
6. Lockout or tagout vehicle as described in the Lock-
out/tagout section.
Crown 2016 PF27592 MA-2360-105
11
SAFETY
C
8 1
F
4 F
Fig. 6 (30731)
1 Lifting tool
2. Lockout or tagout the vehicle as described in the
Lockout/tagout section.
2 Part of third stage mast
3. Place a minimum 100 Ω, 2 W resistor between the
3 Second stage mast
B+ and BNEG terminals of the controller for three
4 Third stage mast
or more seconds.
5 Chassis
6 Clamp hardwood blocks to the chassis
7 Platform
8 Use straps and lifting device to secure and remove the plat-
form
Capacitance
Due to capacitance voltage present in the system con-
troller, whenever performing maintenance that may
permit contact with the bus bars and associated power
cables, discharge the capacitors.
MA-2360-106 Crown 2016 PF27592
12
SAFETY
Fig. 7 (30732)
1 B+ terminals
2 B- terminals
Crown 2016 PF27592 MA-2360-107
13
SAFETY
Warnings
Warnings
Warnings
The following symbols help you to assess the risk to
yourself, other people and materials if you fail to com-
ply with a safety notice:
DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death could happen.
 Follow all instructions indicated by this symbol
in order to avoid injury or death.
WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death could result.
in order to avoid injury or death.
CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury could result.
in order to avoid injury.
CAUTION
This signal word without a symbol warns of
material damage.
Damage to the vehicle, tools and mechanisms could
arise.
 Follow all instructions indicated by this signal word
to avoid material damage.
MA-2460-001 Crown 2016 PF27603 Rev. 7/17
01 Rev. 7/17
14
SAFETY
Transport and Storage
Transport and Storage 6. Guide the lifting belt (2) behind the castor wheels
under the chassis.
Lifting the Vehicle 7. Attach the lifting belts to the crane hook.
8. Position the crane hook above the vehicle so that
the vehicle does not swing when lifted.
WARNING 9. Raise the vehicle carefully.
Falling loads can cause fatal injuries
Fatal injuries can occur if the vehicle or crane crash or
Lifting the vehicle with a forklift
if a load falls. truck
 Make sure that the crane, lifting truck and load han-
dling attachments used have the required capacity.
Information on the required capacity can be found
on the vehicle data plate.
 When using the load handling equipment, refer to 3
the manufacturer’s operating instructions. Pay par-
ticular attention to the load handling equipment’s
capacity and static coefficients (safety factor). 2 1
 Make sure that the components used as strap
points are securely attached to the entire vehicle. >7
50
Lifting the vehicle with a crane Fig. 9 Lifting the vehicle with a forklift truck
1 Tensioning belt
2 Forks of the truck doing the lift-
ing
2 1 3 Tensioning belt
1. Lower the platform fully.

2. Switch off the vehicle and remove the key.
3. Apply the Emergency Disconnect.
4. On the truck performing the lifting, use the maxi-
mum fork spread possible — at least 750 mm.
5. Position the forks (2) underneath the vehicle (see
Fig. 9). The fork tips must extend at least 100 mm
beyond the vehicle.
6. Secure the vehicle with a tensioning belt (1) on the
fork tine positioned below the load deck. Guide the
tensioning belt (1) diagonally under the fork tine
Fig. 8 Lifting the vehicle with a forklift truck (dotted line) and above the load deck (continuous
1 Lifting belt line).
2 Lifting belt 7. Further secure the vehicle with a tensioning belt (3)
on the fork carriage, load backrest or the mast of
1. Lower the platform fully. the truck performing the lifting.
2. Switch off the vehicle. Remove the key. 8. Raise the vehicle carefully.
4. Choose the length of the lifting belts so that the ve-
hicle remains horizontal when raised.
5. Guide the lifting belt (1) between the drive wheels
and the bumper under the chassis.
Crown 2016 PF27602 MA-2460-025
15
SAFETY
Lifting the Vehicle
Loading the vehicle onto a pallet
1 2
Fig. 10 Vehicle on a pallet

1 Forklift truck
2 Pallet

2. Bring a suitable pallet (2) up to the vehicle.
3. Drive the vehicle over a small ramp onto the
pallet (2).
5. Apply the Emergency Disconnect switch.
6. Prevent all wheels from rolling and slipping.
7. Use a forklift truck (1) to remove the pallet from the
platform side of the vehicle.
MA-2460-026 Crown 2016 PF27602
16
SAFETY
Securing the Vehicle for Transport on a Truck Bed
Securing the Vehicle for Trans- 4. Apply the Emergency Disconnect.

5. Place the wooden block (4) on the platform. It must
port on a Truck Bed be high enough so that the tensioning belt (1)
The vehicle must be adequately protected against slip- routed over it does not damage the plastic parts of
ping and tipping over when being transported on a the vehicle.
truck bed. 6. Insert the tensioning belt (1) in the fastening
eyes (3) and pull them taut.
7. For vehicles with a manual load tray, secure the
CAUTION folded load tray with a tensioning belt to the top rail.
This action prevents damage during transport.
An incorrectly secured vehicle can cause acci-
dents Chocking the vehicle with wedges
Vehicles that are not adequately protected from slip- 1. Chock the vehicle with at least eight wedges (2) on
ping and tipping over during transport can damage the the truck bed (see Fig. 11).
load and cause accidents. 2. Secure all wedges (2) to the truck bed (for exam-
 You must be trained and authorised to load the ve- ple, by nailing them).
hicle.
 Load securing measures must be applied and as-
sessed correctly in each individual case.
 Ensure that the tensioning belts used are taut.
 Prevent the tensioning belts from becoming slack
or loosening on their own.
Note: If the vehicle is being transported on an open

truck bed, secure the load deck so that it will not be
lifted off by the airflow.
1 3
Fig. 11 Securing the vehicle

1 Tensioning belt
2 Wedge
3 Fastening Eye
4 Wooden block
5 Tensioning belt
Clamping the vehicle

1. Park the vehicle on the truck bed.
3. Switch off the vehicle. Remove the key.
Crown 2016 PF27602 MA-2460-027
17
SAFETY
Towing the Vehicle
Towing the Vehicle

WARNING
Preparatory measures Incorrect towing and the use of unsuitable equip-
1. Fully lower the platform. There are three methods ment can result in fatal accidents
to do so:  The capacity of the towing truck must be at least
– using the key on the platform half the weight of the vehicle including the battery.
– from the service panel Information on weights can be found on the vehicle
– using the manual lowering valve. data plate.
 Make sure that the vehicle in need of repair does
not slide off the forks of the towing truck.
CAUTION
1 2 Avoid damaging the drive wheels
When the vehicle is de-energised, the brakes are ap-
plied to the drive wheels. If the drive wheels drag along
the ground while the vehicle is being towed, the drive
wheels get damaged.
Fig. 12 Service panel
 Make sure that the drive wheels do not touch the
1 Platform/Base toggle switch
ground as the vehicle is being towed.
2 Raise/Lower switch
Lowering the platform from the service panel

1. Fold out the service panel.
2. Press the Platform/Base toggle switch (1) to the
“Base” position.
3. Press the Raise/Lower switch (2) to the “Lower”
position.
1
 The platform lowers.
Note: The platform can only be moved again using the
buttons on the platform if the toggle switch (1) is set to
“Platform”.
2
Lifting the vehicle and pulling it with
another forklift truck Fig. 13 Towing the vehicle
1 Forks of the towing truck
A de-energised vehicle can be towed over short dis-
2 Drive wheel
tances using a second truck. The de-energised vehicle
must be raised slightly to prevent the braked drive
Towing the vehicle
wheel from dragging along the floor.
1. Position the forks (1) of the towing truck under-
neath the vehicle (see Fig. 13). Take care not to
damage the drive wheels (2).
2. Raise the vehicle until the drive wheels (2) are no
longer in contact with the ground.
3. Pull the vehicle slowly. Travel around slight bends
only.
MA-2460-028 Crown 2016 PF27602
18
SAFETY
Towing the Vehicle
Releasing the brake and pushing the

vehicle
WARNING
Accident risk when pushing a vehicle without
brakes
 Push the vehicle only on horizontal surfaces that
are free of potholes and obstacles.
 Do not allow anyone on the vehicle.
 Do not push faster than 3 km/h.
Fig. 14 Service panel

1 Push/Drive toggle switch
Releasing the brake

1. Fold out the service panel.
2. Press the Push/Drive toggle switch (1) to the
“Push” position.
 The brake is released.
Pushing the vehicle
1. Do not push the vehicle at more than 3 km/h.
2. Steer the vehicle by pushing it sideways at the front
(where the castor wheels are).
Applying the brake again
1. Press the Push/Drive toggle switch (1) to the
“Drive” position.
 The brake is applied.
2. Fold in the service panel.
Crown 2016 PF27602 MA-2460-029
19
SAFETY
Jacking up the Vehicle
Jacking up the Vehicle
WARNING
Accident risk by incorrect jacking procedures
Incorrect jacking procedures, for example, due to the
use of unsuitable equipment, can result in fatal acci-
dents.
 Make sure that the jack has sufficient capacity. In-
formation on weights can be found on the vehicle
data plate.
 Never place your hands or other parts of your body
under the vehicle before it has been supported.
 Always support a raised vehicle with wooden
blocks or other suitable equipment to relieve the
jack.
 Only jack up the vehicle so far as to raise the
wheels off the ground. Any further lifting increases
the risk of tip over.
1 1
Fig. 15 Jacking up the vehicle

1 Hard wooden block
Jacking up the vehicle

2. Switch off the vehicle. Remove the key.
4. Position the jack approximately in the middle of
one side of the vehicle. Raise the vehicle until the
wheels on this side are clear of the ground.
5. Place hard wooden blocks (1) underneath as illus-
trated and lower the vehicle onto them.
6. Carry out this process again to lift and support the
other side of the vehicle.
MA-2460-030 Crown 2016 PF27602
20
SAFETY
Placing the Vehicle in Storage
Placing the Vehicle in Storage

Vehicles not used for more than three months must be
placed in storage.
Taking the vehicle out of service
4. De-commission the battery in accordance with the
manufacturer‘s instructions.
5. Clean the vehicle. See the SAFETY / Cleaning of
Material Handling Equipment in the Service and
Parts Manual.
6. Have the vehicle lubricated by service engineers in
accordance with the service manual.
7. Store the vehicle in a dry room with constant tem-
perature and air humidity.
Do not park the vehicle in the open air or in a humid
environment.
8. The surfaces of vehicles subjected to harsh ambi-
ent conditions such as saline atmosphere must be
treated with suitable preservatives to prevent cor-
rosion.
9. Cover the vehicle with an air-permeable material to
protect against dust. Do not use plastic sheets as
condensation could form.
10. Jack up the vehicle to prevent the wheels from flat-
tening. See the SAFETY / Jacking up the vehicle
section.
Crown 2016 PF27602 MA-2460-031
21
SAFETY
Restoring the Vehicle to Service
Restoring the Vehicle to Service

Carry out the following steps to restore the vehicle to
service after a period of storage:
1. Remove the anti-corrosion agent where neces-
sary.
2. Lift the vehicle, remove the hard wooden blocks
and lower the vehicle.
3. Charge the battery or install a charged battery.
4. Connect the battery.
5. Carry out the daily safety check.
MA-2460-032 Crown 2016 PF27602
22
INTRODUCTION
23
INSPECTION AND LUBRICATION
Notes:
24
INTRODUCTION
Commission
Commission pears if the drive motor temperature is below -12°C

(10°F).
Commissioning the Vehicle into 1. Check the battery state of charge and charge the
battery if necessary.
Service 2. Complete the Pre-Delivery Inspection Report
For vehicle commissioning, carry out the following SF2964. See Figure 16.
steps:
Note: Do not turn on the vehicle if the drive motor tem-
perature is below -12°C (10°F). Service code 49 ap-
New Bremen, Ohio 45869 USA

Tel: 419-629-2311
Pre-Delivery
Inspection Report
Date Dealer Code Model Number of Unit Serial Number
Serviceman’s Signature Model Number of Attachment Serial Number
OK Code OK Code OK Code

1. Battery Checks 4. Steering System 8. Lift Structure
A. Speciﬁc Gravity All Units Stackers/Uprights
B. Voltage A. Steering Operation A. Lift Chains Adj.
C. Polarity B. Steering Stops B. Carriage
C. Steer Tires C. Shimming
2. Electrical System Units with Power Steering D. Latch Operation
A. Visual Inspection D. Steer Chain Tension E. Forks
B. Contactors E. Steering Pump Pallet Trucks
C. Drive Motor F. Steering Hydraulic Pressure F. Fork Adjustment
D. Pump Motor G. Pallet Entry
E. Switches 5. Brake System
F. Terminals (Tightened) All Units 9. Lubrication
G. Short and Ground Test A. Parking Brake A. All Pivot Points
H. Battery Connector B. Brake Operation B. Wheels & Rollers
I. Cable Routing C. Brake Switch Adj. C. Channels
J. Built in Charger D. Brake Drums (Tight) D. Lift Chains
K. Charger Cord
6. Hydraulic System 10. General
3. Electrical Operation A. Oil Level A. Load Backrest
All Units B. Hydraulic Lines & Routing B. Overhead Guard
A. Horn C. Hydraulic Fittings C. Battery Retainers
B. Directional Control D. Hydraulic Pump D. Battery Covers
C. Brake Switch E. Relief Valve E. Sheet Metal Alignment
D. Battery Discharge Indicator F. Cylinders F. Paint
E. Hour Meter G. Control Valves G. Skid Resistant Materials
Units with SCR H. Control Linkage H. Decals
F. Creep Speed I. Nameplate
G. Acceleration 7. Drive
H. 1 A Time A. Oil Level 11. Attachment
I. Plugging B. Leaks A. Operation
J. PMT (Fault Detector) C. Drive Tires B. Controls
C. Leaks
Required Attention Code
Leaks L
Loose (Needs tightening) T
Missing M
Damaged D
Shorted S
Noisy N
Comments:
Attach this report to the installation report and submit both to New Bremen.
SF2964 Rev. 10-11 Original to Crown / Yellow Copy to Dealer Printed in U.S.A.
Fig. 16 (30509)
Crown 2016 PF27542 ITD-2460-100
25
INTRODUCTION
Introduction
Introduction
This manual is for qualified service technicians who
have been appropriately trained to do troubleshooting
and maintenance procedures on the vehicle. The man-
ual contains information about maintenance, trouble-
shooting, and replacement parts.
Operator instructions
Operator instructions ensure that you and your person-
nel know how to operate your Crown vehicle safely.
These instructions are provided in tag or booklet form
with each vehicle and are not included in this manual.
More copies can be ordered if necessary. For operator
instructions, see the WAV60 Series Operator Manual.
Operator training
Crown has operator training programs that are availa-
ble through your Crown dealer. For more information
on operator training, consult your Crown dealer or visit
the “Safety and Training” page on www.crown.com.
Service training
Service training is available for:
• All Crown forklift trucks
• Module systems
• Hydraulic systems
• Electrical systems
For more information on service training, consult your
Crown dealer or visit the “Safety and Training” page on
www.crown.com.
Replacement parts
To ensure correct and fast service, always provide the
following information when contacting Crown for
replacement parts:
• The part number
• The vehicle model number
• The vehicle serial number
• The vehicle data number
Consult your Crown dealer or go to
www.crown.com for:
• Current service manuals
• Current operator manuals
• Operator and service training
• Vehicle capacities
• Vehicle specifications
ITD-2360-001 Crown 2016 PF27474 Rev. 6/17
02 Rev. 6/17
26
INTRODUCTION
Introduction
Manual structure
This manual contains sections that have maintenance
information and replacement parts. The section
descriptions are as follows:
Service and Parts Pages
Maintenance Replacement Parts
Section Description Section Description

MA Safety 1 Power Unit Parts
M1 Inspection & Lubrication 2 Hydraulic Parts
M1.91 Componentry 3 Drive Unit Parts
M2 Hydraulic System 4 Electrical Parts
M3 Drive Unit 5 Brake Parts
M4 Electrical System 7 Lifting Mechanism Parts
M5 Brake System 8 Cylinder Parts
M7 Lifting Mechanism 9 Platform Parts
M8 Cylinders 10 Accessories
M9 Platform 10.9 Labels and Decals
DIA Schematic Diagrams
HYD Hydraulic Schematic
Data plate
See Figure 1. The data plate (1) is located on the lower
rear section of the fourth stage mast in the operator
compartment. The data plate includes the model num-
ber and vehicle data number. These numbers provide
the following information:
1
• The vehicle model
• The vehicle serial number
• The vehicle data number
• Performance
• Capacity
• Specified vehicle data
Fig. 17 (31250)
Crown 2016 PF27474 Rev. 6/17 ITD-2360-002

02 Rev. 6/17
27
INTRODUCTION
Introduction
ANSI vehicle data plate:
Fig. 18 (30434)
EMEA vehicle data plate:
Fig. 19 (30475)
SAA vehicle data plate:
Fig. 20 (13033-01)
ITD-2360-003 Crown 2016 PF27474 Rev. 6/17
02 Rev. 6/17
28
INTRODUCTION
Introduction
WAV60-118
1 2 3 4
Fig. 21 (30436)
1 Image generator - Work Assist® Vehicle
2 Series update - Significant changes to the product that would not merit a new series number (generation)
3 Version - Characteristic that distinguishes the vehicle from other versions
4 Lift height - 2,995 mm (118 in)
The preceding example of the model number (WAV60- Vehicle data number
118) is a WAV60 series. It is a Work Assist® Vehicle. It
The vehicle data number gives you and your Crown
has a lift height of 2,995 mm (118 in).
dealer the necessary information to select the correct
parts for your Crown vehicle. Special equipment or
modifications can change the vehicle capacity. See the
capacity plate on the back of the fourth stage mast.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
_ 118 D 1 1 _ 1 N _ 1 1 35 1 1 _ 06
Fig. 22 (30437-01)
1 Standard, custom, special (see Standard, Custom, Special table) 9 Strobe (see Strobe table)
2 Lift height, displays lift height dimension, 118=2,997 mm (118 in) 10 Bumpers (see Bumpers table)
3 Design (see Design table) 11 Storage tray (see Storage Tray table)
4 Batteries (see Batteries table) 12 Aisle guide (see Aisle Guide table)
5 Battery charger, 1=30 A 13 Accessory cable (see Accessory Cable table)
6 Cord reel (see Cord Reel table) 14 Travel alarm (see Travel Alarm table)
7 Load tray (see Load Tray table) 15 Worklight (see Worklight table)
8 InfoLink® ready system (see InfoLink® Ready System table) 16 Language (see Language table)
Crown 2016 PF27474 Rev. 6/17 ITD-2360-004

02 Rev. 6/17
29
INTRODUCTION
Introduction
Standard, Custom, Special InfoLink® Ready System
Abbreviation Description Abbreviation Description
_ Standard N No InfoLink®
C Custom M Truck monitor
S Special C Cellular truck monitor
S InfoLink® standard
Design Y InfoLink® advantage
Abbreviation Description
D Domestic Strobe
E Europe Abbreviation Description
A Australia
_ No strobe
1 Strobe
Batteries
Abbreviation Description Bumpers

1 Wet, 180 A Abbreviation Description
2 Wet, 220 A
1 Steel
3 Maintenance-free, 205 A
2 Rubber overmold
Cord Reel
Storage Tray
_ No cord reel
_ No storage
1 Cord reel
1 Storage tray
Load Tray
Aisle Guide
1 Adjustable load tray (stamped)
__ No guidance
2 Adjustable load tray (wire mesh)
35 Actual width
3 Powered load tray (stamped)
4 Powered load tray (wire mesh)
Accessory Cable
5 Adjustable load tray (custom size)
6 Powered load tray (custom size) Abbreviation Description
_ No cable
ITD-2360-005 Crown 2016 PF27474 Rev. 6/17
02 Rev. 6/17
30
INTRODUCTION
Introduction
Accessory Cable Language
1 Cable 25 Estonian
26 Latvian
27 Lithuanian
Travel Alarm
28 Slovakian
29 Croatian
_ No alarm
30 Serbian
1 Alarm
31 Romanian
32 Bulgarian
Worklight 33 Chinese
Abbreviation Description 36 Brazilian Portuguese
_ No light
1 Light
Language
_ No language
01 German
02 French
03 Spanish
04 Dutch
05 Italian
06 English
07 Polish
08 Czech
09 Danish
10 Portuguese
17 Hungarian
18 Finnish
19 Norwegian
20 Swedish
21 Russian
22 Turkish
23 Slovenian
24 Greek
Crown 2016 PF27474 Rev. 6/17 ITD-2360-006

02 Rev. 6/17
31
INTRODUCTION
Introduction
Notes:
ITD-2360-006
02 Rev. 6/17
32
33
Notes:
34
Operator’s Daily Checklist
Operator’s Daily Checklist Because of this, Crown recommends an operator's

daily checklist.
To get the maximum life out of your equipment, ap- Before you perform maintenance on the vehicle, you
proved personnel must follow a planned maintenance must move it to an area where there is sufficient space.
(PM) schedule. Operator input is an important part of a This is to make sure that others are safe and that you
planned maintenance schedule. Operator input can perform the correct maintenance on the vehicle.
decrease the time that the vehicle is not available, help
to schedule planned maintenances and save money. This checklist (PF27556) is available through your
Crown dealer.
WAV60 SERIES OPERATOR’S

WORK ASSIST VEHICLE
DAILY CHECKLIST
Week Beginning 20
Model Serial No.
Shift No.
Note: This check must be made by the vehicle operator daily at the start of the shift. Certain
items listed are not included on some models. Check all applicable to unit noted above.
Vehicle No.
Check () appropriate box OK OK Needs repair or adjustments (give details in comments section).
SUNDAY MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY
DAMAGE -
No Bent, Dented, Broken or Missing Parts OK OK OK OK OK OK OK
LEAKS -
None Inside or Under Vehicle OK OK OK OK OK OK OK
TIRES & WHEELS -
Good Condition OK OK OK OK OK OK OK
LOAD TRAY - Vertical Position Latch,
Storage Position Latch OK OK OK OK OK OK OK
VISUAL CHECKS
CHAINS -
In Place, No Rust OK OK OK OK OK OK OK
BATTERIES - Water Level, Vent
Caps in Place, Leaks & Cleanliness OK OK OK OK OK OK OK
MANUAL OF RESPONSIBILITY -
On Vehicle and Complete OK OK OK OK OK OK OK
SERVICE PANEL -
Closed OK OK OK OK OK OK OK
WARNING LABELS, OPERATOR
MANUAL - In Place and Complete OK OK OK OK OK OK OK
STROBE LIGHT(S) (Optional) -
Operating OK OK OK OK OK OK OK
BATTERY CHARGE - No Abnormal
Light While Charging OK OK OK OK OK OK OK
EMERGENCY POWER DISCONNECT -
(Platform/Service Panel) Cuts Power OK OK OK OK OK OK OK
HORN, DISPLAY LIGHTS, BEEPER -
OK OK OK OK OK OK OK
ALARM(S), TRAVEL, RAISE, LOWER
(Optional) - Sounds OK OK OK OK OK OK OK
MOTOR COVER - Display Flashes,
Alarm Beeps When Pressed Downward OK OK OK OK OK OK OK
STEERING - Is Smooth, No Sticking,
No Excess Play, Travels Straight OK OK OK OK OK OK OK
TRAVEL - All Speed Ranges, Forward/
Reverse, No Unusual Noises, No Sticking OK OK OK OK OK OK OK
OPERATIONAL CHECKS
RAISE/LOWER -
No Hang Up, No Unusual Noises OK OK OK OK OK OK OK
POWERED LOAD TRAY (Optional) - Is
Smooth, No Sticking, No unusual noises OK OK OK OK OK OK OK
BRAKING - Stops Vehicle
Within Safe Distance OK OK OK OK OK OK OK
PARKING BRAKE - Vehicle Won't
Move When Pushed OK OK OK OK OK OK OK
SENSORS - Removing Hand or Foot
Will Stop Vehicle OK OK OK OK OK OK OK
PLATFORM GATES - Won't Elevate
Above 20" With Gate Open. Below 20",
Speed is Slower With Gates Closed Than
With Open. OK OK OK OK OK OK OK
TRAVEL SPEED SWITCH - Travels
Slower in Turtle Position OK OK OK OK OK OK OK
HOUR METER READINGS
(H1, H2, H3, H4)
OPERATOR'S INITIALS
SUPERVISOR'S OK
COMMENTS: (Items needing repair or adjustment)
CAUTION - If the vehicle is found to be in need of repair or in any way unsafe, or contributes to an unsafe condition, the matter shall be reported immediately to the designated authority, and
the vehicle shall not be operated until it has been restored to safe operating condition.
If during operation, the vehicle becomes unsafe in any way, the matter shall be reported immediately to the designated authority, and the vehicle shall not be operated until it has been restored
to safe operating condition.
Do not make repairs or adjustments unless specifically authorized to do so.
Crown 2016 PF27556 Printed in U.S.A.
Fig. 23 (30499)
Crown 2016 PF27536 M1.0-2360-001
35
Lubricants, Aerosols and Service Supplies
Lubricants, Aerosols and when you perform planned maintenance on Crown ve-
hicles.
Service Supplies
See the charts in this section for the recommended list
of lubricants, aerosols and service supplies. Use them
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity
A Gear oil 063002-004 Quarts

B Grease (multi-purpose) 063002-024 14.5 oz cartridge
C Hydraulic oil 063001-001 1 gal
D Chain and cable lube 063001-009 14 oz can
E Synthetic aviation grease 063002-065 1 oz container
Alternate Lubricants and Fluids Chart
Type of Lubricant Product Name Manufacturer/ Distributor
A Gear oil Lubriplate SPO-255 Fiske Bros Refining Co.

Dow Corning BR2-Plus
B Grease (multi-purpose) Dow Corning
(Molykote BR2-Plus)
Mobil DTE 24(1) Mobil Oil Co.
Union Unax AW ISO 32 (1) Union Oil Co.
Shell Tellus 32 (1) Shell
C Hydraulic oil Mobile Hydraulic Oil NUTO- Mobile Oil Co.
H-32 (1)
Chevron AW32(1) Chevron Oil Co.
Sohio Energol HLP32(1) Sohio
Lubriplate Chain and Cable Fiske Bros Refining Co.

D Chain and cable lube
Fluid
E Synthetic aviation grease Mobile Grease 28 Exxon Mobile
(1) Denotes allowable substitutes, consult the factory if unavailable
M1.0-2360-025 Crown 2016 PF27537
36
Planned Maintenance
Planned Maintenance 2. Look for damaged components.

3. Look for loose or missing fasteners.
Overview 4. Look for damaged electrical wires or connectors.
To make sure that your vehicle continues to move Planned Maintenance Information
materials safely and quickly, you must perform regular • Lift trucks operated in standard operating
maintenance on your vehicle. conditions should have planned maintenance
performed at the intervals that follow:
– 180 day / 500 hour
CAUTION – 12 month / 2,000 hour
Injury or material damage can occur. • Lift trucks operated in environments such as those
If you operate a vehicle that is unsafe or needs repair, below, require the intervals to be adjusted. Consult
injury or material damage can occur. an authorised Crown dealer to determine the
 Do not operate the vehicle until the vehicle is safe. proper interval for the environment.
 Immediately make a report of the condition to the – Freezer
applicable authority. – Outdoor
 Do not carry out repairs or adjustments on the vehi- – Extremely dusty
cle unless you are approved to do so. – Corrosive
• Use the applicable planned maintenance
inspection report (PF27056) to record
maintenance.
CAUTION • Consult your Crown dealer for planned
maintenance inspection reports.
Injury or material damage can occur.
If you do not correctly prepare the vehicle for Lubrication
maintenance, injury or material damage can occur. The following information gives the correct
 Complete all lockout/tagout procedures. See specifications for lubrication. Use high-grade lubricants
SAFETY / Control of Hazardous Energy. and fluids. See the charts in this section for the
 Obey all safety instructions. See the SAFETY applicable lubricants.
section. Component Access
This section includes components that you must open,
Complete the Operator’s Daily Checklist. See remove or access when you perform maintenance on
INSPECTION AND LUBRICATION / Operator’s Daily the vehicle.
Checklist.
Preparing the vehicle for maintenance
1. Move the vehicle to a maintenance area with a
level floor.
2. Turn off the vehicle.
3. Put chocks against the wheels.
4. Disconnect the battery.
5. Lockout/tagout the vehicle.
6. Release the capacitance voltage in Access 2/3 and
Access 3™. See SAFETY / Control of Hazardous
Energy / Capacitance.
7. Clean the vehicle with weak, dry compressed air.
Inspecting the vehicle
1. Look for unwanted material in or around the
vehicle components.
Crown 2016 PF27540 Rev. 4/18 M1.0-2360-050

01 Rev. 4/18
37
Planned Maintenance
7
12
24
5 4
1
25 6
9 23
13
14
11
18
16
6
2
10
15 11 Solenoid valve (SVL)
3 12 Fuses (F3, F4, F5, F6, F7, F8)

8
13 Motorised load tray circuit breaker
(CB1)
17
21 22 14 Connectors (CA601 and CA602)
15 Emergency disconnect switch (EDS2
19 1 Load deck and EDS4)
2 Service Panel 16 Push and drive switch (DTS)
20
3 Chassis 17 Front strobe light (CHSLF)
4 Rear cover 18 Circuit board for the indicator lights
5 Hydraulic motor (M3) 19 Elevation control switch (ECS)
6 Batteries 20 Emergency raise and lower switch
7 Contactor panel (ERLS)
8 Battery charger 21 Access 2/3 controller
9 Horn (HN) 22 Access 3™ controller
10 Travel signal (ALM2) 23 Fuses (F1 and F2)
Fig. 24 (30543)
M1.0-2360-051 Crown 2016 PF27540
38
Planned Maintenance
Chassis
Remove the load deck to access:
• Access 2/3
• Fuse (F1)
• Access 3™
• Fuse (F2)
• Batteries
• Battery charger
• Switch to select the type of battery being charged
(wet cell or sealed)
• Contactor panel
• Circuit breaker for the motorised load tray (CB1),
optional
• Connectors (CA601 and CA602)
• Fuses (FU3, FU4, FU5, FU6, FU7 and FU8)
• Line contactor (L)
• Relays (K1, K2, K5 and K6)
• Horn (HN)
• Hydraulic unit assembly
• Hydraulic motor (M3)
• Reservoir
• Solenoid valve (SPL)
• Travel signal (ALM2)
Remove the service panel to access:
• Elevation control switch (ECS)
• Emergency disconnect switch (EDS2 and EDS4)
• Emergency raise and lower switch (ERLS)
• Front strobe light (CHSLF), optional
• Indicator lights that show the status of the battery
charging cycle
• Push and drive switch (DTS)
• Status light
Crown 2016 PF27540 M1.0-2360-052
39
Planned Maintenance
2
3 1 Rear chassis cover
2 Traction motor assemblies
3 Gear box
4 Motor cover switches (MCS1-
4 MCS4)
5 Brakes (BRK1 and BRK2)
3 5 6 Chain slack switches (CHS3

and CHS4)
4
Fig. 25 (30544)
M1.0-2360-053 Crown 2016 PF27540
40
Planned Maintenance
Remove the rear chassis cover to access: • Motor cover switches in the front and back (MCS1,
• Brakes (BRK1 and BRK2) MCS2, MCS3 and MCS4)
• Chain slack switches (CHS3 and CHS4) • Rear chassis cover
• Left gearbox • Right gearbox
• Left traction motor assembly (M2, CA204, CA205 • Right brake and traction motor assembly (M1,
and CA206) CA201, CA202 and CA203)
• Lift chain anchor
4
3
5
2 11
1
1 Load tray
9
2 Platform
3 Traction pod
4 Mast cap
6
5 Steering pod
6 Foot brake switches
7 Mast height switches
12 (HGTS20, HGTS84 and
HGTS118)
8 Front strobe light (CHSLF)
9 Gate switches (GOSR,
GCSR, GOSL, and GCSL)
10 Floorboard
10
11 Platform strobe lights (PLSL1
and PLSL2)
7
12 Worklights (LGT1 and LGT2)
Fig. 26 (30545)
Platform and third stage mast • Raise switch (RAS)

• Right-hand proximity sensors (RHS)
Remove the mast cap to access:
• Worklights (LGT1 and LGT2)
• Yoke assembly
Remove the traction control pod to access:
• Access 1 display module
• Emergency disconnect switches (EDS1 and EDS3)
• Indicator light for the right-hand sensor (LED1)
• Horn switch (HNS)
• Lower switch (LOS)
• Potentiometer (POT2)
Crown 2016 PF27540 M1.0-2360-054
41
Planned Maintenance
Remove the steering control pod to access:

• High-speed switch (HSS)
• Indicator light for the left-hand sensor (LED2)
• Key switch (KYS)
• Left-hand proximity sensors (LHS)
• Light switch (LGS)
• Motorised load tray switch (LTS)
• Steering potentiometer (POT1)
• Remove the access panel to access:
Remove the floor mat and floorboard to access:
• Gate alarm (ALM2)
• Lift chain anchor point
• Mast height switches (HGTS20, HGTS84 and
HGTS118)
• Access 4
• Left and right foot brake switches (DMSL and
DMSR)
• Powered load tray relays (K3 and K4)
Remove the gate switch covers to access:
• Left gate closed switch (GCSL)
• Right gate closed switch (GCSR)
• Left gate open switch (GOSL)
• Right gate open switch (GOSR)
M1.0-2360-055 Crown 2016 PF27540
42
Planned Maintenance
L-4
L-9
L-1 Left drive unit

L-2 Right drive unit
L-3 Front axle
L-4 Top 100 mm (4 in) of mast
L-5 Left aisle guide rollers
L-6 Right aisle guide rollers
L-7 Hydraulic reservoir
L-8 Lift chain
L-8
L-9 Powered load tray actuator screw
L-7
L-2
L-6
L-1
L-3 L-5
Fig. 27 (30546)
Crown 2016 PF27540 M1.0-2360-056
43
Planned Maintenance
Lubrication Chart
180 Days 12 Months

Lube
Index Component Quantity
Type
500 Hours 2,000 Hours
150–175 ml
L-1 Left drive unit A Check Change
(5–6 oz)
150–175 ml
L-2 Right drive unit A Check Change
(5–6 oz)
L-3 Front Axle B as required Lubricate
Top 100 mm (4 in)
L-4 B as required Lubricate
of mast
Left aisle guide
rollers
Right aisle guide
rollers
L-7 Hydraulic reservoir C 2.8 l (3 qt) Check Change
L-8 Lift chain D as required Lubricate
Powered load tray 29.6 ml
L-9 E Lubricate
actuator screw (1 oz.)
M1.0-2360-057 Crown 2016 PF27540 Rev. 4/18
01 Rev. 4/18
44
Planned Maintenance
I-13
I-1
I-9
I-11
I-1
I-7
I-6
I-8
I-15
I-1
I-7
I-2
I-14
I-4
I-11
I-10
I-1
I-3
I-5 I-12
I-1 I-8 Battery connector
I-9 Contactor panel
I-1 Electrical (connectors, cables and wi-
I-10 Hydraulic assembly (pump and M3 mo-
ring)
tor)
I-2 Front axle and casters
I-11 Hydraulic reservoir filler cap
I-3 Front and back wheels
I-12 Battery charger
I-4 Service panel
I-13 Dynamic cable tension area
I-5 Front strobe light
I-14 Chassis side covers
I-6 Load deck
I-15 Access 3™ and Access 2/3
I-7 Batteries
Fig. 28 (30623)
Crown 2016 PF27540 M1.0-2360-058
45
Planned Maintenance
Chassis Front Inspection and Adjustment Chart
180 Days 12 Months

Index Component
I-1 Electrical (connectors, cables and wiring) Inspect, clean or adjust=

I-2 Front axle and casters Inspect, clean or adjust=
I-3 Front and back wheels Inspect, clean or adjust=
I-4 Service panel Inspect, clean or adjust=
I-5 Front strobe light, optional Inspect, clean or adjust=
I-6 Load deck Inspect, clean or adjust=
I-7 Batteries Inspect, clean or adjust=
I-8 Battery connector Inspect, clean or adjust=
I-9 Contactor panel Inspect, clean or adjust=
I-10 Hydraulic assembly (pump and M3 motor) Inspect, clean or adjust=
I-11 Hydraulic reservoir filler cap Inspect, clean or adjust=
I-12 Battery charger Inspect, clean or adjust=
I-13 Dynamic cable tension area Inspect, clean or adjust=
I-14 Chassis side covers Inspect, clean or adjust=
I-15 Access 3™ and Access 2/3 Inspect, clean or adjust=
M1.0-2360-059 Crown 2016 PF27540 Rev. 4/18
01 Rev. 4/18
46
Planned Maintenance
I-10
I-9
I-1 Electrical (connectors, cables and

wiring)
I-2 Left drive unit (motor, gearbox and
brake)
I-3 Right drive unit (motor, gearbox and
I-8 brake)
I-1
I-3 I-4 Chain slack switches (CHS1-CHS4)
I-5 Lift chain anchor point
I-7 I-6 Motor cover switches (MCS1-MCS4)
I-11
I-5 I-7 Left rail guidance rollers
I-8 Lift cylinder
I-1 I-9 Right rail guidance rollers
I-6
I-10 Rear chassis cover
I-11 Lift chain compression springs
I-4
I-7
I-6
I-1
I-2
I-1
Fig. 29 (30626)
Crown 2016 PF27540 M1.0-2360-060
47
Planned Maintenance
Back Chassis Inspection and Adjustment Chart
180 Days 12 Months

Index Component

I-2 Left drive unit (motor, gearbox and brake) Inspect, clean or adjust=
I-3 Right drive unit (motor, gearbox and brake) Inspect, clean or adjust=
Chain slack switches (CHS1, CHS2, CHS3
I-4 Inspect, clean or adjust=
and CHS4)
I-5 Lift chain anchor point Inspect, clean or adjust=
Motor cover switches (MCS1, MCS2, MCS3
and MCS4)
I-7 Left rail guidance rollers (optional) Inspect, clean or adjust=
Lift cylinder (for cracks, leakage and secured
to vehicle)
I-9 Right rail guidance rollers (optional) Inspect, clean or adjust=
I-10 Rear chassis cover (in place and secure) Inspect, clean or adjust=
M1.0-2360-061 Crown 2016 PF27540 Rev. 4/18
01 Rev. 4/18
48
Planned Maintenance
I-6 I-4
I-14 I-1 Electrical (connectors, cables and wiring)
I-1 I-2 Traction pod (POT2, HNS, RAS, LOS, EDS1,
I-2 EDS3, RHS, ALM1 and LED1)
I-3 Steering pod (POT1, KYS, HSS, LTS, LGS,
I-7 LED2 and LHS)
I-1 I-4 Platform padding

I-3 I-5 Floorboard mat
I-6 Yoke
I-1 I-7 Load tray
I-15
I-8 Lift chain anchor point for the third stage mast
I-1 I-18 I-9 Dynamic cable tension area
I-12
I-16 I-10 Lift chain
I-11 Lift cylinder
I-8 I-12 Foot brake switches (DMSL and DMSR)

I-5 I-13 Mast lift height switches (HGTS20, HGTS84 and
HGTS118)
I-9
I-1 I-14 Left and right platform gates
I-15 Left and right platform switches (GOSL, GCSL,
I-17 GOSR and GCSR)
I-13 I-16 Worklights (LGT1 and LGT2)

I-1 I-17 Left and right bolsters
I-10 I-18 Floorboard compression springs
I-11
Fig. 30 (30630)
Crown 2016 PF27540 M1.0-2360-062
49
Planned Maintenance
Platform Inspection and Adjustment Chart
180 Days 12 Months

Index Component

Traction pod (POT2, HNS, RAS, LOS, EDS1,
EDS3, LGT1, RHS, ALM1 and LED1)
Steering pod (POT1, KYS, HSS, LTS, LGS,
LGT2, LED2 and LHS)
I-4 Platform padding (wear and tear) Inspect, clean or adjust=
I-5 Floorboard mat (wear and tear or missing) Inspect, clean or adjust=
Yoke (wear and cracks and bolts properly
torqued)
I-7 Load tray (damage and secured to vehicle) Inspect, clean or adjust=
I-8 Lift chain anchor point for the third stage mast Inspect, clean or adjust=
I-9 Dynamic cable tension area Inspect, clean or adjust=
Lift chain (tension, wear and broken or
cracked links)
I-11 Lift cylinder (leaks and cracks) Inspect, clean or adjust=
I-12 Foot brake switches (DMSL and DMSR) Inspect, clean or adjust=
Mast lift height switches (HGTS20, HGTS84
and HGTS118)
I-14 Left and right platform gates (operation) Inspect, clean or adjust=
Left and right platform switches (GOSL,
GCSL, GOSR and GCSR)
I-16 Platform springs (cracked and missing) Inspect, clean or adjust=
Left and right bolsters (cracks and secured to
vehicle)
M1.0-2360-063 Crown 2016 PF27540 Rev. 4/18
01 Rev. 4/18
50
Metric Torque Values

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

Specification
(on Head) Size (mm)
5.8 Class 5.8 M5 to M36
8.8 Class 8.8 M5 to M36
10.9 Class 10.9 M5 to M36
12.9 Class 12.9 M5 to M36
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8
in all its bolted assemblies. Instances do occur when class 8.8 bolts are manufactured
unmarked. When a fastener is replaced that is unmarked, replace the fastener with a
class 8.8.
Fig. 1 (15048-01)
Crown 1989 PF8514 Rev. 2/16 M1.9-06.6-001

05 Rev. 2/16
51
Torque Chart–Metric Hex Head Cap Screws and Nuts
Thread Diameter Torque Nm (ft lb)

and Pitch
Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5–8 (4–6) 7–8 (5–6) 8–10 (6–7)

M6 x 1.00 8–10 (6–7) 12–14 (9–10) 15–16 (11–12)
M8 x 1.25 20–25 (15–18) 28–31 (21–23) 34–37 (25–27)
M10 x 1.50 39–43 (29–32) 56–61 (41–45) 68–75 (50–54)
M12 x 1.75 71–76 (52–56) 100–107 (73–79) 119–127 (88–94)
M14 x 2.00 113–122 (83–90) 159–171 (117–126) 190–205 (140–151)
M16 x 2.00 175–190 (129–140) 247–267 (182–197) 296–320 (218–236)
M20 x 2.50 340 357 (251–271) 479–518 (353–382) 574–621 (423–458)
M24 x 3.00 587–635 (433–468) 824–892 (608–658) 990–1071 (730–790)
M30 x 3.50 1175–1274 (867–940) 1654–1792 (1220–1322) 1985–2150 (1464–1586)
Note: Special torque values in the maintenance and parts sections of this manual override the standard
Torque Chart–Metric Hex Socket Countersink Head Screws

and Pitch
M5 x 0.80 4–7 (3–5) 5–8 (4–6) 7–10 (5–7)

M6 x 1.00 7–10 (5–7) 9–12 (7–9) 11–14 (8–10)
M8 x 1.25 16–19 (12–14) 23–26 (17–19) 27–30 (20–22)
M10 x 1.50 31–34 (23–25) 45–49 (33–36) 54–58 (40–43)
M12 x 1.75 56–60 (41–44) 79–84 (58–62) 94–102 (69–75)
M14 x 2.00
M16 x 2.00 124–146 (99–108) 190–206 (140–152) 228–247 (168–182)
M20 x 2.50 259–281 (191–207) 363–395 (268–291) 437–473 (322–349)
M24 x 3.00 416–451 (307–333) 586–635 (432–468) 702–762 (518–562)
M30 x 3.50
M1.9-06.6-002 Crown 1989 PF8514 Rev. 2/16
05 Rev. 2/16
52
Torque Chart–Metric Socket Head Cap Screws

and Pitch
M5 x 0.80 5–8 (4–6) 7–9 (5–7) 8–11 (6–8)

M6 x 1.00 9–12 (7–9) 12–15 (9–11) 15–18 (11–13)
M8 x 1.25 22–24 (16–18) 30–33 (22–24) 35–38 (26–28)
M10 x 1.50 42–45 (31–33) 58–64 (43–47) 71–76 (52–56)
M12 x 1.75 72–77 (53–57) 102–110 (75–81) 122–132 (90–97)
M14 x 2.00 115–125 (85–92) 161–175 (119–129) 194–210 (143–155)
M16 x 2.00 179–194 (132–143) 251–273 (185–201) 301–327 (222–241)
M20 x 2.50 348–377 (257–278) 489–530 (361–391) 588–637 (434–470)
M24 x 3.00 601–651 (443–480) 846–915 (624–675) 1014–1098 (748–810)
M30 x 3.50 1196–1296 (882–956) 1681–1822 (1240–1344) 2017–2187 (1488–1613)
Torque Chart–Metric Flanged Hex Head Cap Screws and Nuts

and Pitch
M5 x 0.80 5–8 (4–6) 8–11 (6–8) 9–12 (7–9)

M6 x 1.00 9–12 (7–9) 14–16 (10–12) 16–19 (12–14)
M8 x 1.25 22–24 (16–18) 31–34 (23–25) 38–41 (28–30)
M10 x 1.50 44–48 (33–35) 62–68 (46–50) 75–81 (55–60)
M12 x 1.75 77–83 (57–61) 108–117 (80–86) 130–141 (96–104)
M14 x 2.00 123–134 (91–98) 174–187 (128–138) 209–225 (154–166)
M16 x 2.00 193–210 (143–155) 273–294 (201–217) 327–354 (241–2610)
Crown 1989 PF8514 Rev. 2/16 M1.9-06.6-003

05 Rev. 2/16
53
SAE Torque Values
SAE Torque Values

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

Specification
(on Head) Size (in)
SAE - Grade 2 1/4 through 1-1/2
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all its bolted
assemblies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is
replaced that is unmarked, replace the fastener with a Grade 5.
Fig. 1 (14916-02)
M1.9-14.0-001 Crown 1979 PF5067 Rev. 2/16
06 Rev. 2/16
54
SAE Torque Values
Torque Chart
Bolt Grade 5 Grade 8

Diameter
Dry Torque Specification Dry Torque Specification
in ft Ib kg-m Nm ft lb kg-m Nm
1/4 9±3 1.2 ± 0.4 12 ± 4 13 ± 4 1.8 ± 0.5 17.5 ± 5.5

5/16 18 ± 5 2.5 ± 0.7 24.5 ± 7 25 ± 5 3.5 ± 0.7 34 ± 7
3/8 32 ± 5 4.4 ± 0.7 43.5 ± 7 48 ± 10 6.6 ± 1.3 65 ± 13.5
7/16 50 ± 10 6.9 ± 1.4 67.5 ± 13.5 75 ± 10 10.4 ± 1.4 102 ± 13.5
1/2 75 ± 10 10.4 ± 1.4 101.5 ± 13.5 112 ± 15 15.5 ± 2.0 152 ± 20.5
9/16 110 ± 15 15.2 ± 2.0 149 ± 20.5 163 ± 20 22.5 ± 3.0 221 ± 27
5/8 150 ± 20 20.7 ± 2.8 203.5 ± 27 225 ± 30 31.1 ± 4.1 305 ± 41
3/4 265 ± 35 36.6 ± 4.8 359 ± 47.5 400 ± 50 55.2 ± 6.9 542 ± 68
7/8 420 ± 60 58.1 ± 8.3 569 ± 81 640 ± 80 88.3 ± 11.0 868 ± 108
1 640 ± 80 88.5 ± 11.1 868 ± 109 960 ± 115 132.5 ± 15.9 1300 ± 156
1 1/8 800 ± 100 110.6 ± 13.8 1085 ± 136
1 1/4 1000 ± 120 138 ± 16.6 1356 ± 163
1 3/8 1200 ± 150 166 ± 20.7 1630 ± 203
1 1/2 1500 ± 200 207 ± 27.7 2034 ± 271
Torque specifications for bolts related to
hydraulic valves.
5/16 13 ± 2 1.8 ± 0.3 17.5 ± 2.5

3/8 24 ± 2 3.3 ± 0.3 32.5 ± 2.5
7/16 39 ± 2 5.4 ± 0.3 53 ± 2.5
NOTE: Special torque values in the maintenance and parts sections of this manual over-
ride the standard torque values in this section.
Crown 1979 PF5067 Rev. 2/16 M1.9-14.0-002

06 Rev. 2/16
55
SAE Torque Values
Notes:
M1.9-14.0-002
06 Rev. 2/16
56
COMPONENTRY
57
Notes:
58
COMPONENTRY
Componentry and Connectors
Componentry and Connectors

Overview
Components listed in this section help the service tech-
nician find the following information for each compo-
nent:
• Component designator (for example, ALM2) that
appears on the electrical diagram and parts pages.
• Description of the component.
• Location of the component on the vehicle.
• Function of the component.
• Technical data of the component.
• Adjustments required, if applicable.
• Electrical diagrams on which the component ap-
pears. Two numbers immediately follow the page
number. The first number in parentheses is the grid
coordinate, and the second number in parentheses
is the manual page number. For example, DIA-
2360-002 (A-2) (474).
• Parts pages on which the component appears. Two
numbers immediately follow the page number. The
first number in parentheses is the component index
number, and the second number in parentheses is
the manual page number. For example, 04.8-2360-
001 (3) (36).
Crown 2016 PF27559 Rev. 10/16 M1.91-2360-001

01 Rev. 10/16
59
COMPONENTRY
Access 1
Access 1 Adjustment: If the module is replaced, a complete ve-

hicle calibration is recommended to prevent nuisance
Display Module codes. Also, if the replacement module includes up-
Location: On the traction pod. dated software, the software in the remaining modules
must be updated so all software is compatible.
Function: Shows the applicable vehicle information
(for example, battery charge, hours of operation). Diagrams: DIA-2360-002 (B-2) (474)
DIA-2360-007 (A-3) (479).
Data: Receives input from these components:
Parts breakdown: 04.0-2360-003 (20) (26)
– CAN 04.8-2360-800 (58).
– DTS
– FU3 Access 3™
Adjustment: If the module is replaced, a complete ve- Left Traction Control Module
Location: On the chassis.
codes. Also, if the replacement module includes up-
dated software, the software in the remaining modules Function: Controls these components:
must be updated so all software is compatible. – ALM2
Diagrams: DIA-2360-002 (A-2) (474) – BRK1
DIA-2360-003 (B-1) (475). – BRK2
Parts breakdown: 04.6-2360-001 (3) (36). – CHSL
Access 2/3 – ECR2
– K2
Right Traction Control Module – K6
Location: On the chassis. – M2
Function: Controls these components: – TS2
– BRK1 Data: Receives input from these components:
– BRK2 – CAN
– ECR1 – FU2
– HN1 Adjustment: If the module is replaced, a complete ve-
– L hicle calibration is recommended to prevent nuisance
– M1 codes. Also, if the replacement module includes up-
– M3 dated software, the software in the remaining modules
– SPL
Diagrams: DIA-2360-002 (A-2) (474)
– TS1 DIA-2360-005 (B-3) (477)
Data: Receives input from these components: DIA-2360-007 (A-1) (479).
– Battery charger Parts breakdown: 04.0-2360-003 (21) (26)
– CAN 04.8-2360-800 (58).
– CHS3,CHS4
– ECS
– ERLS
– FU1
– MCS1, MCS2, MCS3, MCS4
– SPS
– TLTS
M1.91-2360-002 Crown 2016 PF27559
60
COMPONENTRY
Access 1
Access 1
Access 3™
Access 2/3
Fig. 2 (30620)
Crown 2016 PF27559 M1.91-2360-003
61
COMPONENTRY
Access 4
Access 4 Data: Access 1 supplies a ground to ALM1. See the

UTILITIES output to ALM1 in the U2.3 menu.
Vehicle Control Module Adjustment: N/A.
Location: On the platform. Diagrams: DIA-2360-002 (A-2) (474)
Function: Controls these components: DIA-2360-003 (B-1) (475).
– ECR3 Parts breakdown: N/A.
– ECR4
ALM2
– K3
– K4 Travel Alarm
Data: Receives input from these components: Location: On the chassis.
– ALM3 Function: Alerts the pedestrians of the vehicle move-
ment.
– CAN
Data: Access 3™ supplies a ground ALM2. See the
– CHS1
Access 3™ output to ALM2 in the A3.8 ALM2 menu.
– CHS2
Adjustment: Triangular cord (77/87/97 dB) adjusts the
– DMSL decibel level.
– DMSR Diagrams: DIA-2360-002 (A-2) (474)
– GCSL DIA-2360-005 (C-4) (477)
– GCSR DIA-2360-006 (C-2) (478).
– GOSL Parts breakdown: 04.0-2360-003 (32) (26).
– GOSR
ALM3
– HGTS20, HGTS84, HGTS118
– HNS Gate Alarm
– HSS Location: On the platform.
– LHS Function: Alerts the operator to close the gate.
– LMS1, LMS2 Data: Access 4 supplies a ground to ALM3. See the
Access 4 output to ALM3 in the A4.28 ALM3 menu.
– LOS
Adjustment: N/A
– LTS
Diagrams: DIA-2360-002 (B-4) (474)
– PLSL1, PLSL2
DIA-2360-003 (C-4) (475).
– RHS
Parts breakdown: 04.0-2360-050 (11) (28)
– RAS 09.0-2360-001 (14) (82).
Adjustment: If the module is replaced, a complete ve-
codes. Also, if the replacement module includes up-
dated software, the software in the remaining modules
Diagrams: DIA-2360-002 (A-1) (474)
DIA-2360-003 (A-4) (475).
Parts breakdown: 04.0-2360-050 (7) (28)
09.0-2360-001 (19) (82).
ALM1
Status Alarm
Location: On Access 1.
Function: Gives an audible indication of messages for
the operator.
M1.91-2360-004 Crown 2016 PF27559
62
COMPONENTRY
Access 4
ALM3
ALM2
ALM1
Access 4
Fig. 3 (30621)
Crown 2016 PF27559 M1.91-2360-005
63
COMPONENTRY
ANSI AC Inlet
ANSI AC Inlet Adjustment: See the Brake section of the service

manual.
Vehicle AC Inlet Diagrams: DIA-2360-002 (B-1) (474)
Location: On the service panel. DIA-2360-005 (B-2) (477)
Function: Provides a power source for the battery DIA-2360-006 (A-3) (478).
charger. Parts breakdown: 05.0-2360-001 (1) (63).
Data: 125 V.
CB1 Optional
Adjustment: N/A.
Diagrams: N/A. Load Tray Circuit Breaker
Parts breakdown: 04.8-2360-001 (3) (42). Location: On the contactor panel.
Function: Interrupts the current flow after the relays
Battery Charger detect overcurrent.
Battery Charger Data: EE ratings: 48 Vdc for a 4–12 A rated part.
32 Vdc for a 12–16 A rated part.
Location: On the chassis.
Adjustment: N/A.
Function: Charges the battery.
Diagrams: DIA-2360-002 (C-3) (474)
Data: Input voltage: 85–265 Vac. DIA-2360-006 (C-4) (478).
Output voltage: 24 Vdc. Parts breakdown: 04.1-2360-001 (11) (32).
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-2) (474) CHSL
DIA-2360-005 (C-2) (477)
Chassis Strobe Light
DIA-2360-007 (B-2) (479).
Location: On the service panel.
Parts breakdown: 04.0-2360-004 (34) (27).
Function: Flashing light keeps the vehicle visible to
BRK1 pedestrians.
Data: 12–80 Vdc, 12–82 mA.
Right Traction Motor Brake
Adjustment: N/A.
Location: On the right traction motor.
Diagrams: DIA-2360-002 (A-2) (474)
Function: Provide brake operation force to the right DIA-2360-005 (B-4) (477)
traction motor to stop the vehicle during a hard brake DIA-2360-006 (B-1) (478).
application. The brake prevents movement when the
vehicle is parked. Parts breakdown: 04.8-2360-003 (31) (44).
Data: 12 Vdc, 17 W.
Adjustment: See the Brake section of the service
manual.
Diagrams: DIA-2360-002 (B-1) (474)
DIA-2360-005 (B-2) (477)
DIA-2360-006 (A-4) (478).
Parts breakdown: 05.0-2360-001 (1) (63).
BRK2
Left Traction Motor Brake
Location: On the left traction motor.
Function: Provides the brake operation force to the left
traction motor to stop the vehicle during a hard brake
application. The brake prevents movement when the
vehicle is parked.
Data: 12 Vdc, 17 W.
M1.91-2360-006 Crown 2016 PF27559
64
COMPONENTRY
ANSI AC Inlet
ANSI AC Inlet
Battery Charger
CHSL
CB1
BRK1
BRK2
Fig. 4 (30622)
Crown 2016 PF27559 M1.91-2360-007
65
COMPONENTRY
CHS1
CHS1 Diagrams: DIA-2360-002 (B-2) (474)

DIA-2360-005 (C-2) (477)
Chain Slack Switch 1 DIA-2360-006 (B-3) (478).
Location: On the platform. Parts breakdown: 07.6-2360-003 (40) (74).
Function: Stops the lower function when the mast
chains become slack. Cord Reel Optional
Data: Connected normally open. See the CHS1 input Battery Charger Cord Reel
in the A4.1 CHS1 menu. Location: On the service panel.
Adjustment: N/A. Function: Housing unit for the power cord.
Diagrams: DIA-2360-002 (A-3) (474) Data: N/A.
DIA-2360-003 (A-3) (475).
Adjustment: N/A.
Parts breakdown: 07.6-2360-001 (4) (72).
Diagrams: N/A.
CHS2 Parts breakdown: 04.8-2360-003 (38) (45).
Chain Slack Switch 2 D1 (Not shown)

Location: On the platform.
Line Contactor Coil
Location: Line contactor coil.
chains become slack.
Function: Suppresses the line contactor coil.
Data: Connected normally open. See the CHS2 input
in the A4.2 CHS2 menu. Data: 400 V DC.
Adjustment: N/A. Adjustment: N/A.
Diagrams: DIA-2360-002 (A-3) (474) Diagrams: DIA-2360-002 (B-3) (747)
DIA-2360-003 (A-3) (475). DIA-2360-006 (C-4) (478)
DIA-2360-007 (A-2) (479).
Parts breakdown: 07.6-2360-001 (3) (72).
Parts breakdown: N/A.
CHS3
Chain Slack Switch 3
Location: In the traction motor compartment.
in the A2.6 CHS3 menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-2) (474)
DIA-2360-005 (B-2) (477)
DIA-2360-006 (B-3) (478).
Parts breakdown: 07.6-2360-003 (40) (74).
CHS4
Chain Slack Switch 4
Location: In the traction motor compartment.
in the A2.7 CHS4 menu.
Adjustment: N/A.
M1.91-2360-008 Crown 2016 PF27559
66
COMPONENTRY
CHS1
Cord Reel
CHS1 CHS2
CHS4
CHS3
Fig. 5 (30624)
Crown 2016 PF27559 M1.91-2360-009
67
COMPONENTRY
D2 (Not shown)
D2 (Not shown) D6 (Not shown)

Blocking diode Blocking Diode
Location: In the contactor panel harness. Location: In the chassis harness.
Function: Limits the current for the K5 coil. Function: Limits the current for the K5 relay.
Data: 200 V. Data: 400 V DC.
Diagrams: DIA-2360-002 (A-2) (474) Diagrams: DIA-2360-002 (A-2) (474)
DIA-2360-006 (C-3) (478) DIA-2360-006 (C-3) (478)
DIA-2360-007 (A-2) (479). DIA-2360-007 (A-2) (479).
Parts breakdown: 04.8-2360-800 (58). Parts breakdown: N/A.

Blocking diode Blocking Diode
Location: In the contactor panel harness. Location: In the chassis harness.
Function: Limits the current for the K5 coil. Function: Limits the current for the K5 relay.
Data: 200 V. Data: 400 V DC.
Diagrams: DIA-2360-002 (A-2) (474) Diagrams: DIA-2360-002 (B-1) (474)
DIA-2360-006 (C-3) (478) DIA-2360-005 (C-2) (477)
DIA-2360-007 (A-2) (479). DIA-2360-006 (B-3) (478).
Parts breakdown: N/A. Parts breakdown: N/A.

Right Brake Coil Suppression Blocking Diode
Location: BRK1 brake coil. Location: In the contactor panel harness.
Function: Suppresses the brake coil. Function: Limits the current for the K1 coil.
Data: 400 V DC. Data: 200 V.
Diagrams: DIA-2360-002 (A-2) (474) Diagrams: DIA-2360-002 (C-3) (474)
DIA-2360-006 (B-4) (478). DIA-2360-006 (C-3) (478).
Parts breakdown: N/A. Parts breakdown: N/A.
D5 (Not shown)
Left Brake Coil Suppression
Location: BRK2 brake coil.
Function: Suppresses the brake coil.
Data: 400 V DC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (A-2) (474)
DIA-2360-006 (B-3) (478).
M1.91-2360-010 Crown 2016 PF27559
68
COMPONENTRY
D9 (Not shown)
D9 (Not shown) Data: 400 V DC.

Adjustment: N/A.
K1 Relay Suppression Diagrams: DIA-2360-002 (B-3) (474)
Location: K1 relay coil. DIA-2360-006 (C-4) (478).
Function: Suppresses the relay. Parts breakdown: N/A.
Data: 400 V DC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-3) (474)
DIA-2360-006 (C-4) (478).
D10 (Not shown)

K2 Relay Suppression
Location: K2 relay coil.
Function: Suppresses the relay.
Data: 400 V DC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-3) (474)
DIA-2360-006 (C-4) (478).
D11 (Not shown)

SPL Coil Suppression
Location: SPL coil.
Function: Suppresses the SPL coil.
Data: 400 V DC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-2) (474)
DIA-2360-006 (B-4) (478).
D12 (Not shown)

Data: 400 V DC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-1) (474)
DIA-2360-006 (C-3) (478).
D13 (Not shown)

Crown 2016 PF27559 M1.91-2360-011
69
COMPONENTRY
DMSL
DMSL Adjustment: N/A.

Diagrams: DIA-2360-002 (B-1) (474)
Left Platform Foot Switch DIA-2360-005 (B-1) (477)
Location: On the platform. DIA-2360-006 (A-4) (478).
Function: Used to detect the position of the operator Parts breakdown: N/A.
on the vehicle.
Data: DMSL is connected normally open. See the ECR2
Access 4 input in the A4.9 DMSL menu. Left Traction Motor Encoder
Adjustment: N/A. Location: On the left traction motor.
Diagrams: DIA-2360-002 (B-3) (474) Function: Provides speed and direction data to the
DIA-2360-003 (C-1) (475). motor controller Access 3™.
Parts breakdown: 04.0-2360-052 (25) (30) Data: -55°C–125°C (-67°F–257°F), 7.5 A.
09.0-2360-150 (2) (88).
Adjustment: N/A.
DMSR Diagrams: DIA-2360-002 (A-1) (474)
DIA-2360-005 (B-3) (477)
Right Platform Foot Switch DIA-2360-006 (A-3) (478).
Location: On the platform. Parts breakdown: N/A.
Function: Used to detect the position of the operator
on the vehicle. ECR3
Data: DMSR is connected normally open. See the Right Traction Motor Encoder
Access 4 input in the A4.8 DMSR menu.
Adjustment: N/A.
Function: Provides speed and direction data to the
Diagrams: DIA-2360-002 (B-3) (474) motor controller Access 3™.
DIA-2360-003 (C-1) (475).
Data: -55°C–125°C (-67°F–257°F), 7.5 A.
Parts breakdown: 04.0-2360-052 (25) (30)
Adjustment: N/A.
09.0-2360-150 (2) (88).
Diagrams: DIA-2360-002 (B-1) (474)
DTS DIA-2360-003 (A-4) (475)
DIA-2360-006 (A-4) (478).
Drive Tow Switch Parts breakdown: N/A.
Function: Releases the brake so that the vehicle can
be towed.
Data: DTS is a two position, ON/ON, lever handle
switch.
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-4) (474)
DIA-2360-004 (A-4) (476)
DIA-2360-006 (C-1) (478).
Parts breakdown: 04.8-2360-001 (15) (42).
ECR1
Right Traction Motor Encoder
Function: Provides speed and direction data to the
motor controller Access 3™.
Data: -55°C–125°C (-67°F–257°F), 7.5 A.
M1.91-2360-012 Crown 2016 PF27559
70
COMPONENTRY
DMSL
EDS2
DTS
DMSR
DMSL
EDS1
EDS3
Fig. 6 (30820)
Crown 2016 PF27559 M1.91-2360-013
71
COMPONENTRY
ECR4
ECR4 Parts breakdown: 04.8-2360-001 (13) (42).
Left Traction Motor Encoder EDS3

Location: On the left traction motor. Emergency Disconnect Switch 3
Function: Provides speed and direction data to the Location: On the traction pod.
motor controller Access 3™.
Function: Pushing the button disconnects the vehicle
Data: -55°C–125°C (-67°F–257°F), 7.5 A. power.
Adjustment: N/A. Data: -20°C–55°C (-4°F–131°F).
Diagrams: DIA-2360-002 (A-1) (474) Adjustment: N/A.
DIA-2360-003 (B-4) (475)
Diagrams: DIA-2360-002 (C-4) (474)
DIA-2360-006 (A-3) (478).
DIA-2360-003 (B-1) (475).
ECS EDS4
Elevation Control Switch
Emergency Disconnect Switch 4
Function: Used for emergency raise and lower func-
tions in the base position (also see ERLS).
power.
Data: ECS is connected normally open. See the
Data: -20°C–55°C (-4°F–131°F).
Access 2/3 input in the A2.4 ECS menu.
Adjustment: N/A.
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-3) (475)
Diagrams: DIA-2360-002 (B-2) (474)
DIA-2360-006 (B-1) (478).
DIA-2360-005 (C-2) (477)
DIA-2360-006 (C-1) (478). Parts breakdown: N/A.
Parts breakdown: 04.8-2360-001 (12) (42).
EDS1
Location: On the traction pod.
power.
Data: -20°C–55°C (-4°F–131°F).
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-4) (474)
DIA-2360-003 (B-1) (475).
Parts breakdown: 04.6-2360-001 (31) (36).
EDS2
power.
Data: -20°C–55°C (-4°F–131°F).
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-3) (474)
DIA-2360-006 (C-1) (478).
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COMPONENTRY
ECR4
ECS
EDS4
ECR1
ECR4
ECR2
ECR3
Fig. 7 (30821)
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COMPONENTRY
ERLS
ERLS DIA-2360-004 (B-1) (476)

DIA-2360-006 (B-4) (478).
Emergency Raise Lower Switch Parts breakdown: 04.1-2360-001 (9) (32).
Function: Allows for maintenance or emergency raise FU4
and lower when ECS is in the base position. K1 Relay Control Wire Fuse
Data: ERLS is connected normally open. See the Location: On the contactor panel.
Access 2/3 input in the A2.2 ERLS menu.
Function: Protects the Access 2/3 and Access 3™
Adjustment: N/A. from overcurrent.
Diagrams: DIA-2360-002 (B-2) (474) Data: 5 A.
DIA-2360-005 (B-2) (477)
Adjustment: N/A.
DIA-2360-006 (C-1) (478).
Diagrams: DIA-2360-002 (C-4) (474)
Parts breakdown: 04.8-2360-001 (11) (42).
DIA-2360-006 (C-4) (478).
FU1 Parts breakdown: 04.1-2360-001 (9) (32).
Access 2/3 Fuse FU5

Location: On the Access 2/3 module.
Access 2/3 I/O Control Wire Fuse
Function: Protects the pump motor and the Access 2/
Location: On the contactor panel.
3 module from overcurrent.
Function: Protects the HN1 and Access 2/3 I/O con-
Data: 300 A.
troller from overcurrent.
Adjustment: N/A.
Data: 5 A.
Diagrams: DIA-2360-002 (C-2) (474)
Adjustment: N/A.
DIA-2360-007 (B-2) (479).
Diagrams: DIA-2360-002 (C-3) (474)
Parts breakdown: 04.8-2360-800 (58).
DIA-2360-006 (C-4) (476).
Access 3™ Fuse
Location: On the Access 3™ module.
Function: Protects the Access 3™ module from over-
current.
Data: 125 A.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-2) (474)
DIA-2360-007 (B-1) (479).
Parts breakdown: 04.8-2360-800 (58).
FU3
Key Switch Control Wire Fuse
Function: Protects the control circuits and the brakes
from overcurrent.
Data: 5 A.
Adjustment: N/A.
Diagrams: DIA-2360-002 (C-4) (474)
DIA-2360-003 (B-1) (475)
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COMPONENTRY
ERLS
FU1
FU2
FU5
FU4
FU3
FU6 FU8
FU7
ERLS
Fig. 8 (30638)
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COMPONENTRY
FU6
FU6 GCSR
Access 3™ I/O Control Wire Fuse Right Gate Closed Switch
Location: On the contactor panel. Location: On the platform.
Function: Protects ALM2, CHSL and the Access 3™ Function: Indicates that the safety gate is closed.
I/O controller from overcurrent. Data: GCSR is connected normally open. See the
Data: 5 A. Access 4 input in the A4.16 GCSR menu.
Adjustment: N/A. Adjustment: See M4.0-2360-050 for adjustment in-
Diagrams: DIA-2360-002 (C-3) (474) structions.
DIA-2360-004 (C-4) (476) Diagrams: DIA-2360-002 (B-3) (474)
DIA-2360-006 (C-3) (478). DIA-2360-003 (B-2) (475).
Parts breakdown: 04.1-2360-001 (9) (32). Parts breakdown: 04.8-2360-100 (3) (48).
FU7 Optional GOSL

Load Tray Fuse Left Gate Open Switch
Location: On the contactor panel. Location: On the platform.
Function: Protects the load tray from overcurrent. Function: Indicates that the safety gate is open.
Data: 15 A. Data: GOSL is connected normally open. See the
Adjustment: N/A. Access 4 input in the A4.14 GOSL menu.
Diagrams: DIA-2360-002 (B-3) (474) Adjustment: See M4.0-2360-050 for adjustment in-
DIA-2360-006 (C-4) (478). structions.
Parts breakdown: 04.1-2360-001 (9) (32). Diagrams: DIA-2360-002 (A-3) (474)

DIA-2360-003 (A-3) (475).
Accessory Cable Fuse

Function: Protects the accessory cable from overcur-
rent.
Data: 5 A.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-4) (474)
DIA-2360-006 (C-4) (478).
Parts breakdown: 04.1-2360-001 (9) (32).
GCSL
Left Gate Closed Switch
Function: Indicates that the safety gate is closed.
Data: GCSL is connected normally open. See the
Access 4 input in the A4.15 GCSL menu.
Adjustment: See M4.0-2360-050 for adjustment in-
structions.
Diagrams: DIA-2360-002 (B-3) (474)
DIA-2360-003 (A-3) (475).
Parts breakdown: 04.8-2360-100 (4) (48).
M1.91-2360-018 Crown 2016 PF27559 Rev. 10/16
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COMPONENTRY
FU6
FU6 FU8
FU7
GCSR
GCSL
GOSL
Fig. 9 (30822-01)
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COMPONENTRY
GOSR
GOSR Adjustment: See M4.0-2360-050 for adjustment in-

structions.
Right Gate Open Switch Diagrams: DIA-2360-002 (A-3) (474)
Location: On the platform. DIA-2360-003 (B-1) (475).
Function: Indicates that the safety gate is open. Parts breakdown: 04.8-2360-150 (2) (50).
Data: GOSR is connected normally open. See the
Access 4 input in the A4.17 GOSR menu. HN1
Adjustment: See M4.0-2360-050 for adjustment in- Horn
structions. Location: On the chassis.
Diagrams: DIA-2360-002 (B-3) (474) Function: Supplies an operator-controlled audible in-
DIA-2360-003 (A-3) (475). dicator to warn others of the lift truck location.
Parts breakdown: 04.8-2360-100 (4) (48). Data: Receives +BV from FU5 and B-NEG from
Access 2/3, pin B7. See the Access 2 driver status in
HGTS20 the A2.14 HN menu.
510 mm (20 in) Height Switch Adjustment: N/A.
Location: Below the platform plate. Diagrams: N/A.
Function: Used to determine 510 mm (20 in) platform Parts breakdown: 04.0-2360-003 (29) (26).
height.
Data: HGTS20 is connected normally closed. See the HNS
Access 4 input in the A4.11 HGTS20 menu. Horn Switch
Adjustment: See M4.0-2360-050 for adjustment in- Location: On the traction pod.
structions.
Function: Allows the operator to sound the horn.
Diagrams: DIA-2360-002 (A-3) (474)
Data: HNS is connected normally open. When you
DIA-2360-003 (B-1) (475).
push HNS, it closes. HNS supplies +BV to Access 4,
Parts breakdown: 04.8-2360-150 (2) (50). pin A17. See the Access 4 input in the A4.3 HNS
menu.
HGTS84
Adjustment: N/A.
2,135 mm (84 in) Height Switch Diagrams: DIA-2360-002 (A-3) (474)
Location: Below the platform plate. DIA-2360-003 (B-1) (475).
Function: Used to determine 2,135 mm (84 in) plat- Parts breakdown: 04.6-2360-001 (25) (36).
form height.
Data: HGTS84 is connected normally closed. See the
Access 4 input in the A4.12 HGTS84 menu.
Adjustment: Used to determine 2,135 mm (84 in)
+12.7/-25 mm (+.50/-1.0 in) platform height.
Diagrams: DIA-2360-002 (A-3) (474)
DIA-2360-003 (B-1) (475).
Parts breakdown: 04.8-2360-150 (2) (50).
HGTS118
2,995 mm (118 in) Height Switch
Function: Used to determine 2,995 mm (118 in) plat-
form height.
Data: HGTS118 is connected normally closed. See the
Access 4 input in the A4.13 HGTS118 menu.
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COMPONENTRY
GOSR
HN1
GOSR
HGTS20
HGST84
HGTS118
HNS
Fig. 10 (30625)
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COMPONENTRY
HSS
HSS K1
High-Speed Switch Vehicle Power-Up
Location: On the steer pod. Location: On the contactor panel.
Function: Used to switch from the limited speed to the Function: Provides +BV to the control circuitry at
normal speed operation. power-up.
Data: HSS is connected normally open. See the Data: K1 is a 24 Vdc coil that energises when the key
Access 4 input in the A4.10 HSS menu. switch is in the start position. EDS3 and EDS4 are
Adjustment: N/A. closed.

DIA-2360-003 (A-1) (475). Diagrams: DIA-2360-002 (B-1) (474)
Parts breakdown: 04.6-2360-050 (18) (38). DIA-2360-005 (C-2) (477)
DIA-2360-006 (B-1) (478).
IEC 320 Inlet (Not shown) Parts breakdown: 04.1-2360-001 (12) (32).
EMEA/AUS Vehicle AC Inlet K2

Line Contactor Control
Function: Inlet for a power source.
Data: N/A.
Function: Supplies power to LC and SVL.
Adjustment: N/A.
Data: K2 is a 24 Vdc coil that is energised by KYS,
Diagrams: DIA-2360-007 (B-1) (479). EDS1, EDS2 and Access 3™, pin B6. See the
Parts breakdown: 04.8-2360-002 (3) (43) Access 3™ driver status in the A3.7 K2 menu.
04.8-2360-800 (58). Adjustment: N/A.
Impact Sensor Diagrams: DIA-2360-002 (B-1) (474)
DIA-2360-005 (B-2) (477)
InfoLink® Impact Sensor DIA-2360-006 (A-3) (478).
Function: Provides the vehicle impact information to
the InfoLink® module.
Data: N/A.
Adjustment: N/A.
Diagrams: DIA-2360-004 (B-4) (476).
Parts breakdown: 10.0-2360-300 (3) (102).
InfoLink®
InfoLink® Control
Function: Monitors the vehicle functions and impacts.
InfoLink® requires a pre-operational vehicle check, and
if also equipped with a card reader, operator login au-
thorisation.
Data: N/A.
Adjustment: N/A.
Diagrams: DIA-2360-004 (A-1) (476).
M1.91-2360-022 Crown 2016 PF27559
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COMPONENTRY
HSS
InfoLink®
K2
K1
HSS
Impact
Fig. 11 (30823)
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COMPONENTRY
K3 Optional (Not Shown)
K3 Optional (Not Shown) KYS

Load Tray Motor Control Key Switch
Location: In the wire harness of the load tray. Location: On the steer pod.
Function: Supplies +BV to the load tray. Function: Allows the operator to turn the vehicle on
Data: 24 V DC. See the Access 4 driver status in the and off.
A4.29 K3 menu. Data: 250 V, 10 A.
Diagrams: DIA-2360-002 (B-4) (474) Diagrams: DIA-2360-002 (C-4) (474)
DIA-2360-003 (B-4) (475) DIA-2360-003 (B-1) (475)
DIA-2360-004 (C-3) (476). DIA-2360-004 (A-1) (476)
Parts breakdown: N/A. DIA-2360-005 (B-1) (477).
Parts breakdown: 04.6-2360-052 (58) (40).
L
Load Tray Motor Control
Location: In the wire harness of the load tray. Line Contactor
Function: Supplies +BV to the load tray. Location: On the rear vehicle compartment, behind
the control panel.
Data: 24 V DC. See the Access 4 driver status in the
A4.30 K3 menu. Function: Line contactor tips provide +BV to
Access 3™ and Access 2 power circuit, FU5, FU6 and
Adjustment: N/A. FU7.
Diagrams: DIA-2360-002 (C-4) (474) Data: 20 Vdc. See the Access 2/3 driver status in the
DIA-2360-003 (B-4) (475) A2.17 L menu.
DIA-2360-004 (C-3) (476).
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-2) (474).
K5 Parts breakdown: 04.1-2360-001 (4) (32).
Drive Tow Brake Control

Function: Puts BRK1 and BRK2 in series when the
drive tow switch is used to release the brakes.
Data: 24 V DC. See the Access 3™ driver status in the
A3.7 K2 menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-1) (474)
DIA-2360-006 (C-3) 478).
Parts breakdown: 04.1-2360-001 (12) (32).
K6 Optional
Load Tray Motor Control
Function: Supplies +BV to the load tray.
Data: 24 V DC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-3) (474)
DIA-2360-006 (C-4) (478).
Parts breakdown: 04.1-2360-001 (12) (32).
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COMPONENTRY
KYS
L K6
K5
Fig. 12 (30627)
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COMPONENTRY
LED1
LED1 LGT1 Optional

Right-Hand Sensor 1R LED Right Front Worklight
Location: On the traction pod. Location: On the traction pod.
Function: Senses the right hand. Function: Provides worklight.
Data: 30 V, 100 mA. Data: 24 V DC, 0.6 A.
Diagrams: DIA-2360-002 (A-4) (474) Diagrams: DIA-2360-002 (A-3) (474)
DIA-2360-003 (C-1) (475). DIA-2360-003 (A-2) (475)
Parts breakdown: 04.6-2360-001 (6) (36). DIA-2360-004 (B-3) (476).
Parts breakdown: 04.6-2360-001 (6) (36).
LED2
LGT2 Optional
Left-Hand Sensor 1R LED
Location: On the steer pod. Left Front Worklight
Function: Senses the left hand. Location: On the steer pod.
Data: 30 V, 100 mA. Function: Provides worklight.
Adjustment: N/A. Data: 24 V DC, 0.6 A.

DIA-2360-003 (B-1) (475). Diagrams: DIA-2360-002 (A-3) (474)
Parts breakdown: 04.6-2360-050 (5) (38). DIA-2360-003 (A-2) (475)
DIA-2360-004 (B-3) (476).
LED Board Parts breakdown: 04.6-2360-001 (6) (36).
Battery Charger LED Status Board LHS

Left-Hand Sensor
Function: Alerts the operator of the battery charger
status. Location: On the steer pod.
Data: N/A. Function: Senses hand presence.
Adjustment: N/A. Data: LHS is connected normally open. See the

Access 4 input in the A4.19 LHS menu.
Diagrams: DIA-2360-007 (B-2) (479).
Adjustment: N/A.
Parts breakdown: 04.8-2360-800 (58).
Diagrams: DIA-2360-002 (A-4) (474)
LGS Optional (Not Shown) DIA-2360-003 (B-4) (475).
Parts breakdown: 04.6-2360-050 (5) (38).
Light switch
Location: On the steer pod.
Function: Allows the operator to control the front work-
lights.
Data: LGS is a two position (on/off) rocker switch. LGS
supplies +BV to PS2.
Adjustment: N/A.
Diagrams: DIA-2360-002 (A-3) (474)
DIA-2360-003 (A-1) (475)
DIA-2360-004 (B-4) (476).
Parts breakdown: 04.6-2360-050 (20) (38).
M1.91-2360-026 Crown 2016 PF27559
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COMPONENTRY
LED1
LED2
LED Board
LHS
LED1
LGT1
LGT2
Fig. 13 (30628)
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COMPONENTRY
LMS1 Optional
LMS1 Optional Diagrams: DIA-2360-002 (C-2) (474)

DIA-2360-003 (A-1) (475).
Limit Switch 1 Parts breakdown: 04.6-2360-050 (19) (38).
Location: On the load tray assembly.
Function: Limits the raise of the load tray. M1
Data: 30–250 V DC. LMS1 is connected normally Right Traction Motor
closed. See the Access 4 input in the A4.4.20 LMS1 Location: In the traction motor compartment.
menu.
Function: Supplies the driving force for travel and re-
Adjustment: N/A. generative brake operation.
Diagrams: DIA-2360-002 (B-3) (474) Data: 24 V, 0.5 kW.
DIA-2360-003 (B-4) (475).
Adjustment: N/A.
Parts breakdown: 10.0-2360-050 (19) (94).
Diagrams: DIA-2360-002 (B-1) (474)
LMS2 Optional DIA-2360-003 (A-4) (475)
DIA-2360-005 (B-1) (477)
Limit Switch 2 DIA-2360-006 (A-4) (478)
Location: On the load tray assembly. DIA-2360-007 (A-4) (479).
Function: Limits the lower of the load tray. Parts breakdown: 04.8-2360-800 (58).
Data: 30–250 V DC. LMS2 is connected normally M2
closed. See the Access 4 input in the A4.4.21 LMS1
menu. Left Traction Motor
Adjustment: N/A. Location: In the traction motor compartment.
Diagrams: DIA-2360-002 (B-3) (474) Function: Supplies driving force for travel and regen-
DIA-2360-003 (B-4) (475) erative brake operation.
DIA-2360-004 (C-1) (476). Data: 24 V, 0.5 kW.
Parts breakdown: 10.0-2360-050 (19) (94). Adjustment: N/A.
LOS Diagrams: DIA-2360-002 (C-4) (474)
DIA-2360-003 (B-4) (475)
Lower Switch DIA-2360-005 (B-3) (477)
Location: On the traction pod. DIA-2360-006 (A-4) (478)
DIA-2360-007 (A-2) (479).
Function: Used to lower the platform.
Parts breakdown: 04.8-2360-800 (58).
Data: LOS is connected normally open. See the
Access 4 input in the A4.7 LOS menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (A-3) (474)
DIA-2360-003 (B-1) (475).
Parts breakdown: 04.6-2360-001 (26) (36).
LTS Optional
Load Tray Switch
Location: On the steer pod.
Function: Used to raise and lower the load tray.
Data: 28 Vdc, 10 A. LTS is connected normally closed.
See the Access 4 input in the A4.4 and A4.5 LTS
menu.
Adjustment: N/A.
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COMPONENTRY
LMS1 Optional
LMS1
LOS LMS2
M2
M1
LTS
Fig. 14 (30637)
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COMPONENTRY
M3
M3 MCS3
Hydraulic Motor Motor Cover Switch 3
Location: On the chassis. Location: Below the back chassis cover.
Function: Provides the driving force for the hydraulic Function: Disables the lower and the travel functions
pump. when activated.
Data: 24 V, 2.2 kW. Data: -40°C–85°C (-40°F–185°F) 8 A at 125/250 V AC.
Diagrams: DIA-2360-002 (C-2) (474) Diagrams: DIA-2360-006 (B-4) (478).
DIA-2360-003 (C-4) (475) Parts breakdown: 04.8-2360-250 (1) (56).
DIA-2360-007 (A-2) (479).
Parts breakdown: 02.0-2360-002 (1) (11) MCS4
04.8-2360-800 (58).
Motor Cover Switch 4
M4 Optional Location: Below the back chassis cover.
Function: Disables the lower and the travel functions
Load Tray Motor when activated.
Location: Load tray assembly. Data: -40°C–85°C (-40°F–185°F) 8 A at 125/250 V AC.
Function: Provides the driving force for the load trap Adjustment: N/A.
operation.
Diagrams: DIA-2360-005 (B-2) (477)
Data: 24 Vdc, 6.8 A. DIA-2360-006 (B-4) (478).
Adjustment: N/A. Parts breakdown: 04.8-2360-250 (1) (56).
Diagrams: DIA-2360-002 (B-4) (474)
DIA-2360-004 (C-1) (476).
Parts breakdown: 10.0-2360-050 (26) (94).
MCS1
Location: Below the back chassis cover.
when activated.
Data: -40°C–85°C (-40°F–185°F) 8 A at 125/250 V AC.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-2) (474)
DIA-2360-005 (B-3) (477)
DIA-2360-006 (B-3) (478).
Parts breakdown: 04.8-2360-250 (1) (56).
MCS2
Location: Below the back chassis cover.
when activated.
Data: -40°C–85°C (-40°F–185°F) 8 A at 125/250 V AC.
Adjustment: N/A.
Diagrams: DIA-2360-006 (B-3) (478).
Parts breakdown: 04.8-2360-250 (1) (56).
M1.91-2360-030 Crown 2016 PF27559
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COMPONENTRY
M3
M3
M4
MCS3 MCS4
MCS1
MCS2
Fig. 15 (30629)
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COMPONENTRY
MOV1 Optional
MOV1 Optional Adjustment: N/A.

Diagrams: DIA-2360-002 (A-3) (474)
Load Tray Motor Suppression DIA-2360-003 (B-1) (475).
Location: M4 motor. Parts breakdown: 04.6-2360-001 (28) (36).
Function: Dynamic braking of the power load tray mo-
tor. RHS
Data: 39–200 V. Right-Hand Sensor
Adjustment: N/A. Location: On the traction pod.
Diagrams: DIA-2360-002 (C-4) (474) Function: Senses hand presence.
DIA-2360-004 (C-1) (476).
Data: RHS is connected normally open. See the
Parts breakdown: 10.0-2360-050 (94). Access 4 input in the A4.18 RHS menu.
PLSL 1 Adjustment: N/A.
Diagrams: DIA-2360-002 (A-4) (474)
Right Platform Strobe Light DIA-2360-003 (C-1) (475).
pedestrians. SB1 Optional (Not Shown)
Data: 12–80 Vdc, 12–82 mA. See the Access 4 driver +/- Accessory Cable Suppression
status in the A4.31 PLS menu.
Adjustment: N/A.
Function: Prevents excessive voltage.
Diagrams: DIA-2360-002 (B-4) (474)
Data: N/A.
DIA-2360-003 (C-4) (475)
DIA-2360-004 (B-3) (476). Adjustment: N/A.
Parts breakdown: 04.0-2360-052 (22) (30) Diagrams: DIA-2360-002 (B-3) (474)
09.0-2360-003 (66) (84). DIA-2360-004 (C-3) (476).
PLSL 2
Left Platform Strobe Light
pedestrians.
Data: 12–80 Vdc, 12–82 mA. See the Access 4 driver
status in the A4.31 PLS menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-3) (474)
DIA-2360-003 (C-4) (475)
DIA-2360-004 (B-3) (476).
Parts breakdown: 04.0-2360-052 (22) (30)
09.0-2360-003 (66) (84).
RAS
Raise Switch
Function: Used to raise the platform.
Data: RAS is connected normally open. See the
Access 4 input in the A4.6 RAS menu.
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COMPONENTRY
MOV1 Optional
PLSL2 PLSL1
RAS
RHS
MOV1
Fig. 16 (30824)
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COMPONENTRY
SPS
SPS Diagrams: DIA-2360-002 (C-2) (474)

DIA-2360-005 (C-2) (477)
Service Panel Switch DIA-2360-006 (B-4) (478).
Location: On the service panel. Parts breakdown: N/A.
Function: Indicates that the service panel door is open
and travel is not permitted. TS1
Data: SPS is connected normally open. See the Right Traction Motor Temperature Sensor
Access 2/3 input in the A2.5 SPS menu. Location: On the right traction motor.
Adjustment: N/A. Function: Monitors M1 temperature and communi-
Diagrams: DIA-2360-002 (B-2) (474) cates the information to Access 3™.
DIA-2360-005 (B-2) (477) Data: See the Access 2/3 Input in the A2.11 M1 Tem-
DIA-2360-006 (C-1) (478). perature menu.
Parts breakdown: 01.0-2360-001 (23) (2). Adjustment: N/A.
STR CMD Diagrams: DIA-2360-002 (B-1) (474)
DIA-2360-005 (C-1) (477)
Steering Sensor DIA-2360-006 (A-4) (478).
Location: On the steer pod. Parts breakdown: N/A.
Function: Senses the steering of the vehicle.
Data: See the Access 4 input in the A4.22 STRCMD1
and A4.23 STRCMD2 menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (A-4) (474)
DIA-2360-003 (A-1) (475).
Parts breakdown: 04.6-2360-050 (12) (38).
SPL
Lowering Valve
Location: On the hydraulic unit.
Function: SPL provides protection against an unin-
tended lower operation if there is an issue with SPL or
its control (SPL blocks flow to the reservoir). When the
operator requests the lower function, SPL is energised
and provides a path to the reservoir.
Data: 12–24 Vdc.
Adjustment: N/A.
Diagrams: DIA-2360-005 (B-2) (477).
Parts breakdown: 02.4-2360-002 (9) (13).
TLTS (Only on EMEA Vehicles)

Tilt Sensor
Function: Detects the tilt angle of the vehicle.
Data: 20–26.5 Vdc.
Adjustment: N/A.
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COMPONENTRY
SPS
SPS
TS1
SPL
STR CMD
Fig. 17 (30635)
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COMPONENTRY
TS2
TS2
Left Traction Motor Temperature Sensor
Location: On the left traction motor.
Function: Monitors M2 temperature and communi-
cates the information to Access 3™.
Data: See the Access 3™ input in the A3.2 M1 Tem-
perature menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (A-1) (474)
DIA-2360-005 (C-3) (477)
DIA-2360-006 (A-3) (478).
TXN CMD
Traction Sensor
Function: Senses the traction of the vehicle wheels.
Data: See the Access 4 input in the A4.24 TRACMD1
and A4.25 TRACMD2 menu.
Adjustment: N/A.
Diagrams: DIA-2360-002 (B-4) (474)
DIA-2360-003 (B-1) (475).
Parts breakdown: 04.6-2360-002 (14) (37).
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COMPONENTRY
TS2
TS2
TXN CMD
Fig. 18 (30636)
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COMPONENTRY
Connectors
Connectors The Component column shows the designator or the

connector number that is in the diagrams. The Location
The table at the end of this section is provided to help column gives the general location on the vehicle (for
you find the components in the diagrams and parts example, in the vehicle chassis). The Function column
pages. It includes the following information: gives the function or circuit of the component. The Dia-
• Component gram column gives the page number of the electrical
• Location diagram on which you can find the component. The
value in parentheses after the page number is the
• Function same as the grid coordinate on the electrical diagram.
• Diagram The Parts Breakdown column includes the page num-
• Parts Breakdown ber on which you can find the component and an index
number (in parentheses, if applicable).
BATTERY
Location Function Diagram Parts Breakdown
Battery In the chassis compart- Power supply DIA-2360-006 (B-4) 4.0-2360-002 (25)
ment DIA-2360-007 (C-1, 4.8-2360-800 (58)
C-2, C-3, C-4)
CONNECTIONS
CA101 On the platform Access 4 input (CHS1, CHS2, DIA-2360-002 (A-3, 04.8-2360-075 (46)
GCSL, GCSR, GOCL, GOSR) A-4, C-4) 4.8-2360-800 (52)
CA102 On the platform Access 4 input DIA-2360-002 (A-4) 04.8-2360-075 (46)
DIA-2360-003 (A-4) 4.8-2360-800 (52)
CA103 On the platform Steer pod connection (HSS, DIA-2360-003 (A-2) 4.8-2360-800 (52)
KYS, LGS, LTS) DIA-2360-004 (A-4,
B-4)
CA104 On the platform Steer pod connection DIA-2360-003 (B-2) 4.8-2360-800 (52)
CA105 On the platform Height switch connection DIA-2360-003 (B-2) 4.8-2360-800 (52)
(HGTS20, HGTS84,
HGTS118)
CA106 On the platform Traction pod connection DIA-2360-003 (B-2) 4.8-2360-800 (52)
(EDS1, EDS3, HNS, LOS,
RAS)
CA107 On the platform Traction pod connection DIA-2360-003 (B-2) 4.8-2360-800 (52)
CA108 On the platform Platform foot switches (DMSL, DIA-2360-003 (B-2) 4.8-2360-800 (52)
DMSR)
CA109 On the platform CAN connector DIA-2360-003 (B-2) 4.8-2360-800 (52)
DIA-2360-004 (A-4)
CA110 On the platform Dynamic cable connection DIA-2360-003 (C-2) 4.8-2360-800 (52)
CA111 On the platform Dynamic cable connection DIA-2360-003 (C-3) 4.8-2360-800 (52)
DIA-2360-004 (A-4,
C-4)
CA112 On the platform Load tray connection (K3, K4) DIA-2360-003 (C-4) 4.8-2360-800 (52)
(optional) DIA-2360-004 (C-3)
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COMPONENTRY
Connectors
CONNECTIONS
CA113 On the platform Connection for the strobe on DIA-2360-003 (B-4) 4.8-2360-800 (52)
the right platform (PLSL1) DIA-2360-004 (B-4)
CA114 On the platform Connection for the strobe on DIA-2360-003 (C-4) 4.8-2360-800 (52)
the left platform (ALM3, DIA-2360-004 (B-4)
PLSL1, PLSL2)
CA115 On the load tray assem- Load tray motor connection DIA-2360-004 (C-2) 10.0-2360-050 (94)
bly (optional) (K3, K4, LMS2, M4, MOV1) 4.8-2360-800 (52)
CA116 In the InfoLink® module InfoLink® programming con- 4.8-2360-800 (52)
nection
CA117 On the platform Impact sensor 1 connection DIA-2360-004 (A-4) 4.8-2360-800 (52)
CA118 In the InfoLink® module InfoLink® connection DIA-2360-004 (A-1) 4.8-2360-800 (52)
CA119 In the InfoLink® module Prox reader connection DIA-2360-004 (B-1) 4.8-2360-800 (52)
CA120 In the InfoLink® module InfoLink® alarm connection 4.8-2360-800 (52)
CA121 In the InfoLink® module InfoLink® serial connection 4.8-2360-800 (52)
CA122 In the InfoLink® module InfoLink® bluetooth connec- DIA-2360-004 (C-1) 4.8-2360-800 (52)
tion
CA123 On the platform Impact sensor 1 connection 4.8-2360-800 (52)
CA201 On the traction motor Connection for the tempera- DIA-2360-006 (A-4) 4.8-2360-800 (52)
compartment ture sensor on the right trac-
tion motor (M1, TS1)
CA202 On the traction motor Connection for the right trac- DIA-2360-006 (A-4) 4.8-2360-800 (52)
compartment tion motor (ECR1, M1)
CA203 On the traction motor Right traction motor (ECR3, DIA-2360-006 (A-4) 4.8-2360-800 (52)
compartment M1)
CA204 On the traction motor Connection for the tempera- DIA-2360-006 (A-4) 4.8-2360-800 (52)
compartment ture sensor on the left traction
motor (M2, TS2)
CA205 On the traction motor Connection for the left traction DIA-2360-006 (A-3) 4.8-2360-800 (52)
compartment motor (ECR2, M2)
CA206 On the traction motor Connection for the left traction DIA-2360-006 (A-3) 4.8-2360-800 (52)
compartment motor (ECR4, M2)
CA301 On the steer pod Left control pod (LED2, LHS, DIA-2360-003 (A-12) 4.8-2360-800 (52)
STR CMD)
CA302 On the traction pod Right control pod, Access 1 in- DIA-2360-002 (A-2) 4.8-2360-800 (52)
put (ALM1) DIA-2360-003 (B-1)
CA303 On the traction pod Right control pod (LED2, LHS, DIA-2360-003 (B-1) 4.8-2360-800 (52)
STR CMD)
CA401 Access 2/3 Access 2/3 input (ECR1, TS1) DIA-2360-002 (B-2) 4.8-2360-800 (52)
DIA-2360-005 (B-1)
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COMPONENTRY
Connectors
CONNECTIONS
CA402 Access 2/3 Access 2/3 input (EDS, KYS) DIA-2360-002 (B-2) 4.8-2360-800 (52)
DIA-2360-005 (B-1)
CA403 Access 2/3 Access 2/3 input (BRK1, DIA-2360-002 (B-2) 4.8-2360-800 (52)
BRK2, CHS3, SVL) DIA-2360-005 (B-2)
CA404 Access 2/3 Access 2/3 input (CHS4, ECS, DIA-2360-002 (B-2) 4.8-2360-800 (52)
ERLS, MCS1) DIA-2360-005 (B-2)
DIA-2360-006 (B-2)
CA405 Access 3™ Access 3™ input (ECR2, TS2) DIA-2360-002 (A-2) 4.8-2360-800 (52)
DIA-2360-005 (B-3)
CA406 Access 3™ Access 3™ input (EDS, KYS) DIA-2360-002 (A-2) 4.8-2360-800 (52)
DIA-2360-005 (B-3)
CA407 Access 3™ Access 3™ input (BRK1, DIA-2360-002 (A-2) 4.8-2360-800 (52)
BRK2, K2) DIA-2360-005 (B-3)
CA408 Access 3™ Access 3™ input (ALM2, DIA-2360-002 (A-2) 4.8-2360-800 (52)
CHSL) DIA-2360-005 (B-4)
CA601 On the chassis Contactor panel connection DIA-2360-006 (C-3) 4.8-2360-800 (52)
(CB1, FU3, FU4, FU5, FU6,
FU7, FU8, K1, K2, K6, L, SPL)
CA602 On the chassis Contactor panel connection DIA-2360-006 (C-3) 4.8-2360-800 (52)
(FU8, K5)
CA603 On the chassis Travel alarm connection DIA-2360-006 (C-2) 4.8-2360-800 (52)
(ALM2)
CA604 On the chassis Tilt sensor connection (TLTS, DIA-2360-006 (B-4) 4.8-2360-800 (52)
EMEA option only)
CA605 On the chassis Service panel connection DIA-2360-006 (C-2) 4.8-2360-800 (52)
(DTS, ECS, EDS2, ERLS)
CA606 On the chassis Chassis strobe connection DIA-2360-006 (B-1) 4.8-2360-800 (52)
(CHSL)
CA607 On the chassis CAN terminating resistor DIA-2360-006 (A-2) 4.8-2360-800 (52)
connection
CA608 On the chassis Connection for the right DIA-2360-006 (B-1) 4.8-2360-800 (52)
dynamic cable
CA609 On the chassis Connection for the left DIA-2360-006 (B-1) 4.8-2360-800 (52)
dynamic cable
CA610 On the chassis Connection for the service DIA-2360-006 (C-1) 4.8-2360-800 (52)
panel switch (ECS, ERLS,
SPS)
CA611 On the chassis Service panel connection DIA-2360-006 (B-2) 4.8-2360-800 (52)
(EDS4)
CA612 On the service panel Charger LED board connec- DIA-2360-007 (B-2) 04.8-2360-800 (58)
tion 4.8-2360-800 (52)
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HYDRAULIC SYSTEM
99
Notes:
100
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic System When you press the lower button, the SPL (8) is ener-
gised to open. The weight of the mast puts hydraulic
A gear type pump and a motor assembly power the hy- pressure at the ORF1 (5), CV2 (6) and DSV (7). After
draulic system. This pump supplies oil flow for the lift the SPL (8) opens, it allows the flow regulator to control
function. The maximum pressure of 20,700 kPa the hydraulic pressure. The DSV (7) functions at any
(3,000 psi) is limited by an integral relief valve. height and trips if pressure differential is detected.
7
5 6
2
8
4
3
M
Fig. 20 (30560)
1 Lift cylinder
2 Manifold
3 Power unit
4 Check valve 1 (CV1)
5 Orifice 1 (ORF1)
6 Check valve 2 (CV2)
7 Drop stop valve (DSV)
8 Solenoid proportional valve lower (SPL)
Filling the reservoir with oil

Use the appropriate grade of hydraulic oil as recom-
mended in the Lubricant and Fluid Chart. See the M1.0
Fig. 19 (30559) section of this manual.
See Figure 20. 1. Make sure that the lift cylinder is in the fully lowered
When you press the lift button, the pump motor is acti- position.
vated and hydraulic oil is pumped through CV1 (4) to 2. Make sure that all the air has been bled from the
the lift cylinder (1), ORF1 (5), CV2 (6) and DSV (7). hydraulic system.
With the SPL (8) closed, most of the hydraulic oil flow
Note: The total capacity of the hydraulic system is ap-
goes to the lift cylinder (1).
proximately 2.8 l (3 qt).
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HYDRAULIC SYSTEM
Hydraulic System
3. Fill the reservoir so that the oil level is at the full

mark on the reservoir sight gauge.
Lowering the platform
See Figure 21.
In the event of an electrical malfunction or component
failure, you can use the manual lowering valve to lower
the platform.
1
WARNING
A load tray or platform that falls or lowers can
cause injury or death.
2
The load tray and platform automatically lower when
the hydraulic system pressure releases during manual
lowering, causing injury or death.
3
 Make sure that the load tray and platform is clear of
all personnel and obstructions.
 Make sure that the operator stays inside the plat- Fig. 21 (30561)
form rails. 1 Manual lowering valve
 Stop lowering immediately if the chains become 2 To lower
slack or any part of the platform gets caught. 3 To stop lowering
1. To lower the platform, pull and hold the manual

Maintaining the hydraulic lines and
lowering valve open. fittings
Note: You must hold the manual lowering valve in the
open position for the platform to lower.
2. To stop lowering the platform, release the manual WARNING
lowering valve.
Note: Once released, the manual lowering valve auto-
High-pressure fluids can go through the skin and cause
matically returns to the closed position and the platform
severe injury. High-pressure fluid that goes into the
stops lowering.
when the skin looks normal. There is a delayed start of
pain and severe tissue damage occurs.
 Release the pressure before you disconnect the hy-
draulic plumbing.
pressure.
high-pressure fluids.
 To examine for leaks, use a piece of cardboard or
paper. Do not use your hand.
 You must immediately get medical aid from a spe-
cialist who has experience with this type of injury.
1. Before installing the hoses and lines, blow air

through them to remove any loose particles.
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HYDRAULIC SYSTEM
Hydraulic System
2. Replace any collapsed or kinked lines and rubber

hoses with wire braid inner construction. The lines DANGER
and rubber hoses must be replaced even if the
damage is not visible. A vehicle that falls can cause severe injury or
3. Replace the flexible hose if it collapses while in the death.
normal operating position. Using a hoist or lifting device that does not have suffi-
4. To avoid potential damage, make sure that the cient capacity can result in severe injury or even death.
hoses and lines are kept away from sharp surfaces  Do not perform maintenance under or around a ve-
and edges. hicle that is not correctly secured.
5. Make sure that there are no leaks in any of the con-  See SAFETY / Control of Hazardous Energy / Lift-
nections. ing and Blocking in the Service and Parts Manual
for the applicable lifting and blocking procedures.
Adjusting the lift relief valve
 Read and obey all safety procedures in SAFETY /
The relief valve on the hydraulic unit is factory set at Control of Hazardous Energy / Lifting.
20,700 kPa (3,000 psi). If adjustment is required, do
the following steps:
5. Use a hoist or other lifting device to put a 100 kg
1. Make sure that the hydraulic unit is at ambient tem-
(220 lb) weight on the back of the load tray. Use a
perature.
safety strap to secure the weight on the load tray.
2. Fully lower the platform.
6. Use a hoist or other lifting device to put a 136 kg
3. Remove the hex cover of the relief valve to access (300 lb) weight on the platform. Close both gates
the adjustment screw or relief valve. on the vehicle.
4. See Figure 22. Attach a pressure gauge (1) to the 7. Use the service panel to raise the platform until it is
quick connect port (2) on the hydraulic pump (3). fully raised.
Make sure the coupler is engaged fully. If the cou-
8. With the platform fully raised, push the raise switch
pler does not engage, push the lower switch on the
on the service panel. The oil pressure builds and
service panel to relieve the system pressure.
activates the relief valve.
9. Look at the pressure gauge and record the read-
ing.
10. To increase the relief pressure, tighten the adjust-
ment screw.
11. To decrease the relief pressure, loosen the adjust-
ment screw.
12. After the pressure is correct, use the service panel
to fully lower the platform.
13. Remove the weights from the vehicle.
1 14. Disconnect the pressure gauge from the hydraulic
3 pump.
15. Install the hex cover.
2
Fig. 22 (30703)
1 Pressure gage
2 Quick connect port
3 hydraulic pump
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HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting • Develop a systematic pattern to locate and solve

the hydraulic problems that occur.
The following troubleshooting chart contains general The troubleshooting chart contains symptoms, proba-
information necessary to solve hydraulic problems. ble causes and remedies. The information is general in
The hydraulic troubleshooting technician must: nature and provides a remedy or directs you to another
• Know the system to the best of their ability. section for more troubleshooting.
• Understand the components and their function in
the system.
Hydraulics Troubleshooting Chart
Symptom Probable Cause Remedy
Hydraulic oil is foam- Introduction of air into the pump • Check the reservoir oil level.
ing • Check for the proper oil viscosity.
• Check the plumbing.
Water is in the oil Check the reservoir.
Hydraulic oil is over- The oil is too thin(1) Change to the proper viscosity oil.
heating(1)
The oil is contaminated Empty the reservoir and fill with clean oil.
Introduction of air into the pump Check the plumbing.
The oil level is low Fill the reservoir to the proper level.
Platform will not raise The lift fuse is blown Check for a short in the cables or motor.
If there is not a short, replace the lift fuse.
The manual lowering valve is actuated See the HYDRAULIC SYSTEM / Manual
Lowering Valve section of this manual.
The mast assembly is binding Inspect the mast for abnormalities.
The lift motor or the pump is not operating • Check the Access 1 display for error
messages.
• Make sure the raise switch is operat-
ing correctly at Access 1 display
A4.6.
• Make sure the gate switches are cor-
rect at Access 1 displays A4.14,
A4.15, A4.16 and A4.17.
(1) Make sure that the vehicle has been performing a normal duty cycle.
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HYDRAULIC SYSTEM
Platform will not lower The chain switch is actuated Check the switches at Access 1 display
A4.1 and A4.2.
The solenoid valve does not work • Check the Access 1 display for error
messages.
• Check the solenoid driver at the
Access 1 display A2.15.
The motor cover switch is actuated Check the motor cover for an obstruction
and remove if present.
There is binding in the mast assembly Inspect the mast and the platform for ab-
normalities.
The lower solenoid failed Replace the lower solenoid.
Platform lowers too The flow control valve does not work Use the lift and lower controls to free de-
slow bris.
A blockage in the hydraulic lines Check the plumbing.
normalities.
Platform lowers too The flow control valve does not work Use the lift and lower controls to free de-
fast bris.
There is an external oil leak Check the plumbing for leaks.
Does not lift the capac- The relief valve is not adjusted properly Adjust the relief valve.
ity load
There is binding in the mast assembly Inspect the mast for abnormalities.
There are failures in the hydraulic system Inspect the hydraulic system. See HY-
DRAULIC SYSTEM section of this man-
ual.
Platform does not There is debris in the solenoid valve Use the lift and lower controls to free de-
maintain height bris.
The lift cylinder packings leak • Check the bleeder screw on the cylin-
der for leaks.
• See the CYLINDER/Cylinder section.
Excessive consump- There is an external leak Check the plumbing, the cylinder and the
tion of hydraulic oil other hydraulic components.
Lift pump and motor is The capacity load is too heavy Check the load weight.
overheating (1)
The pump and motor are worn or damaged Inspect, repair or replace the pump and
motor as needed.
The hydraulic oil level is low Make sure the hydraulic oil is at the
proper level. See the HYDRAULIC SYS-
TEM / reservoir section.
(1) Make sure that the vehicle has been performing a normal duty cycle.
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HYDRAULIC SYSTEM
Platform does not The lift chains are not adjusted properly Adjust the lift chains.
raise or lower
smoothly
normalities.
There are failures in the hydraulic system Inspect the hydraulic system. See the
HYDRAULIC SYSTEM section of this
manual.
There is air trapped in the cylinder Bleed the cylinder.
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DRIVE UNIT
107
Notes:
108
DRIVE UNIT
Drive Unit Lubrication

3
DANGER
A vehicle that falls can cause severe injury or
1
death.
Using a lifting device or blocks that do not have suffi-
2
cient capacity can result in severe injury or even death.
 Do not perform maintenance under or around a ve-
hicle that is not correctly secured.
 See SAFETY / Control of Hazardous Energy / Lift-
ing and Blocking in the Service and Parts Manual 2
for the applicable lifting and blocking procedures.
Control of Hazardous Energy / Lifting.
There is a right and left drive unit. To change the oil, the
drive unit must be removed from the vehicle. See the
Lubrication and Adjustment section before proceeding.
1. Follow all the safety procedures. See the SAFETY
chapter in the Service and Parts Manual.
2. Wear the appropriate items for personal safety.
3. Move the vehicle to your work area on a level floor.
4. Raise the platform to access the back of the chas-
sis. Fig. 23 (30639)
5. Block the platform with composite or hardwood Removing the drive unit
blocks. 1. Disconnect the drive unit harnesses.
6. Turn off the vehicle. 2. Remove the flare nut from the centre of the hub.
7. Remove the load deck. 3. Remove the drive wheel with a bar-type puller and
8. Disconnect the batteries. the woodruff key. Replace the woodruff key if it is
9. See Figure 23. Remove the access cover (1), the damaged or worn. If a bar-type puller is not availa-
screws (2) and the cushion mounts (3). ble, use a pry bar. Work around the back of the
drive hub to remove it from the tapered shaft of the
10. Lockout/tagout the vehicle. drive unit.
CAUTION
Improper removal can damage the tyre.
Prying on the tyre results in damage and the tyre must
be replaced.
 Only pry on the steel part of the wheel.
4. Remove the three screws (1, Figure 24), the three

nuts (2) and the three flatwashers (3) that hold the
drive unit to the vehicle.
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DRIVE UNIT
8. Disassemble the coupler and inspect the parts for

wear or damage.
9. Replace any damaged parts.
10. Repeat steps 1–9 for the motor on the other side.
Changing the oil
Note: See the Lubrication and Adjustment section be-
fore proceeding.
1 1. Remove the oil level plug (7, Figure 25). Let the oil
run out of the oil level hole and into a pan.
2. If oil does not run out of the hole, remove the
3 2 breather plug (6, Figure 25).
3. After the used oil has been drained, add oil to the
breather plug hole until it starts to run out of the oil
level hole in the gear case cover (17).
4. Install the oil level plug and the breather plug.
5. Clean up any oil that has spilled.
Installing the drive unit
1. Assemble the brake assembly to the drive motor.
Fig. 24 (30640) See section M5.
5. Remove the drive unit assembly from the vehicle. 2. Assemble the coupler (5, Figure 25).
6. Remove the four screws (3, Figure 25) and the four 3. Install the coupler assembly to the base of the drive
flatwashers (4) that hold the motor (1) to the drive motor.
unit (2). 4. Place one flatwasher (4) on each of the motor in-
stallation screws (3).
5. Install the drive motor assembly (1) to the drive unit
6 (2) with the motor and brake leads facing the back
of the vehicle.
2 6. Insert all four of the screws through the motor base
and into the drive unit housing. Torque the screws
to 12 Nm (9 ft lb).
7 7. Install the three screws (1, Figure 26), the three
nuts and the three flatwashers that hold the drive
unit to the vehicle. Torque the screws to 61 Nm
1 (45 ft lb).
4
3
Fig. 25 (30641)
7. Remove the coupler assembly (5) from the base of
the drive motor.
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DRIVE UNIT
2
1
3 2
2
Fig. 26 (30640)
8. Connect the drive motor (CA601 or CA602) to the
appropriate harness connectors.
9. Connect the brake (CA603 and CA604 or CA605
and CA606) to the appropriate harness connec-
tors.
10. Repeat steps 1–9 for the motor on the other side. Fig. 27 (30639)
Preparing the vehicle for operation 3. Turn on the vehicle.
1. Install the access cover (1, Figure 27), the screws 4. Raise the platform slightly and remove the com-
(2) and the cushion mounts (3). posite or hardwood blocks.
5. Lower the platform and install the load deck.
6. Make sure that the vehicle operates correctly.
Crown 2016 PF27573 M3.0-2360-003
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DRIVE UNIT
Drive Unit Repair
Drive Unit Repair 3. Remove the drive wheel with a bar-type puller and
the woodruff key. Replace the woodruff key if it is
Preparing the vehicle for maintenance damaged or worn. If a bar-type puller is not availa-
1. Follow all the safety procedures. See the SAFETY ble, use a pry bar. Work around the back of the
chapter in the Service and Parts Manual. drive hub to remove it from the tapered shaft of the
drive unit.
4. Raise the platform to access the back of the chas- CAUTION
sis. Improper wheel removal can damage the tyre.
5. Block the platform with composite or hardwood Prying on the tyre results in damage and the tyre must
blocks. be replaced.
6. Turn off the vehicle.  Only pry on the steel part of the wheel.
7. Remove the load deck.
8. Disconnect the batteries. 4. Remove the three screws (1, Figure 29), the three
9. Remove the access cover (1, Figure 28), the nuts (2) and the three flatwashers (3) that hold the
screws (2), and the cushion mounts (3). drive unit to the vehicle.
10. Lockout/tagout the forklift truck.
1
1
2
3 2
Fig. 29 (30640)
5. Remove the drive unit assembly from the vehicle.
6. Remove the four screws (3, Figure 30) and the four
flatwashers (4) that hold the motor (1) to the drive
unit (2).
Fig. 28 (30639)
Removing the drive unit
1. Disconnect the drive unit harnesses.
2. Remove the flare nut from the centre of the hub.
M3.0-2360-004 Crown 2016 PF27573
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DRIVE UNIT
Drive Unit Repair
10. Remove the second pinion subassembly (14–16)

from the gear case cover.
6
4
3
Fig. 30 (30641)
7. Remove the coupler assembly (5) from the base of
the drive motor.
8. Disassemble the coupler and inspect the parts for
wear or damage.
10. Repeat steps 1–9 for the opposite side motor.
Disassembling the drive unit
Note: See the Lubrication and Adjustment section be-
fore proceeding.
1. See Figure 31. Remove the oil level plug (20). Let
the oil run out of the oil level hole and into a pan.
2. If oil does not run out of the hole, remove the
breather plug (21).
3. After the oil is drained, remove the two 25 mm
(1.0 in) long screws (19) and the corresponding
flatwashers (22).
4. Remove the five 38 mm (1.5 in) screws (18) and
the corresponding flatwashers (22).
5. Use your hands to separate the cover (1) from the
other half of the drive unit (17).
6. Remove the seal (2) from the gear case cover (1).
7. Remove the seal (10) from the gear case cover.
8. Remove the gasket (4) from the gear case cover.
9. Remove the first pinion subassembly (11–13) from
the gear case cover (1).
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DRIVE UNIT
Drive Unit Repair
(a)
(a)
18
20 19
(a)
19
(a)
22
22
18
3
20 22
55 66
18
(a) 77
22
22
33 8
8 21
11 44 9
10
11
11
14
14
12
12
15
15
13
13
16
14
17
20
Fig. 31 (30663)
(a) Torque to 7 Nm (5 ft lb)
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DRIVE UNIT
Drive Unit Repair
11. Check all parts for damage or wear. 7. Press the bearing (14) onto the gear end of the
12. Replace any damaged parts. second reduction pinion subassembly (15).
13. Repeat steps 1–12 for the opposite drive unit. 8. Press the bearing (13) onto the first reduction pin-
ion (12) opposite gear side.
Disassembling the drive unit subassemblies
9. Apply a light amount of thread-locking adhesive (P/
1. Heat the first reduction pinion (11–13, Figure 31) in N 061004-005) to the three pipe plugs (20).
an oven at 205°C (400°F) for 30 min.
10. Install one pipe plug (20) into the drain hole of the
2. Remove the bearing (13) from the pinion (12). gear case cover (17).
3. Remove the bearing (11) from the pinion. 11. Install the two pipe plugs (20) into the fill and check
4. Remove the two dowel pins (3) from the subas- holes of the gear case cover (1).
sembly holes as shown. 12. Apply a light amount of thread-locking adhesive (P/
5. Remove the two plugs (20) from the gear case N 061004-014) to the two bores of the gear case
cover. (1) where the bearings (11 and 14) are inserted.
6. Remove one plug (20) from the other half of the 13. Install the bearings (13 and 14) into the bores of
gear case (17). the gear case cover (17).
7. Heat the second pinion assembly (14–16) in an 14. Insert the two dowel pins (3) into the subassembly
oven at 205°C (400°F) for 30 min. holes as shown.
8. Remove the bearings (14) from the second pinion 15. Press the bearing (11) onto the gear side of the first
assembly (15). reduction pinion (12).
9. Remove the first reduction gear (16) from the sec- 16. Repeat steps 1–15 for the drive unit on the other
ond reduction pinion. side.
10. Remove the bearing (5) from the drive shaft as-
sembly (8).
11. Remove the bearing (9) from the tapered end of
the drive shaft (8).
12. Remove the second reduction gear (6) from the
drive shaft.
13. Remove the woodruff key (7) in the slot in the drive
shaft.
14. Check all parts for damage or wear.
16. Repeat steps 1–15 for the drive unit on the other
side.
Assembling the drive unit subassembly
1. Heat the first reduction gear (16, Figure 32) in an
oven at 205°C (400°F) for 30 min.
2. Install the woodruff key (7) in the slot in the drive
shaft (8).
3. Apply grease lubricant to the drive shaft (8) and
press the second reduction gear (6) onto the drive
shaft.
4. Press the bearing (9) onto the tapered end of the
drive shaft (8).
5. Press the bearing (5) onto the drive shaft assembly
(8).
6. Press the first reduction gear (16) onto the second
reduction pinion, (15). Let the assembly cool com-
pletely before proceeding.
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DRIVE UNIT
Drive Unit Repair
(a)
(a)
18
20 19
(a)
19
(a)
22
22
18
3
20 22
55 66
18
(a) 77
22
22
33 8
8 21
11 44 9
10
11
11
14
14
12
12
15
15
13
13
16
14
17
20
Fig. 32 (30663)
(a) Torque to 7 Nm (5 ft lb)
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DRIVE UNIT
Drive Unit Repair
Assembling the drive unit

1. Apply a light amount of retaining compound
(P/N 061004-014) to any exposed bores of the 6
housing subassemblies.
2. Install the drive shaft subassembly into the gear 2
case subassembly (1).
3. Install the second pinion subassembly (14–16) into
the gear case subassembly (1). 7
4. Install the first pinion subassembly (11–13) into the
gear case subassembly (10).
1
Note: Turn the gears to see if any apparent noise or
binding is present.
5. Apply a light coating of gasket sealant
(P/N 065005-002) to both sides of the gasket (4).
6. Install the gasket (4) onto the gear case subas- 5
sembly (1).
7. Use your hands to press the cover assembly (17)
onto the gear case subassembly (1).
4
8. Wrap a single layer of electrical tape around both
3
of the exposed ends of the drive shaft (8).
9. Install the seal (10) into the gear case cover (17). Fig. 33 (30641)
10. Install the seal (2) into the gear case cover (17). 3. Install the coupler assembly to the base of the drive
11. Remove the electrical tape from both ends of the motor.
drive shaft (8). 4. Place one flatwasher (4) on each of the motor in-
12. Apply one drop of removable thread-locking adhe- stallation screws (3).
sive (P/N 061004-006) to the ends of each of the 5. Install the drive motor assembly (1) to the drive unit
screws (18 and 19). (2) with the motor and brake leads facing the back
13. Install the five 38 mm (1.5 in) screws (18) in the lo- of the vehicle.
cations as shown. Torque the screws to 5.1 Nm 6. Insert all four of the screws through the motor base
(45 in lb). and into the drive unit housing. Torque the screws
14. Install the two 25 mm (1.0 in) screws (19) in the lo- to 12 Nm (9 ft lb).
cations as shown. Torque the screws to 5.1 Nm 7. Install the three screws (1, Figure 34), the three
(45 in lb). nuts and the three flatwashers that hold the drive
15. Fill the drive unit with 266 ml (9.0 oz) of gear oil unit to the vehicle. Torque the screws to 61 Nm
(P/N 363506-001) through the vent hole in the gear (45 ft lb).
case cover (17).
16. Install the baffle vent (21) into the gear case cover
(17).
17. Repeat steps 1–16 to assemble the other drive
unit.
Installing the drive unit
1. Assemble the brake assembly to the drive motor.
See section M5.
2. Assemble the coupler (5, Figure 33).
Crown 2016 PF27573 M3.0-2360-008
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DRIVE UNIT
Drive Unit Repair
2
1
3 2
2
Fig. 34 (30640)
8. Connect the drive motor (CA601 or CA602) to the
appropriate harness connectors.
9. Connect the brake (CA603 and CA604, or CA605
and CA606) to the appropriate harness connec-
tors.
10. Repeat steps 1–9 for the motor on the other side.
Preparing the vehicle for operation Fig. 35 (30639)
1. Install the access cover (1, Figure 35), the screws
(2) and the cushion mounts (3).
4. Raise the platform slightly and remove the com-
posite or hardwood blocks.
5. Lower the platform and install the load deck.
M3.0-2360-009 Crown 2016 PF27573
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DRIVE UNIT
Drive Wheel
Drive Wheel 7. Lower the hydraulic jack to allow the vehicle to rest
on the composite or hardwood block with the drive
Preparing the vehicle for maintenance wheel about 6 mm (0.25 in) off the floor.
Recommended Tools and Equipment: Replacing the drive wheel
• Hydraulic jack, P/N 122599 1. Remove the flange nut (2) from the centre of the
• Composite or hardwood block, 50 x 100 x 305 mm hub.
(2 x 4 x 12 in) 2. Remove the drive wheel (1) and the woodruff key
1. Lower the platform. (3) from the hub. Replace the woodruff key if there
2. Turn off the vehicle. is any damage.
3. Remove the load deck. 3. Install the woodruff key (3) and the new drive wheel
(1) on the hub.
4. Disconnect the batteries.
4. Install the flange nut (2). Torque to 81–95 Nm
(60–70 ft lb).
Note: There is an additional torque on the flange nut
CAUTION
(2) when the vehicle is lowered. See Preparing the ve-
Using a hydraulic jack that does not have sufficient hicle for operation.
capacity can result in severe bodily injury or death.
 Make sure that the specifications for the hydraulic
jack agree with the vehicle specifications.
 Refer to SAFETY / Control of Hazardous Energy /
Lifting and Blocking in the Service and Parts Man-
ual for the applicable lifting and blocking proce-
dures.
5. See Figure 36. Put the hydraulic jack (P/N 122599)

at position A. Make sure that the hydraulic jack is
under the frame and lift the vehicle.
Note: Do not try to lift the vehicle if the hydraulic jack is
under the steel side panel to prevent damaging the
side panel.
CAUTION
death.
 Do not perform maintenance below or around a ve-
 See the SAFETY / Control of Hazardous Energy /
dures.
Control of Hazardous Energy / Lifting and Blocking
in the Service and Parts Manual.
6. Put a composite or hardwood block under the rear

frame.
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119
DRIVE UNIT
Drive Wheel
5
(a)
4
B (e)
A 6
3
1
(d)
(f)
2
(b) (c)
Fig. 36 (30500)
(a) Vehicle
(b) Torque to 81–95 Nm (60–70 ft lb) while the vehicle is lifted
(c) Torque to 15 Nm (11 ft lb) when the vehicle is on the ground
(d) Composite or hardwood block 50 x 100 x 305 mm (2 x 4 x
12 in)
(e) Composite or hardwood block 100 x 100 x 355 mm (4 x 4 x
14 in)
(f) Hydraulic jack, P/N 122599
Preparing the vehicle for operation

at position A. Make sure that the hydraulic jack is
2. Remove the wood block.
3. Lower the vehicle.
4. Torque the flange nut (2) to 15 Nm (11 ft lb).
5. Remove the hydraulic jack.
7. Install the load deck.
M3.2-2360-001 Crown 2016 PF27538
120
DRIVE UNIT
Caster Wheel
Caster Wheel 6. Put a composite or hardwood block under the

frame between the hydraulic jack and the caster
Preparing the vehicle for maintenance wheel (5).
Recommended Tools and Equipment: 7. Lower the hydraulic jack to allow the vehicle to rest
• Hydraulic jack, P/N 122599 on the composite or hardwood block.
• Composite or hardwood block, 100 x 100 x 355 mm Replacing the caster wheels
(4 x 4 x 14 in) 1. Remove the retaining ring (6) from the hub.
1. Lower the platform. 2. Remove the caster wheel (5) from the hub.
2. Turn off the vehicle. 3. Inspect the two bearings (4). If they are in good
3. Remove the load deck. condition, remove the two bearings from the wheel
4. Disconnect the batteries. and press them into the new caster wheel. Do not
put pressure on the inside of the bearing race, only
on the outside of the bearing race.
4. Install the new caster wheel (5) on the hub and at-
CAUTION
tach the retaining ring (6).
Using a hydraulic jack that does not have sufficient Preparing the vehicle for operation
capacity can result in severe bodily injury or death.
 Make sure that the specifications for the hydraulic at position B. Make sure that the hydraulic jack is
jack agree with the vehicle specifications. under frame and lift the vehicle.
 See the SAFETY / Control of Hazardous Energy / 2. Remove the wood block.
3. Lower the vehicle.
dures. 4. Remove the hydraulic jack.
5. Connect the batteries
5. See Figure 36. Put the hydraulic jack (P/N 122599) 6. Install the load deck.
at position B. Make sure that the hydraulic jack is
Note: Do not try to lift the vehicle if the hydraulic jack is
under the steel side panel, as it damages the side
panel.
CAUTION
death.
 Do not perform maintenance below or around a ve-
 See the SAFETY / Control of Hazardous Energy /
dures.
Control of Hazardous Energy / Lifting and Blocking
Crown 2016 PF27538 M3.2-2360-002
121
DRIVE UNIT
Caster Wheel
Notes:
M3.2-2360-003
122
ELECTRICAL SYSTEM
123
Notes:
124
ELECTRICAL SYSTEM
Switches
Switches • Used to determine 510 mm (20 in) +12.7/-25 mm

(+.50/-1.0 in) platform height
Left Gate Closed Switch (GCSL) and Left Gate • Adjustment is required
Open Switch (GOSL) 1. To rotate the adjustment screw, remove the switch
See Figure 37. assembly from the vehicle.
• At the lower left of the platform gate 2. Rotate the adjustment screw one full revolution.
• Indicates that the safety gate is open or closed 3. Install the switch assembly back into the vehicle.
• Adjustment is required to ensure that the switch ac- 4. Raise the mast to see if the switch actuates prop-
tuates in the proper gate position erly.
1. Adjust the gate switches. 5. Repeat steps 1–4 if necessary.
2. One click is heard when opening and closing the
gate.
3. If more than one click or no click is heard, adjust
the screws on the switches until the gate operates
properly.
GCSL 1
GOSL GCSR
2
GOSR
Fig. 37 (30552)
1 Adjusting screws
Right Gate Closed Switch (GCSR) and Right Gate 3

Open Switch (GOSR)
See Figure 37.
• At the lower right of the platform gate
• Indicates that the gate is open or closed
• Adjustment is required to ensure that the switch ac- Fig. 38 (30554)
tuates in the proper gate position 1 Adjustment screw
1. Adjust the gate switches. 2 Height switch assembly
2. One click is heard when opening and closing the 3 Height switches HTS20, HTS84 and HTS118
gate.
2,135 mm (84 in) Height Switch (HTS84)
3. If more than one click or no click is heard, adjust
See Figure 38.
the screws on the switches until the gate operates
properly. • Located on the rear side of the platform mast (fac-
ing the operator)
510 mm (20 in) Height Switch (HTS20)
• Used to determine 2,135 mm (84 in) +12.7/-25 mm
See Figure 38. (+.50/-1.0 in) platform height.
• Located on the lower left side of the mast in the plat- • Adjustment is required
form.
1. To rotate the adjustment screw, remove the switch
assembly from the vehicle.
Crown 2016 PF27544 M4.0-2360-050
125
ELECTRICAL SYSTEM
Switches
2. Rotate the adjustment screw one full revolution.

3. Install the switch assembly back into the vehicle.
4. Raise the mast to see if the switch actuates prop-
erly.
5. Repeat steps 1–4 if necessary.
2,995 mm (118 in) Height Switch (HTS118)
See Figure 38.
• Located on the rear side of the platform mast (fac-
ing the operator)
• Used to determine 2,995 mm (118 in) +12.7/-
25 mm (+.50/-1.0 in) platform height
• Adjustment is required
1. To rotate the adjustment screw, remove the switch
assembly from the vehicle.
2. Rotate the adjustment screw one full revolution.
3. Install the switch assembly back into the vehicle.
4. Raise the mast to see if the switch actuates prop-
erly.
5. Repeat steps 1–4 if necessary.
M4.0-2360-051 Crown 2016 PF27544
126
ELECTRICAL SYSTEM
Encoders
Encoders
Operation
Encoders change mechanical movement into a digital 5.0 V
signal. The encoder sends digital signals (channel A
and channel B) to the applicable control module. The
digital signals change from 0 V to the supply voltage at Common 1
different times. The control module then compares the Index 2 V
digital signals to calculate which channel comes first Channel A 3
and how quickly the channels change. Finally, the con-
5V 4
trol module calculates the direction and speed of the
component. Channel B 5
Wire designations +
-
• Supply wire: The supply wire supplies positive volt-
age input to the encoder. The voltage can be 5 V,
11.3 V, or 12 V.
• Common wire: The common wire supplies the neg-
ative voltage input to the encoder. Fig. 39 (25535-01)
• Channel A wire: The channel A wire supplies one of The DVOM should show supply voltage. For example,
the output signals from the encoder to the control- a 5 V encoder should have 5 V between the common
ler. and the supply pins.
• Channel B wire: The channel B wire supplies one of
the output signals from the encoder to the control- Channel feedback overview
ler. The encoder sends a digital pulse of supply voltage
• Index wire: Not all encoders have an index wire. from each channel wire. A DVOM is too slow to show
The index wire supplies a centre reference point in the pulse signal. The DVOM shows the average volt-
functions such as steering feedback. age as the encoder turns. This voltage is approximately
half of the signal voltage. For example, a 5 V encoder
Testing the encoders sends pulses of 5 V on each channel. The DVOM
shows approximately 2.5 V. A voltage that changes
Testing the encoders helps to verify that the data and
from an average of 2.5 V indicates a defective encoder.
feedback from the vehicle is accurate.
Supply voltage test
See Figure 39.
1. Connect the black (negative) probe to the common
pin on the encoder.
2. Connect the red (positive) probe to the supply pin
on the encoder.
3. Measure the supply voltage between the common
and the supply pins.
Crown 2011 PF25302 Rev. 3/16 M4.0-1152-080

02 Rev. 3/16
127
ELECTRICAL SYSTEM
Encoders
Channel A feedback test

See Figure 40.
1. Connect the black (negative) probe to the common
pin on the encoder.
2.5 V
2. Connect the red (positive) probe to the channel A
pin on the encoder.
3. While activating the motor or component the en- Common 1
coder is attached to, measure the supply voltage Index 2 V
between the common and the channel A pins. Channel A 3
5V 4
Channel B 5
+
2.5 V
-
Common 1
Index 2 V
Channel A 3 Fig. 41 (25537-01)
5V 4 The DVOM should show half of the supply voltage. For
Channel B 5 example, a 5 V encoder should have 2.5 V between
the common and channel B pins.
+
- Index voltage overview
The index wire supplies a signal to show the centre or
index position. When the encoder is in the index posi-
tion, the supply voltage is present on the index wire.
Fig. 40 (25536-01) For example, a 5 V encoder sends a 5 V signal on the
index wire when the encoder is in the index position.
The DVOM should show half of the supply voltage. For
example, a 5 V encoder should have 2.5 V between Index voltage test
the common and channel A pins. See Figure 42.
Channel B feedback test 1. Connect the black (negative) probe to the common
See Figure 41. pin on the encoder.
1. Connect the black (negative) probe to the common 2. Connect the red (positive) probe to the index pin on
pin on the encoder. the encoder.
2. Connect the red (positive) probe to the channel B 3. Measure the supply voltage between the common
pin on the encoder. and index pins. If supply voltage is not present,
slowly rotate the encoder shaft 360°.
3. While activating the motor or component that the
encoder is attached to, measure the supply voltage
between the common and channel B pins.
M4.0-1152-081 Crown 2011 PF25302 Rev. 3/16
02 Rev. 3/16
128
ELECTRICAL SYSTEM
Encoders
5.0 V
Common 1
Index 2 V
Channel A 3
5V 4
Channel B 5
+
-
Fig. 42 (25538-01)
When the encoder is in the index position, the DVOM
should show supply voltage. For example, a 5 V en-
coder should have 5 V between the common and index
pins.
Crown 2011 PF25302 Rev. 3/16 M4.0-1152-082

02 Rev. 3/16
129
ELECTRICAL SYSTEM
Fuses
Fuses
When a fuse fails, check the associated circuitry for
short circuits before you replace the fuse. Never jump
a fuse. Always replace the fuse with the same type and
rating specified. Attempting to bypass a fuse could se-
riously damage the associated circuitry.
M4.0-2360-100 Crown 2016 PF27478
130
ELECTRICAL SYSTEM
Fuses
(a) Access 3™
(a)
(b) Access 2 and Access 3
(c) Contactor panel
(b)
3 5 7
6
4 8
(c)
Fig. 43 (30460)
Crown 2016 PF27478 M4.0-2360-101
131
ELECTRICAL SYSTEM
Fuses
Fuse Chart
Index Fuse Location Circuit Type and Size Part Number
1 FU1 Access 2/3 Controller Traction/Hydraulic ANN/CNN 300 A 132083-005

2 FU2 Access 3 Controller Traction ANN/CNN 125 A 132083-008
3 FU3 Contactor Panel Key Switch Auto Blade Fuse 4 A 062765-003
4 FU4 Contactor Panel K1 Relay Auto Blade Fuse 4 A 062765-003
Contactor Panel Access 2/3 and Auto Blade Fuse 4 A 062765-003
5 FU5
Horn
Contactor Panel Access 3, ALM2 Auto Blade Fuse 4 A 062765-003
6 FU6
and Strobe
7 FU7 Contactor Panel Load Tray Auto Blade Fuse 10 A 062765-004
8 FU8 Contactor Panel Accessory Cable Auto Blade Fuse 4 A 062765-003
9 CB1 Contactor Panel Load Tray Circuit Breaker 8 A 148196
M4.0-2360-102 Crown 2016 PF27478
132
ELECTRICAL SYSTEM
Pod Sensors
Pod Sensors
Steer sensor (STR CMD) 3
See Figure 44.

2
• Located in the steer pod.
• Provides command signal to the Access 4 control
module for steering function.
1
• Calibrate the sensor when a service code step re-
quires calibration or when the sensor is replaced.
See ELECTRICAL SYSTEM / Access 1 2 3®/Cali-
bration.
7 6 5 4
1 Fig. 45 (30505)
1 Connects to steer pod sensor
STR CMD 2 Swivel connector assembly
2 3 Rocker
4 Right casting stop
5 Screw
6 Ball link swivel
7 Left casting stop
4. See Figure 46. Check the rotation of the rocker (1).

Fig. 44 (30504)
If the rocker (1) stops at the left casting stop (2), no
1 Steer pod
further adjustment is needed. If the rocker (1) has a
2 Sensor
gap (3) at the left casting stop (2), repeat steps 1–3.
Steer linkage adjustment for the
steer sensor (STR CMD)
See Figure 45.
When the pod sensor, swivel connector assembly (2)
and rocker (3) are assembled correctly, the rocker (3)
freely rotates in both directions. The rocker (3) only
stops at the left casting stop (7) and the right casting
stop (4). If the rocker does not freely rotate to the left
(7) or right (4) casting stop, use one of the following
procedures to adjust the swivel connector assembly
(2).
Rocker does not rotate to the left casting stop
If the rocker (3) does not rotate to the left casting stop
(7), increase the length of the swivel connector assem-
bly (2) as follows:
1. Remove the screw (5) that attaches the swivel con-
nector assembly (2) to the rocker (3).
2. Hold the swivel connector assembly (2) and rotate
the ball link swivel (6) anti-clockwise one revolu-
tion.
3. Connect the swivel connector assembly (2) to the
rocker (3).
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ELECTRICAL SYSTEM
Pod Sensors
1 1
3
2
2
Fig. 46 (30506)
1 Rocker
2. Hold the swivel connector assembly (2) and rotate
the ball link swivel (6) clockwise one revolution.
2 Left casting stop
3. Connect the swivel connector assembly (2) to the
3 Gap
rocker (3).
Rocker does not rotate to the right casting stop 4. See Figure 47. Check the rotation of the rocker (1).
See Figure 45. If the rocker (1) stops at the right casting stop (2),
If the rocker (3) does not rotate to the right casting stop no further adjustment is needed. If the rocker (1)
(4), increase the length of the swivel connector assem- has a gap (3) at the right casting stop (2), repeat
bly (2) as follows: the previous steps.
1. Remove the screw (5) that attaches the swivel con-
nector assembly (2) to the rocker (3).
1 1
2 3
2
Fig. 47 (30507)
1 Rocker
2 Right casting stop
3 Gap
M4.0-2360-151 Crown 2016 PF27543
134
ELECTRICAL SYSTEM
Pod Sensors
Traction sensor (TXN CMD)

See Figure 48.
• Located in the traction pod.
• Provides command signal to the Access 4 control
module for traction function.
• Calibrate the sensor when a service code step re-
quires calibration or when the sensor is replaced.
See ELECTRICAL SYSTEM / Access 1 2 3®/Cali-
bration.
2
TXN CMD
Fig. 48 (30508)
1 Traction pod
2 Sensor
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ELECTRICAL SYSTEM
Control Cables
Control Cables
Fig. 49 (30445)
1 Screw
1. Raise the platform approximately 1.2 m (4 ft) from
the floor.
2 Bracket assembly
2. Block the platform with a composite or hardwood
3 Cotter pin
block. See the SAFETY chapter.
Tensioning the control cables 3. Turn off the vehicle.
The control cables are routed through the mast pulleys. 4. Remove the load deck from the vehicle.
A tension device keeps the control cables seated. The 5. Disconnect the batteries.
tension device is bolted to the chassis in front of the
mast. After adjustment, each control cable will have ap- 6. Remove the floorboard from the platform.
proximately 11.3 kg (25 lb) of pull. To obtain the proper 7. Remove the traction motor covers below the plat-
tension, adjust the control cables using the following form.
procedure. 8. Disconnect CA108 for the DMSR and DMSL
Note: Adjusting the chain and platform height after ten- switches. The switches are located below the back
sioning the control cables can cause stress on the ca- part of the chassis.
bles or loosen them. The chains and platform height 9. See Figure 49. Tighten the screw (1) until the ten-
must be adjusted properly before tensioning the control sion bracket (2) touches the chassis.
cables. 10. Disconnect CA101 and CA102.
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ELECTRICAL SYSTEM
Control Cables
11. See Figure 50. Remove the cable clamps (12) on

both sides of the platform mast and the third stage
mast.
12. Pull the cables and plugs through the holes in the
bottom right- and bottom left-hand sides of the plat-
form.
13. Tighten the cables from the bottom of the third
stage mast around the mast studs (18). Secure the
cables with the clamps (12).
14. Pull the remaining cable tight from the bottom of
the platform mast.
15. Feed the cables back up through the platform
mast.
16. Install the cable clamps into the mating connec-
tors.
17. Loosen the screw (3) until the cotter pin (4) touches
the bracket assembly (9).
18. Install the floorboard and the cover on the chassis.
19. Connect tCA108 for the DMSR and DMSL
switches.
22. Remove the blocks and lower the platform. See the
SAFETY chapter.
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ELECTRICAL SYSTEM
Control Cables
1 Screw 5 Double shoulder washer

2 Cover 6 Compression spring
3 Screw 7 Spacer
F 8 Strain relief fitting
4 Cotter pin
9 Bracket assembly
10 Flat washer
19
11 Hydraulic unit
12 Clamp
13 Nut
16
F 14 Cable track
15 Nut
CA101 16 Guide clamp
C 17 Cable guide
C
18 Mast stud
19 Mast cap
20 Hoses
21 Nuts and lock washers
CA102
21
M3
13
11
12
15
14
17 E
18
D 20
A
4 B
9 To chassis harness
7
5
10
8
3
6 2
A
B 1
Fig. 50 (30446)
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ELECTRICAL SYSTEM
Control Cables
Cable Replacement 2. Remove the two hoses (20) from the hydraulic unit
(11).
See Figure 50.
3. Use a rag to catch any oil that runs from the con-
nection.
4. Plug the two hoses with hydraulic plugs
WARNING (P/N 064220-002).
A truck that falls can cause severe injury or death. 5. Remove the electrical connections from M3. Note
Using a lifting device or blocks that do not have suffi- the location of the wires.
cient capacity can result in severe injury or even death. 6. To remove the hydraulic unit from the vehicle, re-
 Do not do maintenance below or around a truck that move the nuts and lock washers (21).
is not correctly secured.
Removing the cable
 See SAFETY/Control of Hazardous Energy/Lifting
1. Identify the control cable (or cables) that needs re-
and Blocking in the Service and Parts Manual for
placing and remove the connections from the
the applicable lifting and blocking procedures.
chassis harness. Note the locations of the wire on
 Read and obey all safety procedures in SAFETY/ the terminal blocks.
Control of Hazardous Energy/Lifting and Blocking
Note: If one cable is being replaced due to wear,
Crown recommends replacing both control cables.
2. To relieve all of the tension on the control cables,
Preparing the vehicle for cable replacement remove the cotter pin (4), screw (3), and flatwasher
Note: The chains and the platform height must be (10) from the tensioning assembly.
properly adjusted before tensioning the cable. 3. Disconnect CA101 and CA102 and the cable guide
1. Use the service panel to raise the platform until the clamps (16) on the platform.
cable track (14) on the third stage mast is visible. 4. Insert the cable down through the holes in the plat-
2. Temporarily block the platform. form.
3. Remove the nuts (13) from the track. 5. Remove the nuts for the cable track (15) from the
4. Push the studs out of the holes. platform.
5. Lower the track slightly so that the studs are below 6. Push the studs through the mounting holes.
the mounting plate on the mast. 7. Depending on which cable is being replaced, re-
6. Remove the blocks. move the guide and shims on the lower left- or
right-hand side of the platform mast.
7. Lower the platform until it is approximately 915 mm
(36 in) from the ground (measured to the top of the 8. Remove the cable clamp (12) from the third stage
back of the platform skirt). mast.
8. Turn off the vehicle. 9. Pull the cable and the track down from in between
the platform mast and third stage mast.
9. Remove the load deck.
10. Remove the groove cable guides that are J shaped
(17) from the third stage mast.
11. Remove the mast cap (19) from the top of the plat-
11. Pull both cables out of the first stage mast at the
form mast.
end of the tensioning assembly about 240 mm
12. Disconnect CA108 for the DMSR and DMSL (9.5 in) or until CA101 and CA102 are even with
switches located below the back of the floorboard the bottom of the platform mast. Do not put any
chassis. strain on the connector plugs by trying to pull out
13. Remove the floorboard. the cables too far.
14. Remove the cover plate. 12. Remove the end cap on the strain relief and the
rubber insert (8) from the cable that is being re-
Removing the hydraulic unit
placed. Do not loosen the strain relief on the cable
1. Use the manual lowering valve to release the hy- that is not being replaced. If both cables are being
draulic pressure from the system. The manual low- replaced, remove the tension device completely
ering valve is on the end of the solenoid valve from both cables.
(SVL) on the contactor panel.
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ELECTRICAL SYSTEM
Control Cables
13. Put a piece of tape around a couple of the wires 16. Tighten the screw on the tension device until the
from the control cable to a small electrical wire pull spacer and the legs of the tension bracket (9) touch
or a similar device. Keep the taped area as small the chassis.
as possible, but make sure that the cable is secure. 17. Pull both of the cables tight and tighten the strain
14. Stand on the operator platform and pull the control relief. Tighten the cap on the strain relief fitting to
cable out of the top of the third stage mast. 3 N m (30 in lb). There must be a gap between the
15. Pull the cable and wire through the bottom of the cap and the fitting body of approximately 3 mm
third stage mast. (0.125 in). Make sure that the cable cannot go
through the strain relief fitting.
16. Remove the existing cable from the wire pull.
18. Loosen the screw on the tension device until the
Installing the new cable cotter pin touches the U-shaped bracket.
1. Put a piece of tape around the new cable to the
wire pull. Make sure that the tape is tight and bun-
dled as small as possible.
2. Carefully pull the new cable back through and out
of the top of the third stage mast with the wire pull. WARNING
If needed, apply a rubber lubricant to the control Incorrect operation of the truck can cause death or
cable. Do not let the cable kink, tangle or catch on injury.
the lift cylinder. If you do not put all safety devices in place before run-
3. Use the wire pull to pull the cable through the chas- ning an operational check, this could result in death or
sis mast and into the chassis area. Do not let the injury to you or others around you.
cable kink or tangle.  Do not run an operational check on a vehicle that is
4. Pull the cables straight down in between the sec- not correctly secured.
ond and third stage masts.
5. Attach the groove cable guides that are J shaped 19. Install the hydraulic unit on the vehicle and secure
(17). the unit into place. Connect all electrical and hy-
6. Pull the cable out of the side and around the studs draulic components.
(18). 20. Connect the batteries.
7. Pull up the cable and attach the cable clamp (12) 21. Using the raise and lower switch at the front of the
to the side of the third stage mast, maintaining ten- vehicle, raise the mast until the cable track on the
sion until the clamp is tight. third stage mast is visible.
8. Form the cable track (14) into a U shape. Push the 22. Block the platform mast. See the SAFETY chapter.
track up in between the third stage mast and the
23. Connect the cable track to the mounting plate on
platform stage mast.
the third stage mast.
9. Line up the studs with the holes on the mounting
24. Raise the mast and remove the blocks.
platform and fasten the nuts to the studs.
25. Raise and lower the mast for one complete cycle.
10. Feed up the cable through the holes in the plat-
form. 26. With the mast lowered, check the oil level in the
hydraulic reservoir. Fill as needed. See the IN-
11. Connect PC101 to JC101 and PC102 to JC102.
SPECTION AND LUBRICATION/Lubricants, Aer-
12. Attach the cable guide clamps (16) to the platform. osols and Service Supplies section.
13. Install the guides at the bottom of the platform 27. Raise and lower the mast through at least five
mast. more cycles, then raise the mast completely.
14. Install the strain relief fitting (8), the double shoul- Note: At the top front of the chassis mast, there is a
der washer (5) and the compression spring (6) on slotted hole and a slot in the second stage mast. The
the cable and the tension bracket. Do not tighten bleed screw on the cylinder is directly behind those
the strain relief fitting. slots.
15. Put the tension bracket assembly into position and 28. Use a screwdriver to loosen the bleed screw about
secure it with the screw (3), washer (10), spacer (7) one half-turn. When hydraulic oil starts to come
and cotter pin (4). out, tighten the bleed screw.
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ELECTRICAL SYSTEM
Control Cables
29. Lower the mast and check the hydraulic oil level in
the reservoir, fittings and connections. Make sure
that there are no leaks.
30. If there are no leaks, install the floorboard on the
platform.
31. Connect PC108 to JC108 for the DMSR and DMSL
switches.
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ELECTRICAL SYSTEM
Tilt Sensor
Tilt Sensor 15. Install the load deck.
(SAA and EMEA only)

The tilt sensor (TLTS) is on the contactor panel. The
purpose of the tilt sensor is to disable the lift when the
1
2,995 mm (118 in) vehicle is on an incline of 1.5° (2.6%
grade) or more.
Alignment
1. Park the vehicle on a level, dry concrete surface.
2
2. To expose the tilt sensor, remove the load deck.
3. Adjust the three nuts on top of the tilt sensor until
the bubble is centred in the inner circle.
4. Adjust the nuts until one or two threads of the bolt
are visible above the nuts. 3
6. See Figure 51. Use Access 1 to scroll to features
menu F5.10 to turn on the tilt sensor. 4
F5.10 F5.10
TILT SENSOR TILT SENSOR
OFF
F5.10
TILT SENSOR
ON
Fig. 52 (30454)
Fig. 51 (30480) 1 Tilt sensor
7. Verify that the green light on the bottom of the tilt 2 Screw
sensor is on. 3 Spacer
8. With the gates open, raise the platform until the 4 Manifold block - see HYDRAULIC SYSTEM
510 mm (20 in) switch is activated.
9. Close the gates. Drive the vehicle, load deck first,
up an incline greater than 1.5° or 3% grade.
Note: In this position, the bubble on the tilt sensor will
be completely outside of the outer circle.
10. After a three-second delay, an alarm sounds re-
peatedly with three quick beeps. Event Code 235
is displayed.
11. Verify that the red light on the bottom of the tilt sen-
sor is on.
12. Lower the platform. The alarm stops and the event
code clears.
13. Raise the platform until the 510 mm (20 in) switch
is activated while still on an incline. Verify that the
lift is disabled. The alarm sounds, Event Code 235
is displayed and the red light is on.
14. Lower the platform completely and back the vehi-
cle off the incline.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Access 1 2 3® Menus Operator menus

This section includes tables and descriptions of the op- Messages and menus
erator level and service level menus. The following tables and figures illustrate the Access 1
messages and menus.
1 2 Startup Messages
3
Message Menu Descriptions
Crown The Crown name appears for one

second after the vehicle is turned on,
then disappears.
WAVe The vehicle name appears for one
second after the vehicle is turned on,
then disappears.
4 Battery icon This shows the battery life in percent.

P1 This shows the vehicle performance
Fig. 53 (30520)
level.
1 Access 1
2 Message display
Events
3 Navigation arrows - up, down, left, right
4 Enter button Message Menu Descriptions
E1 through E16 Use this menu to show event codes,

time, count and temperature.
Hours
Message Selection Menu Descriptions
H1 Runtime=______ Use this menu to show

the total hours the ve-
hicle is on and operat-
ing.
H2 Hydraulics=____ Use this menu to show
the total hours of oper-
ation of the hydraulic
system.
H3 Traction=______ Use this menu to show
the total hours of oper-
ation of M1 and M2.
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ELECTRICAL SYSTEM
Service
Message Selection Menu Descriptions
Service Menu Enter Service Code 1. Push the up or down arrow to scroll to the first number.
2. Push the right arrow to go to the next number.
3. Repeat steps 1–2 until all four numbers are entered.
4. Push enter to accept the user code.
Technician Tips: To exit this menu, turn off the vehicle.
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ELECTRICAL SYSTEM
Operator menus
Crown
WAVe These items display briefly after the vehicle is turned on.
Battery Icon
P1
E
Code: XXX
Events E1 Time: XXX
CNT: X
T: C (f)
Code: XXX
E2 Time: XXX
CNT: X
T: C (f)
Code: XXX
E3 Time: XXX
CNT: X
T: C (f)
Code: XXX
E4 Time: XXX
CNT: X
T: C (f)
Hours H1 Runtime=________ _______ Hours
H2 Hydraulics=______ _______ Hours

H3 Traction=________ _______ Hours
Service Menu Enter Service Code Edit 0000–9999 Turn off the vehicle to return to the main menu.
continued on page -004
Fig. 54 (30526-01)
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ELECTRICAL SYSTEM
Analyser menus
continued from page -003
Analyzer A1 Access 1 A1.1 Travel Speed=_ KPH

(mph)
A1.2 Battery Voltage=_ V
A1.3 Battery Level=_ Percent
A1.4 Speed Limit=_ MF1, MF2, MF3, MF4,

MR1, MR2, MR3, MR4
A1.5 Height Zone=_ HZ1, HZ2, HZ3
A2 Access 2/3 A2.1 Charger Inhibit=_ 0/1
A2.2 ERLS - R=_ 0/1
A2.3 ERLS - L=_ 0/1
A2.4 ECS=_ 0/1
continued on page -005 0/1

A2.5 SPS=_
A2.6 CHS3=_ 0/1
A2.7 CHS4=_ 0/1
A2.8 MCS=_ 0/1

A2.9 TLTS=_ 0/1
A2.10 M1 Speed=_ RPM
A2.11 M1 Temperature=_ C or F
A2.12 M1 Current=_ A
A2.13 Access 2/3 Temp=_ C or F
A2.14 HN=_ On/Off
A2.15 SVL=_ On/Off
A2.16 BRK1=_ On/Off
A2.17 L=_ On/Off
Fig. 55 (30527)
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ELECTRICAL SYSTEM
A3 Access 3 A3.1 M2 Speed=_ RPM
A3.2 M2 Temperature=_ C or F
A3.3 M2 Current=_ Amp
A3.4 Access 3 Temp=_ C or F
A3.5 BRK2=_ On/Off
A3.6 CHS=_ On/Off
A3.7 K2=_ On/Off
A3.8 ALM2=_ On/Off
Fig. 56 (30528)
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ELECTRICAL SYSTEM
A4 Access 4 A4.1 CHS1=_ 0/1
A4.2 CHS2=_ 0/1
A4.3 HNS=_ 0/1
A4.4 LTS - R=_ 0/1
A4.5 LTS - L=_ 0/1
A4.6 RAS=_ 0/1
A4.7 LOS=_ 0/1
A4.8 DMSR=_ 0/1
A4.9 DMSL=_ 0/1
A4.10 HSS=_ 0/1
A4.11 HGTS20=_ 0/1
A4.12 HGTS84=_ 0/1
A4.13 HGTS118=_ 0/1
A4.14 GOSL=_ 0/1
A4.15 GCSL=_ 0/1
Fig. 57 (30529)
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ELECTRICAL SYSTEM
A4.16 GOSR=_ 0/1
A4.17 GCSR=_ 0/1
A4.18 RHS=_ 0/1
A4.19 LHS=_ 0/1
A4.20 LMS1=_ 0/1
A4.21 LMS2=_ 0/1
A4.22 STRCMD1=_ V
A4.23 STRCMD2=_ V
A4.24 TRACMD1=_ V
A4.25 TRACMD2=_ V
A4.28 ALM3=_ On/Off
A4.29 K3=_ On/Off
A4.30 K4=_ On/Off
A4.31 PLS=_ On/Off
Fig. 58 (30530)
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ELECTRICAL SYSTEM
Calibration menus
Calibration Steer Command Steer Command Steer Command Steer Command E

C1 E E
Full Left - V Center - V Full Right - V
Calibration Passed
Calibration Failed
Traction Command Traction Command Traction Command Traction Command

C2 E E E
Full Forward - V Center - V Full Reverse - V
Calibration Passed
Calibration Failed
C3 Adjust Battery Adjust Battery - V E* * Use the up and down arrows to adjust the volt-
age. Then press enter.
Fig. 59 (30531)
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ELECTRICAL SYSTEM
Features menus
Features F1 Language=____ English
Español
Français
Deutsch
Nederlands
Italiano
Polski
Cestina
Dansk
Magyar
Suomi
Norsk
Svenska
Slovenski
F2 Unit of Measure=_ English E
Metric E
The operator is able to switch the perfor-

F3 User Performance=_ E On
mance modes (P1, P2, P3).
Off The performance mode (P1, P2, P3) is fixed

in the last mode that was set.
Fig. 60 (30532-01)
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ELECTRICAL SYSTEM
F4 User Codes=_ F4.1 Operator Code=_ On E
Off E
F4.2 Operator Code Type Number=_ E Wait Code Reset

Resets the codes when
Operator Code Type Command=_ E Wait Code Reset changing from one code
type to another
Operator Code Type Display=_ E Wait Code Reset
F4.3 Add Operator Code=_ ID Code P E Sure? N Not a New Code
Invalid Code
Sure? Y New Code Saved

ID = This is the user ID associated with the assigned code.
The ID is limited to four numeric characters only (0–9).
Code = This is the code associated with the assigned user ID and the operator level.
The code is limited to four numeric characters only (0–9).
P = This is the performance level (1, 2, 3) associated with the user ID.
F4.4 Edit Operator Code=_ No Code
ID Code P E Sure? N Not a New Code
Sure? Y Code Saved
F4.5 Delete Operator Code=_ No Code
ID Code P E Sure? N No Code. Reset to Default
Sure? Y Code Deleted
F4.6 Edit Service Code=_ Code E Sure? N Invalid Code
Sure? Y Code Deleted

continued on page -011 Code = This is the code associated with the service level.
The code is limited to four numeric characters only (0–9).
Fig. 61 (30533)
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ELECTRICAL SYSTEM
F5 Options=_ F5.1 20" Speed Limit=_ On E
Off E
F5.2 20" Gate Alarm=_ On E
Off E
F5.3 Gate Travel=_ On E
Off E
On = Automatic Presence Override Mode when hands are

F5.4 Hand Presence=_ On E
removed from the pods.
Off = All functions are disabled when hands are removed from
Off E
the pods.
F5.5 Lift Limit=_ Lift Limit HGTS118 The lift stops when the HGTS118 switch is activated.
Lift Limit HZ3 W/ORS Press and hold the arrow up button on the display to operate
the lift again.
Lift Limit HGTS84 The lift stops when the HGTS84 switch is activated.
Lift Limit HZ2 W/ORS Press and hold the arrow up button on the display to operate
the lift again.
Lift Limit HGTS20 The lift stops when the HGTS20 or the MCS switch is acti-
vated and Feature 5.1 is enabled.
Lift Limit HZ1 W/ORS The lift stops when the HGTS20 or the MCS switch is
activated and Feature F5.1 is enabled. Press and hold the
arrow up button on the display to operate the lift again.
Fig. 62 (30534-01)
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ELECTRICAL SYSTEM
F5.6 Sleep Delay=_ Off E
Minutes E
F5.7 Travel Alarm=_ Off E
Forward E
Reverse E
Both E
F5.8 Lift Alarm=_ Off E
Lift E
Lower E
Both E
F5.9 Strobe Lights=_ Off E

The strobe lights turn on when the key is on.
Key E
Operator E The strobe lights turn on when the operator is on

both DMS pedals.
F5.10 Tilt Sensor=_ Off E

EMEA option only
On E
F5.11 Power Load Tray=_ Off E
On E
Fig. 63 (30535-01)
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ELECTRICAL SYSTEM
Performance menus
Performance P1 Performance 1=_ P1.1 Max Forward 1=_ KPH E

(mph)
P1.2 Max Forward 2=_ KPH E
(mph)
continued on page -017 (mph)
(mph)
P1.5 Max Reverse 1=_ KPH E
(mph)
(mph)
(mph)
(mph)
P1.9 Forward Accel=_ 1-9 E
P1.10 Reverse Accel=_ 1-9 E
P1.11 Coast=_ 1-9 E
P1.12 Plug=_ 1-9 E
P1.13 Raise Speed=_ 1-9 E
P1.14 Lower Speed=_ 1-9 E
Fig. 64 (30536)
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ELECTRICAL SYSTEM
P2 Performance 2=_ P2.1 Max Forward 1=_ KPH E

(mph)
(mph)
(mph)
(mph)
(mph)
(mph)
(mph)
(mph)
P2.11 Coast=_ 1-9 E
P2.12 Plug=_ 1-9 E
Fig. 65 (30537)
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ELECTRICAL SYSTEM
P3 Performance 3=_ P3.1 Max Forward 1=_ KPH E

(mph)
(mph)
(mph)
(mph)
(mph)
(mph)
(mph)
(mph)
P3.11 Coast=_ 1-9 E
P3.12 Plug=_ 1-9 E
Fig. 66 (30538)
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ELECTRICAL SYSTEM
P4 Steering=_ P4.1 High Speed Str=_ 1-9 E
P4.2 Low Speed Str=_ 1-9 E
P4.3 High Speed Str H=_ 1-9 E
P4.4 Low Speed Str H=_ 1-9 E
P4.5 Steer Straight=_ 1-9 E
P4.6 Steer Response=_ 1-9 E
P5 Performance H=_ P5.1 Coast H=_ 1-9 E
P5.2 Plug H=_ 1-9 E
P6 BDI=_ P6.1 BDI Adj Startup=_ 1-9 E
P6.2 Bat Max Adj=_ 1-9 E
P6.3 Bat Min Adj=_ 1-9 E
P6.4 Lift Lockout=_ 20-40 Percent E
P7 Turtle Mode=_ P7 Turtle Mode=_ 1-99 Percent E
P8 Load Factory Default Values=_ Load Factory

Factory Values Loaded
No Yes
Fig. 67 (30539)
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ELECTRICAL SYSTEM
Utilities menus
Utilities U1 SW Part Number U1.1 Access 1=_
U1.2 Access 2/3=_
U1.3 Access 3=_
U1.4 Access 4 M=_
U1.5 Access 4 S=_
U2 Tester U2.1 Tester BRK1=_ On/Off E
U2.2 Tester BRK2=_ On/Off E
U2.3 Tester ALM1=_ On/Off E
U2.4 Tester ALM2=_ On/Off E Press the enter button to turn on

the driver for three seconds.
U2.5 Tester ALM3=_ On/Off E SRO = Yes
U2.6 Tester K3=_ On/Off E Press the enter button to turn off
the driver.
U2.7 Tester K4=_ On/Off E SRO = No
U2.8 Tester Strobe=_ On/Off E
U2.9 Tester Horn=_ On/Off E
U2.10 Tester SVL=_ On/Off E
U3 Clear Events Clear All Module Events=_
No Yes All Module Events Cleared
U4 Clear EEPROM Clear All Module EEPROM=_
No Yes All Module EEPROM Cleared
Fig. 68 (30540-01)
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ELECTRICAL SYSTEM
Hours menus
Hours H1 Runtime Hours
H2 Hydraulics Hours
H3 Traction Hours
H4 PM Timer H4.1 Tag=_ Tag None E
Tag H1 E
Tag H2 E
Tag H3 E
H4.2 Interval=_ Interval Hours 00000 to 65535 E
Fig. 69 (30541)
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Analyser Menus
Analyser Menus 2. Scroll to the SERVICE menu.

3. Push the right arrow.
Analyser menus overview  Enter Service Code shows ****.
4. Push the up or the down arrow to scroll to the first
The Analyser menus allow the operator to check and
number.
test the components and the circuits. The menus are:
• A1 Menu - Access 1 inputs
6. Repeat steps 4–5 until all four numbers are en-
• A2 Menu - Access 2/3 inputs
tered.
• A3 Menu - Access 3™ inputs
7. Push the enter button to accept the service code.
• A4 Menu - Access 4 inputs  Access 1 shows ANALYZER.
Analyser menus access 8. Push the right arrow to go to the A1 Access menu.
Note: To scroll through the Analyser menus, see the A1 Inputs menu
tables in this section of the service manual.
These menus show the Access 1 inputs.
1. Turn on the vehicle and push the enter button.
A1 Inputs
A1 Status Menu Menu Description
A1.1 TRAVEL SPEED = ____ This menu shows the travel speed in km/h or mph.
A1.2 BATTERY VOLTAGE = ____ This menu shows the battery voltage. This number can
vary slightly.
A1.3 BATTERY LEVEL = ____ This menu shows the battery level in percent.
A1.4 SPEED LIMIT = ____ This menu shows the speed limit of the vehicle.
A1.5 HEIGHT ZONE = ____ This menu shows the height zone of the vehicle.
A2 Inputs menu A2.X Access 2/3 inputs menu

These menus show the Access 2/3 inputs. This menu shows the component inputs to Access 2/3.
A2 Inputs
Submenus Access 2/3 Inputs Menu Menu Description
A2.1 CHARGER INHIBIT = ____ 0 = The battery charger is connected to an AC outlet.

1 = The battery charger is off or disconnected.
A2.1 ERLS - R = ____ 0 = The raise portion of the emergency raise lower switch is
open.
1 = The raise portion of the emergency raise lower switch is
closed.
A2.1 ERLS - L = ____ 0 = The lower portion of the emergency raise lower switch is
open.
1 = The lower portion of the emergency raise lower switch is
closed.
A2.4 ECS = ____ 0 = The elevation control switch is in the platform position.
1 = The elevation control switch is in the base position.
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Analyser Menus
A2 Inputs
Submenus Access 2/3 Inputs Menu Menu Description
A2.5 SPS = ____ 0 = The service panel switch is open.

1 = The service panel switch is closed.
A2.6 CHS3 = ____ 0 = The chain slack switch 3 is open.
1 = The chain slack switch 3 is closed.
A2.8 MCS = ____ 0 = One of the motor cover switches is open.
1 = The motor cover switches are closed.
A2.9 TLTS = ____ 0 = The tilt sensor is activated.
1 = The tilt sensor is level.
A2.10 M1 SPEED = ____ This menu shows the right traction motor speed in rpm.
A2.11 M1 TEMPERATURE = ____ This menu shows the right traction motor temperature in °C or °F.
A2.12 M1 CURRENT = ____ This menu shows the current in the right traction motor circuit.
A2.13 ACCESS 2/3 TEMP = ____ This menu shows the master traction and Access 2 temperature
in °C or °F.
A2.14 HN = ____ On = The horn driver is enabled.
Off = The horn driver is disabled.
A2.15 SVL = ____ On = The solenoid valve is energised.
Off = The solenoid valve is not energized.
A2.16 BRK1 = ____ On = The right traction motor brake is released.
Off = The right traction motor brake is applied.
A2.17 L = ____ On = The line contactor is energised.
Off = The line contactor is not energised.
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Analyser Menus
A3 Inputs menu A3.X Access 3™ inputs menu

These menus show the Access 3™ inputs. This menu shows the Access 3™ inputs to the compo-
nents.
A3 Inputs
A3.1 Access 3™ Inputs Menu Access 3™ Inputs Menu
A3.1 M2 SPEED = ____ Shows the left traction motor speed in rpm.
A3.2 M2 TEMPERATURE = ____ Shows the left traction motor temperature in °C or °F.
A3.3 M2 CURRENT =____ Shows the current in the left traction motor circuit.
A3.4 ACCESS 3™ TEMP = ____ Shows the Access 3™ temperature in °C or °F.
A3.5 BRK2 = ____ On = The left traction motor brake is released.
Off = The left traction motor brake is applied.
A3.6 CHS = ____ On = The chain slack switch is on.
Off = The chain slack switch is off.
A3.7 K2 = ____ On = The line contactor control relay is on.
Off = The line contactor control relay is off.
A3.8 ALM2 = ____ On = The travel alarm is on.
Off = The travel alarm is off.
A4 Inputs menu A4.X Access 4 inputs menu

These menus show the Access 4 inputs. This menu shows the component inputs to Access 4.
A4 Inputs
Submenus Access 4 Inputs Menu Menu Description

A4.1 HNS = ____ 0 = The horn switch is open.
1 = The horn switch is closed.
A4.4 LTS - R = ____ 0 = The right motorised load tray switch is open.
1 = The right motorised load tray switch is closed.
A4.5 LTS - L = ____ 0 = The left motorised load tray switch is open.
1 = The left motorised load tray switch is closed.
A4.6 RAS = ____ 0 = The raise switch is open.
1 = The raise switch is closed.
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Analyser Menus
A4 Inputs
A4.7 LOS = ____ 0 = The lower switch is open.

1 = The lower switch is closed.
A4.8 DMSR = ____ 0 = The right operator presence switch is open.
1 = The right operator presence switch is closed.
A4.9 DMSL = ____ 0 = The left operator presence switch is open.
1 = The left operator presence switch is closed.
A4.10 HSS = ____ 0 = The high-speed switch is open or in turtle mode.
1 = The high-speed switch is closed or in rabbit mode.
A4.11 HGTS20 = ____ 0 = The mast switch actuator is above 508 mm (20 in). The
switch is open.
1 = The mast switch actuator is below 508 mm (20 in). The
switch is closed.
A4.12 HGTS84 = ____ 0 = The mast switch actuator is above 2,134 mm (84 in).
The switch is open.
1 = The mast switch actuator is below 2,134 mm (84 in).
The switch is closed.
A4.13 HGTS118 = ____ 0 = The mast switch actuator is above 2,997 mm (118 in).
The switch is open.
1 = The mast switch actuator is below 2,997 mm (118 in).
The switch is closed.
A4.14 GOSL = ____ 0 = The left gate open switch is open.
1 = The left gate open switch is closed.
A4.15 GCSL = ____ 0 = The left gate closed switch is open.
1 = The left gate closed switch is closed.
A4.16 GOSR = ____ 0 = The right gate open switch is open.
1 = The right gate open switch is closed.
A4.17 GCSR = ____ 0 = The right gate closed switch is open.
1 = The right gate closed switch is closed.
A4.18 RHS = ____ 0 = The right-hand sensor is open.
1 = The right-hand sensor is closed.
A4.19 LHS = ____ 0 = The left-hand sensor is open.
1 = The left-hand sensor is closed.
A4.20 LMS1 = ____ 0 = The limit switch 1 is open.
1 = The limit switch 1 is closed.
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Analyser Menus
A4 Inputs
A4.21 LMS2 = ____ 0 = The limit switch 2 is open.

1 = The limit switch 2 is closed.
A4.22 STRCMD1 = ____ Shows the voltage of steer command 1.
A4.23 STRCMD2 = ____ Shows the voltage of steer command 2.
A4.24 TRACMD1 = ____ Shows the voltage of traction command 1.
A4.25 TRACMD2 = ____ Shows the voltage of traction command 2.
A4.26 M1 SPEED = ____ Shows the right traction motor speed in rpm.
A4.27 M2 SPEED = ____ Shows the left traction motor speed in rpm.
A4.28 ALM3 = ____ On = The gate alarm is on.
Off = The gate alarm is off.
A4.29 K3 = ____ On = The motorised load tray motor control relay K3 is on.
Off = The motorised load tray motor control relay K3 is off.
A4.30 K4 = ____ On = The motorised load tray motor control relay K4 is on.
Off = The motorised load tray motor control relay K4 is off.
A4.31 PLS = ____ On = The platform strobe lights are on.
Off = The platform strobe lights are off.
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Calibration Menus
Calibration Menus
Calibration menus overview
The Calibration menus show the steer command, trac-
tion command and battery adjustment of the vehicle.
CAUTION
The failure to make sure that the calibrations and
adjustments are correct could cause incorrect ve-
hicle operation.
The vehicle operates incorrectly.
When you replace an access module or update the
module software, carry out the following steps:
 Calibrate the vehicle.
 Make sure that the Features Menus are set cor-
rectly.
 Make sure that the Performance Menus are set cor-
rectly.
Calibration menus access

Note: To scroll through the Calibration menus, see the
2. Scroll to the SERVICE menu.
 Enter Service Code shows ****.
4. Push the up or the down arrow to scroll to the first
number.
tered.
 Access 1 shows ANALYZER.
8. Push the up or the down arrow to scroll to the Cali-
bration menu.
9. Push the right arrow to go to the C1 STEER COM-
MAND menu.
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Calibration Menus
C1 Calibration
Menu Level Display Menu Description
C1 STEER COMMAND = ____ Use this menu to calibrate the steer command.
STEER COMMAND FULL LEFT = ____ Use the steer pod to go fully to the left and hold.
Then push the enter button.
A pass or fail is shown.
The steer command value is shown in volts.
STEER COMMAND CENTER= ____ Keep the steer pod in the middle. Then push the
enter button.
STEER COMMAND FULL RIGHT= ____ Use the steer pod to go fully to the right and hold.
Then push the enter button.
C2 TRACTION COMMAND = ____ Use this menu to calibrate the traction command.
TRACTION COMMAND FULL FORWARD = Use the traction pod to go fully forward and hold.
____ Then push the enter button.
The traction command value is shown in volts.
TRACTION COMMAND CENTER = ____V Keep the traction pod in the middle. Then push
the enter button.
TRACTION COMMAND FULL REVERSE = Use the steer pod to go fully to the right and hold.
____V Then push the enter button.
C3 ADJUST BATTERY = ____V Use the up and down arrows to adjust the battery
voltage and then push the enter button.
This battery value is the adjustment between the
battery voltage and the key-in pin voltage on
Access 2/3 and Access 3™.
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Feature Menus
Feature Menus 3. Push the right arrow.

Features menus overview 4. Push the up or the down arrow to scroll to the first
number.
The Features menus allow the operator to set the
Access 1 2 3® parameters to the vehicle hardware and
the customer specifications. See the vehicle data plate, 6. Repeat steps 4–5 until all four numbers are en-
capacity plate and specification sheet for the vehicle tered.
hardware information. For the vehicle data plate and 7. Push the enter button to accept the service code.
the capacity plate information, see the INTRODUC-  Access 1 shows ANALYZER.
TION/Introduction section. 8. Push the up or the down arrow to scroll to the Fea-
tures menu.
Features menus access 9. Push the right arrow to go to the F1 LANGUAGE
Note: To scroll through the Features menus, see the menu.
1. Turn on the vehicle and push the enter button. F1 Language menu
2. Scroll to the Service menu.
F1 Features
Submenus Display Menu Description
N/A F1 LANGUAGE = ____ Use this menu to set the language on Access 1.
English = English
Español = Spanish
Français = French
Deutsch = German
Nederlands = Dutch
Italiano = Italian
Polski = Polish
Cestina = Czech
Dansk = Danish
Portuguese = Portuguese
Magyar = Hungarian
Suomi = Finnish
Norsk = Norwegian
Svenska = Swedish
Pyccкий = Russian
Türkçe = Turkish
Eλληνικά = Greek
Slovenski = Slovenian
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Feature Menus
F2 Units of measure menu
F2 Features
N/A F2 UNITS OF MEASURE = ____ This menu sets the system for weights, speed and
measurements.
English
Metric
F3 User performance menu
F3 Features
N/A F3 USER PERFORMANCE = ____ Off = The vehicle stays locked in the performance set-
ting that was last chosen.
On = Allows the operator to set the performance level
of the vehicle.
F4 User codes menu
F4 Features
N/A F4 USER CODES = ____ Use this menu to make a maximum of 25 four-digit user codes.
If the F3 User Performance menu is set to on, then each user
code applies to one of the three performance levels (P1, P2 or
P3).
F4.1 OPERATOR CODE = ____ On = The operator must enter a user code to operate the vehicle.
Off = The user codes are off.
F4.2 OPER CODE TYPE This menu resets the codes for Command, Display and Number.
To reset the codes:
Push the right arrow.
Access 1 shows COMMAND.
Push the enter button.
Access 1 shows WAIT CODE RESET.
Push the up or the down arrow to scroll to Display or Number.
Repeat steps 1–2 to reset the Display and Number codes.
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Feature Menus
F4 Features
F4.3 ADD OPR CODE Use this menu to add an operator code.
To add an operator code:
Access 1 shows ID, Code and P numbers.
Push the up or the down arrow to scroll to the first number.
Push the right arrow to go to the next number.
Repeat steps 2–3 until all four numbers are entered.
Push the right arrow to go to Code.
Push the up or down arrow to select the up, down, left or right
arrow icons.
Push the right arrow to go to the next digit to select the arrow
icon.
Repeat steps 6–7 until all four digits are entered.
Push the right arrow to go to P.
Push the up or the down arrow to select 1, 2 or 3.
Push the enter button to save all the numbers.
The display shows ARE YOU SURE? Push the left arrow for no
or the right arrow for yes.
If yes, Access 1 shows NEW CODE SAVED.
F4.4 EDIT OPR CODE Use this menu to edit an operator code.
To edit an operator code:
 Access 1 shows existing ID, Code and P numbers.
3. Push the up or the down arrow to scroll to the first number.
5. Repeat steps 2–4 to edit additional numbers.
6. Push the right arrow to go to CODE.
7. Push the up or down arrow to select the up, down, left or
right arrow icons.
8. Push the right arrow to go to the next digit to select the arrow
icon.
9. Repeat steps 7–8 until all four arrow icons are entered.
10. Push the right arrow to go to P.
11. Push the up or the down arrow to select 1, 2 or 3.
12. Push the enter button to save all the numbers.
13. The display shows ARE YOU SURE? Push the left arrow for
NO or the right arrow for YES.
14. If yes, Access 1 shows CODE SAVED.
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Feature Menus
F4 Features
F4.5 DELETE OPR CODE Use this menu to delete an operator code.
To delete an operator code:
 Access 1 shows the operator code.
2. Push the enter button.
 Access 1 shows OPERATOR CODE DELETED — NO
CODE.
3. Push the left arrow to go back to the F4.5 menu.
F4.6 ADD SERVICE CODE Use this menu to add a service code.
To add a service code:
 Access 1 shows CODE.
2. Push the up or the down arrow to scroll to the first number.
4. Repeat steps 2–3 until you enter all four numbers.
5. Push the enter button.
6. The display shows ARE YOU SURE? Push the left arrow for
NO or the right arrow for YES.
7. If yes, Access 1 shows CODE SAVED.
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Feature Menus
F5 Options menu
F5 Features
N/A F5 OPTIONS This menu sets the vehicle option parameters.

F5.1 20 SPEED LIMIT = ____ 0 = Off - Height zone 1 is set to step height. (MCS)
1 = On - Height zone 1 is set to 20 switch height.
F5.2 20 GATE ALARM = ____ 0 = Off - Height zone 1 is set to gate alarm. (MCS)
1 = On - Height zone 1 is set to gate alarm.
F5.3 GATE TRAVEL = ____ 0 = Off - Travel in the height zone is restricted unless the
gates are fully closed.
1 = On
F5.4 HAND PRESENCE = ____ Off - All vehicle functions are disabled when operator hands
are removed from the pods.
On - The vehicle goes into automatic presence override
mode when operator hands are removed from the pods.
F5.5 LIFT LIMIT = ____ HGTS118 - The lift is allowed up to HGTS118.
HZ3 with ORS - The lift is only allowed above HZ3 if the op-
erator presses and holds the up arrow key.
HGTS84 - The lift is not allowed above HGTS84.
HGTS20 - The lift is not allowed above HGTS20.
F5.6 SLEEP DELAY = ____ Off = Sleep delay is disabled.
Minutes = 90
Once the vehicle is in sleep delay mode, it requires a rekey.
F5.7 TRAVEL ALARM = ____ This menu sets the operation parameters for ALM2.
Off
Forward
Reverse
Both
F5.8 LIFT ALARM = ____ This menu sets the operation parameters for ALM2.
Off
Lift
Lower
Both
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Feature Menus
F5 Features
F5.9 STROBE LIGHTS = ____ This menu sets the operation parameters of the strobe lights.
Disabled
Key - The strobe lights turn on when the key is on.
Operator - The strobe lights turn on when the operator is on
both operator presence switch pedals.
F5.10 TILT SENSOR = ____ Off
On
F5.11 POWER LOAD TRAY = ____ Off
On
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Performance Menus
Performance Menus 3. Push the right arrow.

Performance menus overview 4. Push the up or the down arrow to scroll to the first
number.
The Performance menus have multiple levels of ac-
cess and authorisation. The three levels are:
• P1
tered.
• P2
• P3  Access 1 shows ANALYZER.
Performance menus access 8. Push the up or the down arrow to scroll to the PER-
FORMANCE menu.
Note: To scroll through the Performance menus, see 9. Push the right arrow to go to the P1 PERFOR-
the tables in this section of the service manual. MANCE 1 menu.
2. Scroll to the SERVICE menu. P1.X Travel speeds menu
P1 Performance
P1.1 MAX FORWARD 1 = ____ This menu sets the operation parameters for the maximum
forward 1 travel speeds.
The default setting is 8 km/h (5 mph).
The platform height must be less than or equal to 508 mm
(20 in) with the gates open.
(20 in) with the gates closed.
The platform height must be greater than 508 mm (20 in) but
less than or equal to 2,134 mm (84 in) with the gates closed.
The platform height must be greater than 2,134 mm (84 in)
but less than or equal to 2,997 mm (118 in) with the gates
closed.
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Performance Menus
P1 Performance
P1.5 MAX REVERSE 1 = ____ This menu sets the operation parameters for the maximum
reverse 1 travel speeds.
The platform height must be greater than 2,134 mm (84 in)
but less than or equal to 2,997 mm (118 in) with the gates
closed.
P1.9 FORWARD ACCEL = ____ This menu sets the operation parameters for the forward ac-
celeration value.
The default setting is 5.
Use the arrow keys to adjust from 1–9.
P1.10 REVERSE ACCEL = ____ This menu sets the operation parameters for the reverse ac-
celeration value.
P1.11 PLUG = ____ This menu sets the plug value for the vehicle.
P1.12 COAST = ____ This menu sets the coast value for the vehicle.
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Performance Menus
P1 Performance
P1.13 RAISE SPEED = ____ This menu sets the raise speed value for the vehicle.
P1.14 LOWER SPEED = ____ This menu sets the lower speed value for the vehicle.
P2.X Travel speeds menu
P2 Performance
P2.1 MAX FORWARD 1 = ____ This menu sets the operation parameters for the maximum for-
ward 1 travel speeds.
The default setting is 6 km/h (3.7 mph).
The platform height must be less than or equal to 508 mm (20 in)
with the gates open.
with the gates closed.
The platform height must be greater than 508 mm (20 in) but less
than or equal to 2,134 mm (84 in) with the gates closed.
The platform height must be greater than 2,134 mm (84 in) but
P2.5 MAX REVERSE 1 = ____ Use this menu to set the operation parameters for the maximum
with the gates open.
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Performance Menus
P2 Performance
P2.6 MAX REVERSE 2 = ____ This menu sets the operation parameters for the maximum re-
verse 2 travel speeds.
with the gates closed.
The platform height must be greater than 508 mm (20 in) but less
than or equal to 2,134 mm (84 in) with the gates closed.
P2.9 FORWARD ACCEL = ____ This menu sets the operation parameters for the forward acceler-
ation value.
P2.10 REVERSE ACCEL = ____ This menu sets the operation parameters for the reverse acceler-
ation value.
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Performance Menus
P3.X Travel speeds menu
P3 Performance
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Performance Menus
P3 Performance
P3.9 FORWARD ACCEL = ____ This menu sets the operation parameters for the forward accel-
eration value.
P3.10 REVERSE ACCEL = ____ This menu sets the operation parameters for the reverse accel-
eration value.
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Performance Menus
P4.X Steering menu
P4 Performance
P4.1 HIGH SPEED STR = ____ This menu sets the high-speed turn rate value.
P4.2 LOW SPEED STR = ____ This menu sets the low-speed turn rate value.
P4.3 HIGH SPEED STR H = ____ This menu sets the high-speed turn rate elevated value.
P4.4 LOW SPEED STR H = ____ This menu sets the low-speed turn rate elevated value.
P4.5 STEER STRAIGHT = ____ This menu sets the steer straight value.
P4.6 STEER RESPONSE = ____ This menu sets the steer response value.
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Performance Menus
P5.X Performance H menu
P5 Performance
P5.1 COAST H = ____ This menu sets the coast elevated value.
P5.2 PLUG H = ____ This menu sets the plug elevated value.
P6.X BDI menu
P6 Performance
P6.1 BDI ADJ STARTUP = ____ This menu adjusts the reset level of the battery charge table.
P6.2 BAT MAX ADJ = ____ This menu sets the upper level of the battery charge table.
P6.3 BAT MIN ADJ = ____ This menu sets the lower level of the battery charge table.
P6.4 LIFT LOCKOUT = ____ This menu sets the lower level of the battery charge table.
The default setting is 20%.
Use the arrow keys to adjust the percentage in increments of 5–40%.
P7 Turtle mode menu
P7 Performance
P7 TURTLE MODE = ____ This menu shows the turtle mode percentage.
The default setting is 62%.
Use the arrow keys to adjust the percentage in increments of 1–100%.
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Performance Menus
P8 Load factory default values menu
P8 Performance
P8 LOAD FACTORY DEFAULT VALUES = ____ This menu resets the vehicle to factory default val-
ues.
ARE YOU SURE? N= The factory default settings
are not set.
ARE YOU SURE? Y= The factory default settings
are set.
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Utilities Menus
Utilities Menus 4. Push the up or the down arrow to scroll to the first
number.
Utilities menus overview 5. Push the right arrow to go to the next number.
The UTILITIES menus contain software part numbers,
tered.
component test and other vehicle utilities.
Utilities menus access  Access 1 shows ANALYZER.
Note: To scroll through the UTILITIES menus, see the 8. Push the up or the down arrow to scroll to the UTIL-
tables in this section of the service manual. ITIES menu.
1. Turn on the vehicle and push the enter button. 9. Push the right arrow to go to the U1 SW PART
NUMBER menu.
2. Scroll to the SERVICE menu.
3. Push the right arrow. U1 SW part numbers menu
U1 Utilities
N/A SW PART NUMBER This menu shows the software values of the vehicle.
U1.1 ACCESS 1 = ____ This menu shows the software value of Access 1.
U1.2 ACCESS 2/3 = ____ This menu shows the software value of Access 2/3.
U1.3 ACCESS 3 = ____ This menu shows the software value of Access 3™.
U1.4 ACCESS 4M = ____ This menu shows the software value of Access 4M.
U1.5 ACCESS 4S = ____ This menu shows the software value of Access 4S.
U2 Tester menu
U2 Utilities
N/A U2 TESTER This menu tests the various components in the vehicle.
U2.1 BRK1 TEST = ____ On = When this setting is on, it is only operational with the neces-
sary SRO (Yes). To perform this test, move the vehicle to level
ground, the DMS/hand sensors must be inactive (the operator is
not on the vehicle), fully lower the platform, pull in the line contactor
and energise BRK1 for 3 s. The fork heel hold feature is now ac-
tive.
Off = When this setting is off, it is enabled for 3 s and then disabled.
U2.2 BRK2 TEST = ____ On = When this setting is on, it is only operational with the neces-
sary SRO (Yes). To perform this test, the following must be met: the
vehicle is on level ground, the DMS/hand sensors are not active
(the operator is not on the vehicle), the platform is fully lowered, the
line contactor is pulled in and the BRK2 is energised for 3 s. The
fork heel hold feature is now active.
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ELECTRICAL SYSTEM
Utilities Menus
U2 Utilities
U2.3 ALM1 TEST = ____ On = When this setting is on, it is enabled for 3 s and then disabled.
Off = When this setting is off, there is no necessary SRO.
U2.6 K3 TEST = ____ On = When this setting is on, it is only operational with the neces-
sary SRO (Yes). To perform this test, the following must be met: No
SRO for DMS/Hand sensor, use the same SRO as the regular op-
eration of the powered load tray, the platform is fully lowered and
the line contactor (K2) is on. The K3 relay is on for 3 s.
U2.7 K4 TEST = ____ On = When this setting is on, it is only operational with the neces-
sary SRO (Yes). To perform this test, the following must be met: no
SRO for DMS/Hand sensor, use the same SRO as the regular op-
eration of the powered load tray, the platform is fully lowered and
the line contactor (K2) is on. The K4 relay is on for 3 s.
U2.8 STROBE TEST = ____ On = When this setting is on, it is enabled for 3 s and then disabled.
U2.9 HORN TEST = ____ On = When this setting is on, it is enabled for 3 s and then disabled.
U2.10 SVL TEST = ____ On = When this setting is on, it is only operational with the neces-
sary SRO (Yes). To perform this test, the following must be met: the
DMS/hand sensors are not active (the operator is not on the vehi-
cle), the platform is fully lowered (MCS active), and the line contac-
tor is on. The SVL is on for 1–3 s.
U3 Clear events menu

U3 Utilities
N/A U3 CLEAR EVENTS This menu clears all the module events.
N/A CLEAR ALL MODULE EVENTS ARE YOU SURE? N = This action does not clear the
module events.
ARE YOU SURE? Y = This action clears the module
events.
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ELECTRICAL SYSTEM
Utilities Menus
U4 Clear EEPROM menu
U4 Utilities
N/A U4 CLEAR EEPROM This menu clears the EEPROM for all modules.
N/A CLEAR ALL MODULE EVENTS ARE YOU SURE? N = This action does not clear the mod-
ule EEPROM.
ARE YOU SURE? Y = This action clears the module EE-
PROM.
Clear the EEPROM and turn off the vehicle. Turn on the
vehicle and calibrate the vehicle.
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ELECTRICAL SYSTEM
Hour Menus
Hour Menus 3. Push the right arrow.

Hour menus overview 4. Push the up or the down arrow to scroll to the first
number.
The HOUR menus show the runtime, hydraulics time,
traction time and PM timer of the vehicle.
Hour menus access tered.
Note: To scroll through the HOUR menus, see the ta- 7. Push the enter button to accept the service code.
bles in this section of the service manual.  Access 1 shows ANALYZER.
1. Turn on the vehicle and push the enter button. 8. Push the up or the down arrow to scroll to the
HOUR menus.
2. Scroll to the SERVICE menus.
9. Push the right arrow to go to the H1 RUNTIME
menu.
H1 Hour
Menus Level Display Menu Description
H1 RUNTIME = ____ This menu shows the runtime hours.

The operator must be on both operator presence switch
pedals.
H2 HYDRAULICS = ____ This menu shows the hydraulics hours.
H3 TRACTION = ____ This menu shows the traction hours.
H4 PM TIMER This menu sets the hours for the PM timer menus.
H4.1 TAG = ____ This menu sets which hour meter the system monitors to
control the PM timer.
NONE
TAG H1
TAG H2
TAG H3
H4.2 INTERVAL = ____ This menu sets the interval between PM alerts.
The interval is 1 hr–65,535 hr.
The value is a countdown timer, not a target value. The
value decreases as the vehicle runs. The operator can
view how many hours are left until the PM timer runs out.
When the timer runs out, the message is shown, but the
vehicle drives normally. When the PM is complete, the
operator must reset the interval value back to the PM
interval time.
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ELECTRICAL SYSTEM
Contactor Panel
Contactor Panel Inspection

Contacts
• The contacts can blacken, swell and roughen dur-
ing normal operation. These conditions are normal.
• There is no need to file or polish the contacts. Phys-
ically reworked contacts burn out rapidly.
• Replace the contacts only if the silver layer has
worn off the contact points.
Coils
Coils cannot be repaired. Replace the coils if:
• The coil resistance ≠ 29 Ω
• There is no resistance
• You measure an endless resistance between the
connections using a digital volt ohm-meter (DVOM)
Springs
Always replace the springs when fitting new contacts.
Always replace the springs whenever the contacts
show signs of corrosion or discolouring due to over-
heating.
Servicing the line contactor

See Figure 71.
Fig. 70 (30439)
This contactor has fixed contacts that are connected to
Contactor assembly the cover, and the contact must always be replaced in
pairs. To service the contactors, you need a complete
cover, two moving contacts and two contact springs.
WARNING Disassembly
1. Remove the screws (6) from the cover (5).
Risk of injury.
To prevent injury, disconnect the battery before work- 2. Remove the cover (5).
ing on the contactors. 3. Remove the movable contact (2).
 Disconnect the battery. 4. Unscrew the nuts and take off the fixed contacts
 Raise the drive wheels clear of the floor and place (1).
the blocks under the vehicle frame. 5. Clean, check and, if necessary, replace the com-
ponents.
Note: Only use original Crown contactors as replace- Assembly
ments, or Crown spare parts for repairs. The contactors 1. Insert the movable contact into the holes provided.
are specially made for the vehicle.
2. Install the screws. Torque to 8–9 Nm (6–7 ft lb).
General Use thread-locking adhesive (P/N 053050-006) to
secure the screws in place.
• Do not change the position of the contactors.
• Do not change the wiring.
• When disassembling a contactor for inspection or
repairs, clearly mark the position of the contacts.
• Make sure that the contacts are assembled in the
same way they were taken apart. If the contacts are
not assembled correctly, excessive wear and pre-
mature failure will occur.
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ELECTRICAL SYSTEM
Contactor Panel
1 4
Fig. 71 (7931-02)
1 Fixed contact
2 Movable contact
3 Coil
4 Spring
5 Cover
6 Screw
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ELECTRICAL SYSTEM
Battery
Battery
Battery indicator 1 2
The battery indicator, located on the traction pod (1),
displays the battery state-of-charge on Access 1 (2).
Fig. 73 (25445-01)
1 Wet cell battery
2 Maintenance-free battery
1
CAUTION
Fig. 72 (30633) Risk of gas explosion or severe burns.
1 Access 1 Battery gases are explosive. An injury or death could
occur if the battery gas explodes.
The ideal time to recharge industrial batteries is when
 Do not smoke, use an open flame, or make an arc
a 20% charge remains. Recharging at this level is vital
or sparks around the battery.
to ensure proper recharge and maximum battery life.
 Batteries contain sulphuric acid, which causes se-
Duty cycle directly affects battery charge. The slower
vere burns. Wear protective clothing such as a rub-
the batteries discharge, the more total ampere hours
ber apron, gloves, boots and full-face shields when
are available. Therefore, it is difficult to measure bat-
performing any maintenance on the batteries.
tery discharge.
 Do not allow electrolyte to contact eyes, skin, cloth-
WAVE batteries reach about 80% discharge when the
ing or floor.
battery reads 22.7 V with the batteries disconnected.
Batteries beyond this voltage discharge rather quickly.  If electrolytes comes into contact with the skin or
With a battery setting of seven in an average duty cy- eyes, immediately rinse with clean water for several
cle, the controller configuration calculates 20% charge minutes, and then seek medical assistance.
when the battery voltage reaches 22.7 V with the bat-  If electrolyte contacts the skin, rinse at once with
teries disconnected. clean water and wash with soap.
Matching the duty cycle to the correct battery rate set-  Immediately neutralise and thoroughly rinse any
ting achieves the following benefits: electrolyte. Crown sells a battery spill kit (P/N
• Batteries use maximum power before recharging 300035) to clean up battery acid spills. To use the
kit, follow the directions of the manufacturer.
• Maximum efficiency in recharging occurs
 WAVE batteries are wired in series. Therefore,
• Maximum battery life is achieved
when disconnecting a power cable from one bat-
• Low voltage event codes are eliminated tery, insulate the cable end with electrical tape to
avoid arcing with other metal parts.
Battery
WAVE® vehicles are equipped with four, 6 V standard
wet cell batteries or with optional maintenance-free Safety rules
batteries. • Always wear the appropriate personal safety equip-
ment when performing work on batteries. This
equipment includes, but is not limited to:
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ELECTRICAL SYSTEM
Battery
– Face shield Inspection

– Rubber apron
• Check for corroded terminals, cracks and intercon-
– Acid-resistant gloves necting cable connections.
– Safety-toe shoes • Inspect the battery for lifted cells, loose or broken
• Do not allow electrolyte to come into contact with cell connections and excessive moisture.
the eyes, skin, clothing or floor. • Check the electrolyte level in the wet cell batteries
• If electrolytes comes into contact with the skin or before each charge.
eyes, immediately rinse with clean water for several Maintain the electrolyte level in the wet cell batteries at
minutes, and then seek medical assistance. 12 mm (0.5 in) above the plates or just below the lower
• If electrolyte contacts the skin, rinse at once with lip of the filler hole at all times. If low, add distilled water
clean water and wash with soap. at the end of a charge cycle. Do not overfill. For maxi-
• Immediately neutralise and thoroughly rinse any mum battery life, take and record specific gravity read-
spilled battery acid. Crown sells a battery spill kit (P/ ings on a pilot cell. Choose a different pilot cell on a
N 300035) to clean up battery acid spills. To use the monthly basis, with readings taken on all cells at semi-
kit, follow the directions of the manufacturer. annual or annual intervals. Do not take specific gravity
readings immediately after adding water. Thoroughly
• WAVE batteries are wired in series. When discon-
mix water and electrolyte by charging the battery be-
necting a power cable from one battery, insulate the
fore taking a specific gravity reading. Normal fully-
cable end with electrical tape to avoid arcing with
charged specific gravity should be between 1.265 and
other metal parts.
1.285.
• Keep the vent plugs firmly in place except when
adding water or taking hydrometer readings. Cleaning
• Do not bring any flames, sparks or other ignition Always keep the vent plugs tightly in place when clean-
sources near the battery. Gas formed while charging the battery. When properly charged, the battery re-
ing the battery is explosive. This gas remains in the mains clean and dry. Blow off any collected dust or dirt.
cells long after charging.
• If electrolyte spills or overflows from a cell, neutral-
• Do not lay metallic or conductive objects on the bat- ise it with a battery spill kit (P/N 300035).
tery. Arcing could occur.
• Use the battery cleaner (P/N 363124-001) to clean
• Do not allow dirt, cleaning solution or other un- the battery and terminals. Follow the instructions of
wanted material to enter the battery cells. Impurities the manufacturer, brushing the solution beneath the
in the electrolyte have a neutralising effect, reduc- connectors and removing the grime from the cov-
ing available charge. ers.
• Do not touch non-insulated parts of the DC output • Overcharged or overfilled batteries stay wet con-
connector or battery terminals to avoid possible sistently. If you find that the batteries are constantly
electrical shock. wet, locate and fix the problem.
• Disconnect all AC and DC power connections be- • Use the battery protector (P/N 363125-001) to seal
fore servicing the charger. and protect the battery terminals.
• The charger is not for outdoor use. Do not expose
the charger to rain or snow. Do not charge a frozen Maintenance-free batteries
battery.
Sealed maintenance-free batteries contain a pressure
• Only use the charger for lead acid batteries. Trying release valve. Under normal conditions, these batter-
to charge dry-cell batteries causes them to burst, ies do not need special ventilation.
and will result in personal injuries and property
damage.
• Do not use the charger if it has been dropped or
damaged.
• Follow the instructions of the battery manufacturer
on repair practices and procedures.
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ELECTRICAL SYSTEM
Battery
Charging requirements
CAUTION Charging requirements vary depending on vehicle use.
The chart that follows lists the estimated charging
Risk of injury by high pressure. times to fully charge a battery after discharging the bat-
Injury can occur to you or others around you if you tery to 80% of full capacity. The charging time assumes
open the battery or remove the pressure release valve. a 6 hr discharge rate. The minimum battery voltage
 Do not try to open the battery or remove the pres- needed for the charger to turn on is 12 V.
sure release valve.
Battery 30 A Charger
In maintenance free batteries, a glass separator, which
acts like a sponge, absorbs the sulphuric acid. The 220 Ah wet cell 10.5 hr
gases generated while the battery is charging are re-
180 Ah wet cell 8 hr
combined. When severely overcharged, such as when
connected to an improperly sized charger, a significant 205 Ah maintenance-free 10 hr
amount of gases are released from the battery. Mainte-
nance-free batteries are valve-regulated batteries and Charging
do not need water added to the cells.
Charger WARNING
The battery charger features an automatic start and
stop charging cycle to reduce battery damage resulting Risk of gas explosion.
from over or under charging. Battery gases are explosive. An injury or death could
occur if the battery gas explodes.
See Figure 25452-01. Before charging, remove the
deck and make sure that the charger is set (1) for either  Do not smoke, use an open flame, or make an arc
a wet or sealed (maintenance-free) battery. See the or sparks around the battery.
chart that follows. The yellow LED remains on while  Do not use a source of ignition (for example, a cig-
charging when set for the wet batteries. The yellow arette, lighter or grinder) near the battery or battery
LED flashes at a one-second rate for the sealed (main- charging area.
tenance-free) batteries.  Make sure that the area where you charge the bat-
tery is correctly vented.
Selector position Battery type  Use designated areas for charging batteries if they
are available.
0, 1, 3 Maintenance-free
2 Wet cell To charge the batteries, plug the charger into a 120 V,
15 A (minimum) AC outlet. To stop the charger during
charging, unplug the charger.
To check the charging status, see the three LEDs on
the service panel.
Fig. 74 (25452-01)
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ELECTRICAL SYSTEM
Battery
2. Disconnect the charger and measure the total bat-

tery voltage. The voltage must be 25.3–26 V.
3. Disconnect the power cables to isolate individual
batteries. Measure and record the voltage
1 across each battery. Each battery must be be-
tween 6.3–6.5 V.
4. Replace any battery that measures less than 6 V.
Batteries that are 0.3 V less than the other batter-
ies may be showing signs of undercharging.
5. Connect all of the batteries and return the vehicle
to service.
Note: Check the battery voltage both static and loaded.
Fig. 75 (30634)
1 Charger LEDs
LED State Indication
Red Flashing Shorted battery

Red Flashing Exceeded charge time
Red On Charger temperature high
Yellow On Charging (wet battery)
Yellow Flashing Charging (maintenance-free)
Green On Charge complete
If all the LEDs are off, the charger is not connected to

an AC power source. All the LEDs flash three times
when the battery is initially plugged into an AC source.
Red LED (abnormal charge sequence)
• Exceeded charge time: 10 hr for maintenance-free
batteries or 15 hr for wet cell batteries. Discharging
a battery too deeply causes the red LED. Unplug
the charger from the AC source to clear the red
LED. Wait one minute before plugging the charger
back into the AC source.
• The charger detects a shorted battery. If the battery
does not have a short circuit, disconnect the
charger from the batteries and plug it back in. The
LED should stop flashing and resume charging.
• The charger temperature is exceeded. Allow the
charger to cool, then disconnect it from the AC
source and plug it back in to resume the charge
cycle.
Battery testing
The steps that follow outline the procedure for verifying
battery integrity.
1. Fully charge the batteries.
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ELECTRICAL SYSTEM
Battery
BDI information
Display Adjustments
Menu Menu Default Minimum Maximum Increments Units Description Zapi Parameter
Level 1 Level 2
BDI BDI ADJ 5 0 9 1 Adjust the reset BDI ADJ

Startup = level of battery STARTUP
Value charge table
BAT MAX 5 0 9 1 Adjust the upper BAT MAX ADJ
ADJ = level of battery
Value charge table
BAT MIN 5 0 9 1 Adjust the lower BAT MIN ADJ
ADJ = level of battery
Value charge table
Lift 20 20 40 5 % BDI % adjustable DIS RAISE
Lockout = in increments of LOWBAT
Value 5%
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ELECTRICAL SYSTEM
Battery
Troubleshooting
The charger does not turn on and • The AC circuit breaker is open - Check for AC voltage, close the
does not go through self-test circuit breaker
• The AC circuit breaker is open - Reset the circuit breaker
on the charger
The charger will not turn on after • Charger is not connected to the - Connect the battery to the charger
self-test battery
• There is incorrect plug polarity - Connect the plugs according to
between the charger and the the polarity
battery
The charger cycles between on and • The AC voltage to the charger is - Check for proper AC voltage
off low
• Low charging current - The battery and the charger volt-
age do not match. The battery
voltage is too high. Make sure that
the charger and the battery volt-
age are properly matched. Recon-
nect the battery to the charger to
reset the voltage readings.
Red abnormal LED flashes • The output current is too high - Remove the short circuit condition
due to a shorted battery - The battery can be too deeply dis-
charged
• The charging time is exceeded - Unplug the charger to clear the
flashing LED and plug the charger
back in
Red abnormal LED stays on • The charger temperature is ex- - Unplug the charger, let the battery
ceeded cool down and plug the charger
back in
Decreased runtime • Battery failure - Test the batteries as described in
Battery testing in this section
• Insufficient charge time - Allow enough charging time (see
Charging requirements) for the
batteries to reach a full charge
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ELECTRICAL SYSTEM
Motor
Motor 7. Disconnect the electrical connections from M1 and

M2 and the brake.
Inspection 8. Remove the four brake bolts on the right brake.
9. Remove the right brake.
10. Remove the four brake bolts on the left brake.
CAUTION 11. Remove the left brake.
12. Remove the four motor bolts from M1.
Risk of burns by short circuits and high current.
Unapproved handling of tools on batteries can cause 13. Remove M1 from the vehicle.
an injury or damage to the vehicle. 14. Remove the four motor bolts from M2.
 Only conduct maintenance and repair on batteries 15. Remove M2 from the vehicle.
if you have been approved for this work. 16. Remove M1 and M2 from the vehicle.
 Do not allow metal objects to come in contact with
the top of battery cells. Lift Pump Motor (M3)
 Disconnect the batteries before inspecting the mo- Removing the brush and spring assembly
tors.
1. To avoid head injuries, move the load tray out of
the way. For vehicles with manual load trays, ro-
When inspecting the pump motor, carry out the follow- tate and lock the load tray in the full vertical posi-
ing steps: tion. For vehicles with powered load trays, move
• Check that the connecting cables are not worn or the tray up to its maximum height.
damaged and are secure at the motor terminals. 2. Turn off the vehicle.
• Check the commutator for any discolouration, 3. Remove the cover for the load deck.
which may indicate signs of raised bars or stalls. If
the commutator is glazed or dirty, clean it with a
piece of No. 00 sandpaper. Remove all of the dirt 5. See Figure 76. Remove the two power cables (1)
and grit with weak, dry compressed air. from the motor. Make sure that you note which ca-
ble goes to the positive terminal and which cable
• Replace the pump motor brushes when they reach
goes to the negative terminal.
a length of 9 mm (0.34 in) or less.
• Use an ohmmeter on a high resistance scale, such
as R x 10,000, to check the motor for shorts be-
tween the terminals and the motor frame. If a read-
ing of less than 50,000 Ω is observed, the motor
must be repaired before the unit is placed into oper-
ation to prevent further damage.
Right and Left Traction Motors (M1

and M2)
Removing the motors
1. Raise the platform to a height that allows easy ac-
cess to M1 and M2.
2. Block the platform using composite or hardwood
blocks.
3. Remove the cover for the load deck.
5. Remove the cover for the rear chassis.
6. Remove the “H” frame, which consists of the front
frame (P/N 153010), rear frame (P/N 127192) and
rod (P/N 127193).
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ELECTRICAL SYSTEM
Motor

5. See Figure 76. Remove the two power cables (1)
from M3. Make sure that you note which cable
3 goes to the positive terminal and which cable goes
to the negative terminal.
6. Remove all nuts and washers (2) from the M3 ter-
minals.
Note: When reconnecting the power cables to the mo-
tor, torque to 6–7 Nm (55–65 in lb).
7. See Figure 77. Disconnect the elbow (10), which
connects to the return hose, and the connector
(11), which connects to the supply hose. Cap the
2 lines and hoses with plastic plugs to avoid oil leak-
age and contamination.
10
4
1
Fig. 76 (30513)
1 Power cable
11
2 Nuts and washers
3 Screw
4 Cover
6. Remove all nuts and washers (2) from the M3 ter-

minals. Fig. 77 (30514)
Note: When reconnecting the power cables to the mo- 10 Elbow
tor, torque to 6–7 Nm (55–65 in lb). 11 Connector
7. Remove the two screws (3) on the top of M3. Note: When reconnecting the hoses, the elbow and the
8. Push the field cable terminals through the commu- connector are torqued to 32–37 Nm (24–27 ft lb).
tator cover (4) and remove the cover. 8. See Figure 78. Remove the three screws (17) from
9. Remove the lead screws from the brush. the hydraulic unit bracket (18).
10. Remove the brush and spring assembly.
Removing M3
1. To avoid head injuries, move the load tray out of
the way. For vehicles with manual load trays, ro-
tate and lock the load tray in the full vertical posi-
tion. For vehicles with powered load trays, move
the tray up to its maximum height.
3. Remove the cover for the load deck.
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ELECTRICAL SYSTEM
Motor
17
17
18 19
Fig. 78 (30515)
17 Screw
18 Hydraulic unit bracket
19 Manual lowering valve
9. Note the position of M3 on the hydraulic unit. Re-

move M3 from the unit. Be careful not to bump or
damage the manual lowering valve (19).
10. Remove the reservoir clamp (P/N 156651) from
the hydraulic assembly.
Note: When installing the clamp, torque to 8–9 Nm
(6–7 ft lb).
11. Remove M3 from the hydraulic assembly.
Note: When M3 is removed, the oil in he hydraulic res-
ervoir is exposed. Do not allow the oil in the reservoir
to become contaminated.
Checking the current

Make sure that the following conditions are met when
checking the current:
• Travel
– Make sure that the platform is empty.
– Check the current at full travel speed.
– The current is displayed on the analyser menus.
M1 is at A2.12. M2 is at A3.3.
– The current should measure from 6–12 A for
each motor.
• Lift
– Make sure that the platform is empty.
– Check the current while raising the platform.
– The current should measure from 80–90 A.
– The current should measure from 80–90 A.
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ELECTRICAL SYSTEM
Event Code Introduction
Event Code Introduction Software

To make sure that your truck has the newest
Access 1 2 3® software, do these steps:
CAUTION 1. Turn the truck ON.
If you connect the control connectors when the 2. Use ACCESS 1 go into LEVEL 2: FIELD SERVICE
truck is ON, the truck could be damaged. MODE.
The truck electrical system could be damaged. 3. Push the up or down arrows to go to the UTILITIES
• Do not turn the truck ON with the control connectors menu. From there you can see the control module
disconnected. and software part numbers that are applicable to
• Do not remove or connect the control connectors your truck.
while the truck is ON.
No event code
If the truck malfunctions and no event code shows, the
malfunction is usually not electrical. If you turn the truck
CAUTION ON, but an event code does not show, the malfunction
is usually mechanical or hydraulic, but not electrical.
When you replace a control module and do an up- The mechanical and hydraulic data is in the applicable
date to the module software, make sure that the ad- section in this manual.
justments are correct.
The truck will not operate correctly. Component Locations
• Calibrate the forklift truck. Refer to the ELECTRI- The component and wire location maps are at locations
CAL > Access 1 2 3® > CALIBRATION section. on the truck to help you quickly find the location of the
components. All components are clearly identified at
the connection points. Refer to the COMPONENTRY
Troubleshooting Steps section for more data on each component.
Most malfunctions occur in or at output devices (relays,
contactors, and motors). The next components to ex-
amine are connectors, wires, and input devices
(switches, potentiometers, and encoders). The last
components to examine are the control modules. You
must do a test of the output devices, then the input de-
vices, and then the control module to which these de-
vices attach. When you measure the voltage and
resistance of these components, use a digital volt-ohm
multimeter (DVOM). Make sure that you connect all
components after you complete the event code steps.
Malfunctions
When a malfunction occurs, use ACCESS 1 to go into
LEVEL 2: FIELD SERVICE MODE
Note: Your monitor system has three user levels:
LEVEL 1: OPERATOR MODE
LEVEL 2: FIELD SERVICE MODE (Full Truck Opera-
tion)
LEVEL 3: Analyser/TEST MODE (No Truck Operation)
This section includes LEVEL 2 and LEVEL 3 data. For
LEVEL 1 data, refer to the Operator Manual and the
ELECTRICAL > Access 1 2 3® section. For menu data,
refer to the ELECTRICAL > Access 1 2 3® section.
M4.8-ITD-001 Crown 2010 PF25130-1 Rev. 6/12
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ELECTRICAL SYSTEM
Event Code Introduction
Test Points
The test points in the event code descriptions are on
the distribution panel. For an example, refer to
Figure 79. The distribution panel and test point loca-
tions could be different than in Figure 79.
Fig. 79 (24633)
Power Cable Connections
WARNING
A charged capacitor could be dangerous.
Because of capacitance voltage in some control mod-
ules, an injury or damage to the truck could occur.
• When you do the truck maintenance around the bus
bars and related power cables, discharge the ca-
pacitors.
• Refer to the SAFETY > Control of Hazardous En-
ergy > Capacitance section for procedures to dis-
charge the capacitors
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ELECTRICAL SYSTEM
Event Codes
Event Codes Display Messages

During vehicle operation, messages can appear that
Access 1 2 3® Modules Overview serve as a visual aid to the operator. After you’ve cor-
Access 1: Display module rected the condition that caused the message, the con-
Access 2/3: Right traction and hydraulic control mod- dition will be removed. The table that follows contains
ule a list of the messages that appear on Access 1 and a
description of their function.
Access 3™: Left traction control module
Access 4: Vehicle control module
Messages after the operator turns on the vehicle and during operation
Display Description
CHARGE BATTERY The battery charge is low as the vehicle travels. If the battery charge is not low,
follow the procedures for Event Code 215.
CHARGING The vehicle batteries are charging.
GRAB CONTROLS The operator must grab onto the handles.
CENTRE CONTROLS The vehicle was turned on during a traction request. Return the controls to neutral.
Turn off the vehicle, and then turn on the vehicle again.
CYCLE HANDS The operator must reposition their hands on the vehicle handles.
CYCLE PEDALS The operator must reposition their feet on the vehicle pedals.
LOWER PLATFORM The platform must be lowered to continue with the request.
RELEASE LOWER The lower switch is being selected at the same time as another request. Release
SWITCH the switch to continue with the request.
RELEASE SWITCHES Multiple switches are being selected at the same time as another request. Release
the switches to continue with the request.
MOTOR HOT CODE XXX One of the motors is over temperature. Troubleshoot the corresponding code.
SENSOR ISSUE XXX There is an issue with the sensor. Troubleshoot the corresponding code.
NO POWER The vehicle has no power and must be charged.
PM DUE Planned maintenance is due for the vehicle. Troubleshoot event 105.
TIMED OUT The vehicle has been turned off. Turn on the vehicle to power up.
CLOSE GATES The gates are open and must be closed to proceed with the request.
DEPRESS PEDALS The operator is not standing on the pedals and must be to proceed with the re-
quest.
CHECK MOTOR COVER The motor cover switch has been activated. Check to make sure that the cover is
clear of any objects.
CLOSE SERVICE PANEL The service panel is open. The vehicle will not move until it is closed.
BASE CONTROL ON The base control for the vehicle is on. Press the drive/tow switch (DTS) to return
to normal vehicle functions.
RAISE PLATFORM The platform must be raised to continue with the request.
RELEASE RAISE SWITCH The raise switch is being selected at the same time as another request. Release
the switch to continue with the request.
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Event Codes
Messages after the operator turns on the vehicle and during operation
Display Description
RELEASE TRAY SWITCH The tray switch is being selected at the same time as another request. Release the
switch to continue with the request.
RELEASE HORN SWITCH The horn switch is being selected at the same time as another request. Release
the switch to continue with the request.
CONTROLLER HOT CODE The vehicle controller is over temperature. Troubleshoot the corresponding event
### code.
POWER OFF The vehicle is turned off.
ENTER CODE #### If the user codes are enabled, entry of a User PIN is required.
Event Code 100 CAN Circuit Test

Access 1 has reset to Factory Default operation. 3. The resistance should be approximately
Step 1: Turn off the vehicle, and then turn on the ve- 120 ohms.
hicle again. 4. Replace the terminating resistor if the resistance
Step 2: Enter the Utilities menu (U.4) and perform a is less than 115 ohms or greater than 125 ohms.
Clear EEPROM.
5. Check the resistance of the CAN circuit if the ter-
Step 3: Recalibrate all vehicle functions. minating resistor has a resistance between
Step 4: Apply any customer preferred settings in the 115 ohms and 125 ohms.
Features and Performance menus.
6. Replace the appropriate module if the terminat-
Step 5: Turn off the vehicle, then turn on the vehicle ing resistor and CAN circuit test find no faults.
again.
• If: The event does not return
Event Code 102
– Then return the vehicle to service
• If: The event returns Access 1 does not communicate with Access 3™.
– Then replace Access 1 Step 1: Turn off the vehicle.
Step 2: Verify that B-NEG is present at Access 1
Event Code 101 CA630-4 and the Access 3™ B-NEG terminal.
• If: B-NEG is present at all of the modules
Access 1 does not communicate with Access 2/3.
– Then continue to step 3
Step 1: Turn off the vehicle.
Step 3: Perform a CAN circuit test using the following
Step 2: Verify that B-NEG is present at Access 1 table.
CA302-01, and the Access 2/3 B-NEG terminal.
• If: B-NEG is present at all of the modules
CAN Circuit Test
Step 3: Perform a CAN circuit test using the following 1. Disconnect CA607.
table. 2. Check the resistance between CA607-1 and
CA607-2.
CAN Circuit Test 3. The resistance should be approximately
120 ohms.
1. Disconnect CA607.
4. Replace the terminating resistor if the resistance
2. Check the resistance between CA607-1 and
is less than 115 ohms or greater than 125 ohms.
CA607-2.
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Step 1: Turn off the vehicle, and then turn on the ve-
CAN Circuit Test
hicle again.
5. Check the resistance of the CAN circuit if the ter- • If: The event clears.
minating resistor has a resistance between – Then verify the Performance menu and the Fea-
115 ohms and 125 ohms. tures menu settings and return the vehicle to ser-
6. Replace the appropriate module if the terminat- vice
ing resistor and CAN circuit test find no faults. • If: The event does not clear and the software was
recently updated
Event Code 103 – Check the version of the software and reload the
software
Access 1 does not communicate with Access 4.
• If: The event does not clear and the software was
Step 1: Turn off the vehicle. not recently updated
Step 2: Verify that B-NEG is present at Access 1 – Then replace Access 2/3 if the event returns
CA630-4 and the Access 4 B-NEG terminal.
Note: If the vehicle operates, this could be a random
• If: B-NEG is present at all of the modules nuisance event. Monitor the event frequency. If it grad-
– Then continue to step 3 ually increases for no apparent reason, replace
Step 3: Perform a CAN circuit test using the following Access 2/3.
table.
Event Code 201
CAN Circuit Test Overcurrent protection has been activated.
1. Disconnect CA607. All vehicle movement is disabled.
Step 1: Follow the procedures for Event Code 200.
2. Check the resistance between CA607-1 and
CA607-2.
Event Code 202
3. The resistance should be approximately
120 ohms. Access 2/3 Detects Traction Motors Voltage Feed-
back circuit out of range
4. Replace the terminating resistor if the resistance
A bad line contactor (L) causes this event.
is less than 115 ohms or greater than 125 ohms.
Access 1 2 3® records this event after the vehicle tem-
5. Check the resistance of the CAN circuit if the ter- perature increases to the usual temperature of opera-
minating resistor has a resistance between tion. The symptoms can be intermittent.
115 ohms and 125 ohms. Step 1: Turn off the vehicle. Verify that the motor
6. Replace the appropriate module if the terminat- power cables are connected to the proper terminals of
ing resistor and CAN circuit test find no faults. each traction motor and Access 2/3.
• If: The cables are incorrectly connected
Event Code 104 – Then connect them properly
Access 1 does not detect Access 4. • If: The cables are connected properly
Step 1: Follow the Event Code 103 procedures. – Then continue to step 2
Step 2: Keep the vehicle turned off. Check for a trac-
Event Code 105 tion motor (M1) short to the chassis.
Step 3: Check the resistance from each motor termi-
Planned maintenance is required. nal to the frame of the vehicle.
Step 1: Perform the planned maintenance on the ve- • If: A short is detected
hicle.
– Then replace the appropriate motor
Step 2: Go to H4.2 and reset the PM interval.
• If: There is an open circuit (O/L)
Event Code 200 – Then replace Access 2/3
All vehicle movement is disabled.
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Event Code 203 Event Code 206

Access 2/3 has detected an under or overvoltage There is low voltage on the right traction motor
condition at key switch (KYS) input. (M1) terminal outputs.
Note: Overvoltage threshold is 26 V DC; undervoltage All vehicle movement is disabled.
threshold is 22 V DC. If this event occurs during power- This event is logged if the line contactor tips open dur-
up, idle or traction request, then an undervoltage con- ing normal forklift truck operation.
dition is likely. The battery condition and state of charge Step 1: Turn off the vehicle. Check the coil connec-
should be taken into consideration. tions of the line contactor, the tip condition of the line
Step 1: Check the voltage between the B-NEG termi- contactor, FU1 and the cable connections between the
nal and CA402-1 on Access 2/3, with the vehicle on line contactor and Access 2/3.
and the operator in the seat. • If: The line contactor, cables, FU1 and connections
• If: The voltage is less than 22 V DC or greater are good
than 26 V DC – Then continue to step 2
– Then check the circuit between the key switch Step 2: Keep the vehicle turned off. Remove the
and CA402-1 power cables from M1 and check between the motor
• If: The voltage is between 22–66 V DC terminals and the vehicle chassis for shorts.
– Then replace Access 2/3 • If: A short is detected
– Then replace M1
Event Code 204 • If: There is an open circuit (O/L)
There is low voltage on the pump motor terminal – Then replace Access 2/3
outputs.
All vehicle movement is disabled. Event Code 207
This event is logged if the line contactor tips open dur- The right traction motor (M1) output is higher than
ing normal forklift truck operation. expected.
Step 1: Turn off the vehicle. Check the coil connec- All vehicle movement is disabled.
tions of the line contactor, the tip condition of the line
Step 1: Follow the procedure for Event Code 206.
contactor, FU1 and the cable connections between the
line contactor and Access 2/3.
• If: The line contactor, cables, FU1 and connections
Event Code 208
are good Voltage is present at the Access 2/3 B+ terminal
– Then continue to step 2 prior to power-up.
Step 2: Keep the vehicle turned off. Remove the All vehicle movement is disabled
power cables from the pump motor and check between Step 1: Check line contactor tip condition.
the motor terminals and the vehicle chassis for shorts. • If: • If: The tips are in a good condition
• If: A short is detected – Then proceed to step 2
– Then replace the pump motor Step 2: Turn the vehicle off and check the voltage be-
• If: There is an open circuit (O/L) tween the B+ and the B-NEG terminals on Access 2/3.
– Then replace Access 2/3 Note: Access 2/3 internal capacitors charge when the
vehicle is turned on. Voltage may be present between
Event Code 205 B+ and B-NEG on the module for approximately 10 min
after the vehicle is turned off.
The pump motor output is higher than expected.
• If: The reading is 22–28 V DC
– Then a short exists between the battery and the
Step 1: Follow the procedures for Event Code 204. B+ terminal on Access 2/3
• If: The voltage is steadily dropping towards 0 V DC
or at 0 V DC.
– Then replace Access 2/3
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B+ from Line Contactor is not present at Access 2/ The Access 2/3 temperature is out of range.
3 after power-up Note: The vehicle will continue to operate, but perfor-
All vehicle movement is disabled mance may be reduced to manage the thermal limits of
Step 1: Using the service manual, perform a C3 cali- the controller.
bration. Turn off the vehicle, and then turn on the vehi- Step 1: Check the controller temperature using the
cle again. Analyser menu A2.2.5.
• If: The event clears • If: The temperature is 85°C (185°F) or greater
– Then return vehicle to service – Allow the vehicle to cool off for 15 min, then
• If: The event does not clear check to see if the module cools
– Then proceed to step 2 • If: If it does not cool
Step 2: In the correct operating position and with the – Then continue to step 2
vehicle on, check the voltage between the B+ and B- • If: The temperature is less than 85°C (185°F)
NEG terminals on Access 2/3. – Then replace Access 2/3
Note: The Access 2/3 internal capacitors charge when Step 2: Turn off the vehicle, and then turn on the ve-
the vehicle is turned on. Voltage may be present be- hicle again
tween B+ and B-NEG on the module for approximately
10 min after the vehicle is turned off. • If: The event does not clear
• If: The reading is less than 22 V DC – Then replace Access 2/3
– Then check FU1, the line contactor (L) tip condi-
tion and the power cable connections between
the battery connector and Access 2/3
• If: The reading is greater than 22 V DC
Event Code 210

This test is performed when the pump motor is run-
ning, and it verifies that the current feedback sen-
sor is not constantly stuck to zero.
Event Code 211

The current sensor or the current feedback circuit
is damaged in the controller. The sensor seems to
detect current different from zero.
Step 1: Replace Access 2/3.
Event Code 212

Access 2/3 has detected an under or overvoltage
condition at key switch (KYS) input.
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Event Code 214 Step 2: Enter Calibration Menu (C3), perform a BATT
ADJ calibration. Turn off the vehicle, and turn on the
The lift motor is over temperature. vehicle again.
Step 1: Check the thermal sensor (TS2) using the • If: Event clears.
Analyser menu A2.2.3. – Then return truck to service.
• If: The temperature is 150°C (320°F) or greater • If: Event does not clear.
– Then proceed to step 2 – Then replace Access 2/3.
• If: The temperature is less than 150°C (320°F)
– Then turn off the vehicle. Turn on the vehicle and Event Code 216
monitor the event frequency
The driver of the main contactor coil is shorted.
Step 2: Determine whether the vehicle is under ex-
treme duty cycles or high ambient temperatures.
Step 1: With the key off and battery unplugged, dis-
• If: The vehicle is under extreme duty cycles or high
connect wires 2947 and 5903 from the line contactor
ambient temperatures
coil. Connect the battery and turn on the vehicle.
– Then continue to use the vehicle
• If: The event changes
Note: If extreme duty cycles are normal for an applica-
– Then replace line contactor coil
tion, consider installing a cooling fan for the pump mo-
tor. • If: The event returns
• If: The duty cycles and ambient temperature are – Then proceed to step 2
normal Step 2: Disconnect CA403 at Access 2/3. With line
– Then proceed to step 3. contactor coil wires (2947 and 5903) disconnected,
check the resistance between CA605-2 and CA406-6.
Step 3: Make sure that the vehicle is on. Check TS2
voltage between B-NEG and CA606-6. • If: Resistance is detected
• If: The voltage is 0.2 V DC – Then repair shorted wiring to the line contactor
coil
– Then go to step 4
• If: The voltage is greater than 0.2 V DC
– Then proceed to step 6
Step 4: Turn off the vehicle. Check the wiring be-
tween CA606-5 and CA404-25.
Event Code 217
• If: The wiring is correct The line contactor driver is open.
– Then go to step 5 All vehicle movement is disabled.
Step 5: Disconnect CA606. Check the resistance of Step 1: Connect a DVOM to wires 2947 (+) and 5903
TS2 between PC606-5 and PC606-6. (-) at the line contactor (L). Turn on the vehicle.
• If: The resistance is greater than 1.8 K ohm • If: The reading is 17–22 V DC
– Then replace the traction motor (M2) – Then replace the line contactor
• If: The resistance is between 0.5 K to 1.8 K ohm • If: The reading is less than 17 V DC
– Then replace Access 2/3 – Then proceed to step 2
Step 2: Check if the line contactor circuit is open.
Event Code 215 • If: The circuit is OK
Incorrect battery voltage is detected at Access 2/3 – Then replace Access 2/3
Step 1: Check that the correct battery is installed and
charged. Event Code 218
• If: The correct battery is installed and charged cor- The traction command (TXN CMD) is out of the
rectly. electrical limit.
– Then proceed to step 2. Step 1: Check the TXN CMD voltage using the Anal-
yser menu A4.24.
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• If: The reading is 0.2 V with no traction request or

4.5 V with a full traction request
Menu Switch Input
– Then calibrate the TXN CMD using Calibration
Menu C2 A4.14 GOSL 0
• If: The reading is 4.8 V or greater A4.15 GCSL 1
A4.16 GOSR 0
Step 2: Check the voltage with a DVOM between
CA612-A (+) and CA612-C (-). A4.17 GCSR 1
• If: The reading is 4.5–5 V DC A4.18 RHS 1
– Then proceed to step 3 A4.19 LHS 1
• If: The reading is less than 4.4 V DC or greater
than 5.3 V DC • If: Any of the inputs are incorrect
– Then proceed to step 5 – Then verify condition and operation of switches,
sensors and associated wiring
Step 3: Check the voltage between CA612-B (+) and
CA612-C (-). • If: All inputs are correct
• If: The reading is 0.2 V with no traction request or – Then proceed to step 2
4.8 V during a full traction request Step 2: Enter the Analyser menu and scroll to A4.24
– Then proceed to step 4 with the twist grip released (neutral). The reading
should be 2.8–3.2 V DC. Scroll to A4.25 with the
• If: The reading is greater than 4.8 V DC or the volt-
twist grip released (neutral). The reading should be
age does not change as traction is requested
1.4–1.5 V DC.
– Then replace the TXN CMD
• If: A4.24 is less than 2.8 V DC or A4.25 is less
Step 4: Check the voltage between CA402-16 (+) than 1.4 V DC
and CA402-15 (-).
• If: The voltage does not change as traction request
• If: A4.24 is between 2.8–3.2 V DC and A4.25 is
returns to neutral
between 1.4–1.5 V DC
– Then check the wiring between CA402-16 and
CA612-B
Step 3: Connect a DVOM to CA101-4 (+) and
• If: The reading is 0.2 V with no traction request or
CA101-2 (-) on Access 4. Record the voltage while se-
4.8 V with a full traction request
lecting full forward and full reverse travel.
• If: The reading is less than 4.0 V DC (full reverse)
Step 5: Check the voltage with a DVOM between or greater than 1.1 V DC (full forward)
CA402-3 (+) and CA402-15 (-).
– Then replace TRX CMD.
• If: The reading is 4.5–5 V DC
• If: The reading is between 4.0 V DC (full reverse)
– Then check connections and wiring between and 1.1 V DC (full forward)
CA402 and CA612
– Then replace Access 4
• If: The reading is less than 4.4 V DC or greater
Step 4: Enter the Analyser menu and scroll to A4.22,
than 5.3 V DC
with steering pod released (neutral). The reading
– Then replace Access 2/3 should be 3.1–3.3 V DC. Next, scroll to A4.23, with
steering pod released (neutral). The reading should
Event Code 219 be 1.5–1.7 V DC.
This is a warning for an incorrect starting se- • If: A4.22 is less than 3.1 V DC or A4.23 is less
quence. than 1.5 V DC
Step 1: Enter the Analyser Menu and scroll through – Then proceed to Step 5.
the following inputs. With operator on foot switches, • If: A4.22 is between than 3.1–3.3 V DC or A4.23 is
gates closed and hands in operating position, the fol- between 1.5–1.7 V DC
lowing conditions should be met: – Then replace Access 1
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Step 5: Connect DVOM to CA101-15 (+) and CA101-

2 (-). Select full left and full right turn.
Event Code 222
• If: The reading is less than 2.1 V DC (full right) or Indicates steer command potentiometer is out of
greater than 4.5 V DC (full left) range.
– Then replace STR CMD. Step 1: Enter the Analyser menu and scroll to A4.22,
• If: The readings are 2.1 V DC for a full right with steering pod released (neutral). The reading
request, 4.5 V DC for a full left request and 3.2 V should be 3.1–3.3 V DC. Next, scroll to A4.23, with
DC in neutral steering pod released (neutral). The reading should
be 1.5–1.7 V DC.
– Then replace Access 2/3.
• If: A4.22 is less than 3.1 V DC or A4.23 is less
than 1.5 V DC
Event Code 221
Access 2/3 detects that the M1 speed does not • If: A4.22 is between than 3.1–3.3 V DC or A4.23 is
match the traction request. between 1.5–1.7 V DC
Step 1: Block the drive tyres off the floor (see the – Then replace Access 1
Control of Hazardous Energy section in the Service
Step 2: Connect DVOM to CA101-15 (+) and CA101-
and Parts Manual for proper blocking procedures).
2 (-). Select full left and full right turn.
Turn on the vehicle and enter the Analyser menu
A2.10, release the brakes and request forward travel. • If: The reading is less than 2.1 V DC (full right) or
greater than 4.5 V DC (full left)
• If: The reading is 0 rpm
– Then replace STR CMD
• If: The readings are 2.1 V DC for a full right
• If: The rpm increases as traction is requested
request, 4.5 V DC for a full left request and 3.2 V
– Then replace Access 2/3 DC in neutral
Step 2: Check the ECR1 voltage between CA202-1 – Then continue to step 3
(+) and CA202-2 (-).
Step 3: Enter the Calibration menu and perform a C1
• If: The reading is 11.3–12.3 V DC calibration.
– Then continue to step 3 • If: The event does not clear
• If: The reading is less than 11.3 V DC – Then replace Access 2/3
Step 3: Check the wiring condition and connections Event Code 223
between CA202-3 and 4 (ECR1) and CA401-1 and
CA401-4 on Access 2/3. A mismatch of the gate switch on one or both sides
is detected.
• If: The connections are OK
Step 1: Enter the Analyser menu and scroll through
– Then continue to step 4 the following inputs. With operator on foot switches,
Step 4: Check the ECR1 voltage between CA401-2 gates closed and hands on hand grips, the following
(+) and CA401-5 (-) on Access 2/3. conditions should be met:
• If: The reading is 11.3–12.3 V DC
– Then check the wiring condition and connections Menu Switch Input
between CA202-1 and 2 and CA402-1 and 2.
A4.14 GOSL 0
• If: The reading is less than or greater than
11.3–12.3 V DC A4.15 GCSL 1
– Then replace Access 2/3 A4.16 GOSR 0
A4.17 GCSR 1
• If: A4.15 indicates 1 and A4.15 indicates 0

• If: A4.15 indicates 0 and A4.15 indicates 0
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– Then proceed to step 3 Event Code 225

• If: The inputs are correct
– Then replace Access 2/3 Hands are seen already present when the vehicle is
turned on.
Step 2: Connect a DVOM to CA102-2 (-) on Access 4
and check the positive connections from the following Step 1: Follow the procedures for Event Code 413.
table.
Event Code 226
Gate Switch Positive Lead Voltage The pedals are seen already present when the ve-
Connection hicle is turned on.
Step 1: Check which of the two pedal signals is
GOSL CA101-10 0
wrong using tester functionality.
GCSL CA101-9 22–26 Step 2: Check the wires for crimping.
GOSR CA101-21 0 • If: There is a crimp or damage in the wire
GCSR CA101-22 22–26 – Then replace the wire
• If: There is no damage to the wires
• If: A voltage reading is incorrect
– Then check the wiring between the key switch
Step 3: Use a DVOM to check the signal value on the
and the appropriate gate switch
Access 4 connector.
• If: The wiring is OK
• If: There is a mismatch between the values in input
– Then replace the appropriate gate switch and the values read
• If: The voltage reading is correct – Then replace Access 4
Event Code 227
Event Code 224
The lift switch is pressed when the vehicle is
Access 2/3 detects that the elevation control turned on.
switch (ECS) is closed. Step 1: Check the status of the lift switch.
Step 1: Check the status of the ECS. • If: The switch was pressed when the vehicle was
• If: The switch is set to base turned on
– Then set the switch to platform – Turn off the vehicle, then turn on the vehicle
• If: The switch is set to platform again and do not press the lift switch during start-
up
• If: The switch was not pressed when the vehicle
Step 2: Check the voltage at CA605-10 in reference
was turned on
to B-NEG.
• If: The reading is 0 V DC
to B-NEG.
• If: The reading is less than 5 V DC
– Replace the ECS
Step 3: Check PC404-12 in reference to B-NEG.
– Replace the lift switch
– Replace or repair the circuit
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Event Code 228 • If: The reading is 0 V DC

The lower switch is pressed when the vehicle is
turned on. Event Code 230
Step 1: Check the status of the lower switch.
The horn switch is pressed when the vehicle is
• If: The switch was pressed when the vehicle was
turned on.
turned on
Step 1: Check the status of the horn switch.
– Turn off the vehicle, then turn on the vehicle
again and do not press the lower switch during • If: The switch was pressed when the vehicle was
start-up turned on
• If: The switch was not pressed when the vehicle – Turn off the vehicle, then turn on the vehicle
was turned on again and do not press the horn switch during
start-up
• If: The switch was not pressed when the vehicle
was turned on
to B-NEG.
to B-NEG.
– Replace the lower switch
– Replace the horn switch
Event Code 229 • If: The reading is 0 V DC
The tray switch is pressed when the vehicle is
turned on. Event Code 231
Step 1: Check the status of the tray switch.
The service panel switch (SPS) is activated and
• If: The switch was pressed when the vehicle was
there is a request for movement.
turned on
Step 1: Check the status of the service panel.
again and do not press the tray switch during • If: The service panel was open when the vehicle
start-up was turned on
• If: The switch was not pressed when the vehicle – Turn off the vehicle, then turn on the vehicle
was turned on again and make sure that the service panel is
closed during start-up
• If: The service panel was closed when the vehicle
was turned on
to B-NEG.
to B-NEG.
– Replace the tray switch
– Replace the service panel switch
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Step 3: Check PC404-12 in reference to B-NEG. Step 2: Check the voltage at CA605-10 in reference
• If: The reading is less than 5 V DC to B-NEG.
– Replace or repair the circuit • If: The reading is 0 V DC
• If: The reading is 0 V DC – Then continue to step 3
– Then replace Access 2/3 • If: The reading is less than 5 V DC
– Replace the emergency button switch
Event Code 232 Step 3: Check PC404-12 in reference to B-NEG.
Access 2/3 does not detect Access 1 • If: The reading is less than 5 V DC
All vehicle movement is disabled. – Replace or repair the circuit
Step 1: Check the CAN interface. • If: The reading is 0 V DC
• If: The messages are also not received by other – Then replace Access 2/3
nodes
– Then replace the CAN interface
Event Code 235
• If: The messages are also received by other nodes The tilt input is activated.
– Then continue to step 2 Note: TLTS is only present on European and Austral-
Step 2: Check the CAN line of Access 4. ian EEC-compliant trucks. If Tilt = On for non-EEC
compliant truck, then disable the setting before begin-
• If: The line is damaged or disconnected
ning the following procedures.
– Then replace or reconnect the CAN line
Step 1: Verify that the vehicle is not being operated
• If: The line is properly connected on a grade and the height switches and gate switches
– Then continue to step 3 are functioning properly.
Step 3: Turn off the vehicle, then turn on the vehicle • If: The grade is less than 1.5°
again. – Then proceed to step 2
• If: The alarm occurs permanently Step 2: Enter the Analyser menu and scroll to A2.9
– Then replace Access 2/3 TLTS.
• If: TILT INPUT = 1
Event Code 233 – Then proceed to step 3
This fault is signalled when Access 4 is in alarm • If: TILT INPUT = 0
Step 1: Check the events history. – Then replace Access 2/3
Step 2: Troubleshoot the occurring or the last oc- Step 3: Use a DVOM to measure the voltage be-
curred 400 series event code tween CA402-1 (+) and CA404-2
Event Code 234 – Then replace TLTS
The emergency button has been pressed, but the • If: The reading is less than 22 V DC
module stays active. – Then replace Access 2/3
Step 1: Check the status of the emergency button.
• If: The button was pressed when the vehicle was
turned on
again and do not press the emergency button
during start-up
• If: The button was not pressed when the vehicle
was turned on
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The slack chains input is activated. The motor cover input is activated.
Step 1: Check the status of the slack chain switches. Backwards direction is disabled.
• If: The switches are damaged or worn Step 1: Follow the procedures for Event Code 200.
– Then replace the switches
• If: The switches are not damaged or worn Event Code 240
– Then continue to step 2 Before switching on the line contactor, the soft-
Step 2: Check the voltage at CA605-10 in reference ware checks the output voltage on the -P connec-
to B-NEG. tor and expects it to be at a steady state value.
• If: The reading is 0 V DC If the voltage is too low, this alarm occurs.
– Then continue to step 3 Step 1: Check the motor internal connections.
• If: The reading is less than 5 V DC • If: Damage or disconnects are found in the internal
– Replace the slack chain switches connections
Step 3: Check PC404-12 in reference to B-NEG. – Then repair or connect the bad connections
• If: The reading is less than 5 V DC • If: No problems are found in the internal connec-
– Replace or repair the circuit tions
• If: The reading is 0 V DC – Then continue to step 2
– Then replace Access 2/3 Step 2: Check the connections of the motor and
power cables.
Event Code 237 • If: Damage or disconnects are found in the connec-
tions
The charge input is activated. – Then replace or repair the motor cables
Step 1: Make sure that the battery charger is not • If: No disconnects are found
plugged in.
Step 2: Check the signals coming from the battery
Step 3: Check if the motor cables have short circuits
charger.
to the vehicle chassis.
Step 3: Go to the Analyser menu A2.1 CHARGER
• If: Short circuits are found
INHIBIT.
– Then replace the motor cables
• If: The menu reads 0
• If: No short circuits are found
• If: The menu reads 1
– Then replace Access 2/3 Event Code 241
Step 4: Use a DVOM to measure the voltage be-
tween CA402-1 (+) and CA404-14 (-). Access 2/3 senses movement in the lift pump when
• If: The reading is less than 22 V DC no request for movement has been made.
– Then continue to step 5 Step 1: Follow the procedures for Event Code 240.
Event Code 242
Step 5: Replace the wiring. The side gate open input is activated.
• If: The event continues Step 1: Follow the procedures for Event Code 223.
– Replace the charger
• If: The event continues after replacing the charger
Event Code 243
– Then replace Access 2/3 Step 1: Follow the procedures for Event Code 206.
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Event Code 244 – Then go to step 2

• If: The rpm increases as traction is requested
Before switching on the line contactor, the soft- – Turn off the vehicle, turn on the vehicle again and
ware checks the voltage of the power bridge with- monitor event frequency
out driving it. The software expects the voltage to
be at a steady state value. If it is too low, this alarm Step 2: Check the ECR1 voltage between CA202-1
occurs. (+) and CA202-2 (-).
All vehicle movement is disabled • If: The reading is 11.3–12.3 V DC
Step 1: Follow the procedure for Event Code 206. – Then go to step 3
• If: The reading is less than 11.3 V DC
Event Code 245 – Then go to step 4
Step 3: Check the wiring condition and connections
A hardware or software defect has been detected.
This alarm does not inhibit the machine opera- between CA202-4 and CA202-3 (ECR1). Then check
tions, but the vehicle works with the default values. between CA401-4 and CA401-1 on Access 2/3.
Step 1: Enter the Utilities menu (U.4) and perform a • If: The connections are good
Clear EEPROM. – Then replace ECR1
Step 2: Recalibrate all the vehicle functions. Step 4: Check the ECR1 voltage between CA401-2
Step 3: Apply any customer preferred Features and (+) and CA401-5 (-) on Access 2/3.
Performance settings. • If: The reading is 11.3–12.3 V DC
Step 4: Turn off the vehicle, and then turn on the ve- – Then check wiring condition and connections
hicle again. between CA202-1 and CA202-2 and between
• If: The event does not return CA401-2 and CA401-5
– Then return the vehicle to service • If: The reading is less than or greater than
11.3–12.3 V DC
• If: The event returns

Auto-shutdown is activated.
A complete parameters set restore was made since
the vehicle was last turned off. All vehicle movement is disabled.
Step 1: Follow the procedure for Event Code 245. Step 1: Turn off the vehicle, and then turn on the ve-
hicle again.
Event Code 247 • If: The event returns
All vehicle movement is disabled
hicle again.
Event Code 250
• If: The event returns All vehicle movement is disabled.
– Then replace Access 2/3 Step 1: Follow the procedure for Event Code 249.
Event Code 248

Access 2/3 detects that the traction motor (M1) has
stalled.
Step 1: Block the drive wheels off the floor. (See the
Control of Hazardous Energy section in the service
manual for the proper blocking procedures). Turn on
the vehicle, enter the Analyser menu A2.10, release
the brakes and request forward travel.
• If: The reading is 0 rpm
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Event Code 252

Height Switch Positive Lead Voltage
Access 2/3 detects that the SVL driver is shorted. Connection
Step 1: With the key off and battery unplugged, dis- HGTS20 CA101-18 22–26
connect wires 2964 and 5912 from the lower solenoid HGTS84 CA101-7 22–26
valve (SVL) coil. Connect the battery and turn on the
vehicle. HGTS118 CA101-19 22–26
• If: The event changes • If: The voltages are not correct.
– Then replace line contactor coil – Then go to step 3.
• If: The event returns • If: The voltages are correct
– Then proceed to step 2 – Then replace Access 4
Step 2: Disconnect CA403 at Access 2/3 and Step 3: Check the wiring between the key switch
CA601. With the SVL coil wires (2964 and 5912) dis- (KYS) and Access 4 through the appropriate height
connected, check the resistance between CA601-5 switch.
and CA403-3. • If: The wiring is not correct
• If: Resistance is detected – Then repair or replace the wiring
– Then repair shorted wiring between CA601 or • If: The wiring is correct
CA403 and the SVL coil
– Then replace the appropriate height switch.
– Then replace Access 2/3 Event Code 254
Event Code 253 Access 2/3 has detected that the pump motor has
stalled.
There is a mismatch between the height switches. All vehicle movement is disabled.
Step 1: Enter the Analyser menu and scroll through This event is logged if the line contactor tips open dur-
the following inputs. With the platform fully lowered, the ing normal forklift truck operation.
operator on foot switches, the gates closed and hands
on the hand grips, the following conditions should be Step 1: Turn off the vehicle. Check the coil connec-
met: tions of the line contactor, the tip condition of the line
contactor, FU1 and the cable connections between the
line contactor and Access 2/3.
Menu Switch Input • If: The line contactor, cables, FU1 and connections
A4.11 HGTS20 1 are good
A4.12 HGTS84 1
Step 2: Keep the vehicle turned off. Remove the
A4.13 HGTS118 1 power cables from the pump motor and check between
the motor terminals and the vehicle chassis for shorts.
• If: Any of the inputs indicate 0
• If: A short is detected
– Then replace the pump motor
• If: All of the inputs indicate 1
– Replace Access 4
Step 2: Connect a DVOM to CA102-2 (-) on
Access 4. Check each location in the following table
with the positive meter lead of the DVOM.
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Event Code 255 Step 1: Connect the DVOM to CA407-1 (+) on

Access 3™ and CA403-5 (-) on Access 2/3. Enter the
The temperature of the right traction motor (M1) is Utilities menu U2.1 Tester BRK1, press Enter and re-
out of range. cord the voltage displayed.
Step 1: Turn on the vehicle. Go to the Analyser Menu • If: The voltage is 15–26 V DC
A2.11 (M1 temperature) and record the reading. – Then continue to step 2.
• If: There is no temperature displayed or the tem- • If: The voltage is less than 15 V DC
perature is less than 150°C (302°F) – Then determine which voltage polarity is missing
– Then check the wires between Access 2/3 and and replace appropriate module
the M1 thermal sensors. Step 2: Connect DVOM to wires 2996 (+) and 5926
• If: The temperature is greater than 150°C (302°F) (-) at BRK1. Enter the Utilities menu U2.1 Tester BRK1,
– Turn off the vehicle, then turn on the vehicle press Enter and record the voltage displayed.
again and monitor event frequency • If: The voltage is 15–26 V DC
• If: The alarm occurs permanently – Then replace BRK1
– Then replace Access 2/3 • If: The voltage is less than 15 V DC
Note: If the vehicle operates, this could be a random – Then repair the wiring between CA407-1,
nuisance event. Monitor the event frequency. If it grad- CA403-5 and BRK1
ually increases for no apparent reason, replace
Access 2/3. Event Code 260
Event Code 256 The line contactor coil (LC) driver or the brake
(BRK1) driver has shorted.
+BV Missing at CA403-2 All vehicle movement is disabled.
All vehicle movement is disabled Step 1: Turn off the vehicle. Disconnect wire 5908
Step 1: Check the connection of CA403-2. from the line contactor (LC) coil. Connect the battery
• If: The connection is good and turn on the vehicle.
– Then continue to step 2 • If: The event changes
• If: The connection is bad – Then replace the line contactor coil
– Then repair the connection • If: The event returns
Step 2: Check FU5. – Then proceed to step 2
• If: The fuse is blown Step 2: Disconnect CA403-6 and CA403-3 on
– Then replace FU5 Access 2/3. With the LC coil wire 5908 disconnected,
check the resistance between CA403-6 and CA403-3.
• If: The fuse is not blown
• If: Resistance is detected
– Then repair the shorted wiring between CA403
Step 3: Check the circuit between FU5 and CA403.
and the LC coil, and continue to step 3
• If: The circuit is good
• If: There is an open circuit.
Step 3: Turn off the vehicle and unplug the battery.
Event Code 259 Disconnect wire 5926 from the brake (BRK1). Connect
The right brake (BRK1) is open. the battery and turn on the vehicle.
To release the brakes, 24 V is applied to the brake coil • If: The event changes
momentarily. All vehicle movement is disabled. – Then replace BRK1
Note: Access 2/3 and Access 3™ supply the negative • If: The event returns
voltage to the brake on the motor that is active. They – Then continue to step 4
supply the positive voltage to the brake on the opposite
motor.
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Step 4: Disconnect CA403 on Access 2/3 and

CA407 on Access 3™. With the BRK1 wires (5926 and
Event Code 266
2996) disconnected, check the resistance between The driver of one of the low side outputs is shorted.
CA403-5 and the negative on BRK1. The number shown in the alarm label identifies the
Note: This test is looking for a short in the wiring. High driver.
resistance or an open circuit is normal due to the di- Step 1: Follow the procedures for Event Code 200.
odes in the harness.
• If: A short is found Event Code 268
– Then repair the wiring between CA403 and BRK1 Step 1: Turn off the vehicle, and then turn on the ve-
• If: No short is found hicle again.
– Then replace Access 2/3 • If: The event clears
– Then check that the Features and Performance
Event Code 261 settings are correct and perform C1 and C2 cali-
brations
The voltage on pin CA403-1 is at the high value
• If: The event does not clear
even if the smart driver of the left controller is off.
The voltage on the CA403-1 pin is evaluated by the – Then replace Access 2/3
controller through the NEB (CA403-5) internal feed- Note: If the vehicle operates, this could be a random
back circuit. nuisance event. Monitor the event frequency. If it grad-
All vehicle movement is disabled. ually increases for no apparent reason, replace
Access 2/3.

This fault is signalled when communication with
Step 1: Clear the event by clearing the EEPROM in
Access 4 is not present.
Access 2/3 using the Utilities menu (U4).
Step 2: Recalibrate all vehicle functions.
Step 3: Apply any customer preferred settings in the
Features and Performance menus.
Event Code 263
All vehicle movement is disabled hicle again.
Step 1: Follow the procedures for Event Code 200. • If: The event does not return
Event Code 264 • If: The event returns
One or more on/off valve drivers is not able to drive Step 5: Then replace Access 2/3
the load (cannot close). Note: If the vehicle operates, this could be a random
Step 1: Follow the procedures for Event Code 200. nuisance event. Monitor the event frequency. If it grad-
Event Code 265 Access 2/3.
Before switching on the line contactor, the soft- Event Code 270
ware checks the power bridge. It expects the volt-
age of the power capacitors not to decrease. If the The Access 2/3 software is not compatible with the
voltage decrease happens, this alarm occurs. Access 2/3 module.
All vehicle movement is disabled. All vehicle movement is disabled.
Step 1: Follow the procedures for Event Code 206. Step 1: Follow the procedures for Event Code 269.
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The lower solenoid valve (SVL) is open. At start-up, the controller checks the battery volt-
Step 1: Connect the DVOM to CA601-5 (+) and age (measured on the key input pin A10) and veri-
CA403-3 (-) on Access 2/3. Enter the Utilities menu fies that it is ±20% from the nominal value.
U2.10 Tester SVL, press Enter and record the voltage All vehicle movement is disabled.
displayed. Step 1: Follow the procedures for Event Code 203.
• If: The voltage is 15–26 V DC
– Then continue to step 2 Event Code 278
• If: The voltage is less than 15 V DC The outputs of the amplifiers (used to measure the
– Then determine which voltage polarity is missing motor voltage) are checked. This alarm occurs
and replace appropriate module when voltage signals are greater than 3 V or less
Step 2: Connect DVOM to wires 2964 (+) and 5912 than 2 V at the input.
(-) at SVL. Enter the Utilities menu U2.10 Tester SVL, All vehicle movement is disabled.
press Enter and record the voltage displayed. Step 1: Follow the procedures for Event Code 269.
• If: The voltage is 15–26 V DC
– Then replace SVL Event Code 279
• If: The voltage is less than 15 V DC
The Access 2/3 internal memory reverts to factory
– Then repair the wiring between CA601-5, settings.
CA403-3 and SVL
Note: The vehicle will function using the factory default
settings.
Event Code 272 Step 1: Turn off the vehicle, and then turn on the ve-
The EB coil driver is not able to drive the load. The hicle again.
device itself or its driving circuit is damaged. • If: The event clears
All vehicle movement is disabled. – Then verify that the features and performance
Step 1: Follow the procedures for Event Code 259. settings are correct for the application and per-
form C1 and C2 calibrations
Event Code 273 • If: The event does not clear
An acquisition of the current gains is occurring.
Step 1: Follow the procedures for Event Code 269. Note: If the vehicle operates, this could be a random
nuisance event. Monitor the event frequency. If it grad-
Event Code 274 Access 2/3.
Access 2/3 cannot communicate with Access 1.
Step 1: Follow the procedures for Event Code 101. The EB driver is shorted or the microcontroller de-
tects a mismatch between the output setpoint and
Event Code 276 the driver voltage measured on the EB output.
The output of the controller thermal sensor is out
of range. Step 1: Follow the procedures for Event Code 260.
Event Code 281
Step 1: Follow Event Code 279 procedures.
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Event Code 282 • If: The cables are connected properly

The EB coil is worn or damaged. Step 2: Keep the vehicle turned off. Check for a trac-
Step 1: Follow the procedures for Event Code 260. tion motor (M2) short to the chassis.
Step 3: Check the resistance from each motor termi-
Event Code 283 nal to the frame of the vehicle.
The EB coil is worn or damaged. • If: A short is detected
Step 1: Follow the procedures for Event Code 260. – Then replace the appropriate motor
Event Code 300 – Then replace Access 3™
Event Code 303
hicle again. Access 3™ has detected an under or overvoltage
• If: The event clears. condition at key switch (KYS) input.
– Then verify the Performance menu and the Fea- Note: Overvoltage threshold is 26 V DC; undervoltage
tures menu settings and return the vehicle to ser- threshold is 22 V DC. If this event occurs during power-
vice up, idle or traction request, then an undervoltage con-
• If: The event does not clear and the software was dition is likely. The battery condition and state of charge
recently updated should be taken into consideration.
– Check the version of the software and reload the Step 1: Check the voltage between the B-NEG termi-
software nal and CA406-1 on Access 3™, with the vehicle on
and the operator in the seat.
• If: The event does not clear and the software was
not recently updated • If: The voltage is less than 22 V DC or greater
than 26 V DC
– Then replace Access 3™ if the event returns
– Then check the circuit between the key switch
If the vehicle operates, this could be a random nui-
and CA406-1
sance event. Monitor the event frequency. If it gradually
increases for no apparent reason, replace Access 3™. • If: The voltage is between 22–66 V DC
– Then replace Access 3™
Event Code 301
Event Code 304
Step 1: Turn off the vehicle, and then turn on the ve- There is low voltage on the left traction motor (M2)
hicle again. terminal outputs.
• If: The event returns All vehicle movement is disabled.
– Then replace Access 3™ This event is logged if the line contactor tips open dur-
ing normal forklift truck operation.
Event Code 302 Step 1: Turn off the vehicle. Check the coil connec-
tions of the line contactor, the tip condition of the line
Access 3™ detects that the traction motors voltage contactor, FU2 and the cable connections between the
feedback circuit is out of range line contactor and Access 3™.
A bad line contactor (L) causes this event. • If: The line contactor, cables, FU2 and connections
Access 1 2 3® records this event after the vehicle tem- are good
perature increases to the usual temperature of opera-
tion. The symptoms can be intermittent.
Step 2: Keep the vehicle turned off. Remove the
Step 1: Turn off the vehicle. Verify that the motor
power cables from M2 and check between the motor
power cables are connected to the proper terminals of
terminals and the vehicle chassis for shorts.
each traction motor and Access 3™.
• If: A short is detected
• If: The cables are incorrectly connected
– Then replace M2
– Then connect them properly
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• If: There is an open circuit (O/L) Note: The Access 3™ internal capacitors charge when
– Then replace Access 3™ the vehicle is turned on. Voltage may be present be-
tween B+ and B-NEG on the module for approximately
Event Code 305 10 min after the vehicle is turned off.
The left traction motor (M2) output is higher than – Then check FU2, the line contactor (L) tip condi-
expected. tion and the power cable connections between
All vehicle movement is disabled. the battery connector and Access 3™
Step 1: Follow the procedures for Event Code 304. • If: The reading is greater than 22 V DC
Event Code 306
Voltage is present at the Access 3™ B+ terminal Event Code 308
prior to power-up. The current sensor or the current feedback circuit
All vehicle movement is disabled is damaged in the controller. The sensor seems to
Step 1: Check line contactor tip condition. detect current different from zero.
• If: • If: The tips are in good condition Step 1: Follow the procedures for Event Code 301.
Step 2: Turn the vehicle off and check the voltage be-
Event Code 309
tween the B+ and the B-NEG terminals on Access 2/3. Access 3™ has detected an under or overvoltage
Note: Access 3™ internal capacitors charge when the condition at key switch (KYS) input.
vehicle is turned on. Voltage may be present between Step 1: Follow the procedures for Event Code 303.
B+ and B-NEG on the module for approximately 10 min
after the vehicle is turned off. Event Code 310
– Then a short exists between the battery and the The driver of the K2 coil is shorted.
B+ terminal on Access 3™ All vehicle movement is disabled.
• If: The voltage is steadily dropping towards 0 V DC Step 1: Disconnect CA601 and C4A07 at
or at 0 V DC. Access 3™. Check the resistance from CA601-10 to
– Then replace Access 3™ CA601-9.
Event Code 307 – Then repair the wiring between Access 3™ and
CA601
B+ from Line Contactor is not present at
Access 3™ after power-up.
Step 1: Using the service manual, perform a C3 cali-
bration. Turn off the vehicle, and then turn on the vehi-
Event Code 311
cle again. The line contactor driver is open.
• If: The event clears All vehicle movement is disabled.
– Then return vehicle to service Step 1: Follow the procedures for Event Code 310.
Step 2: In the correct operating position and with the
vehicle on, check the voltage between the B+ and B-
NEG terminals on Access 3™.
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Event Code 312 Step 2: Check if the motor cables have short circuits
to the vehicle chassis.
Access 3™ detects that the M2 speed does not • If: Short circuits are found
match the traction request. – Then replace the motor cables
Step 1: Block the drive tyres off the floor (see the
• If: No short circuits are found
Control of Hazardous Energy section in the Service
and Parts Manual for proper blocking procedures). – Then continue to step 3
Turn on the vehicle and enter Analyser menu (A3.1), Step 3: Check the resistance between the motor
release brakes and request forward travel. power phase terminals and B-NEG.
• If: The reading is 0 rpm • If: An incorrect resistance is found
– Then proceed to step 2 – Then replace the motor cables
• If: The rpm increases as traction is requested • If: There are no resistance problems
– Then replace Access 3™. – Then replace Access 3™
Step 2: Check the ECR1 voltage between CA401-2
(+) and CA401-5 (-). Event Code 314
• If: The reading is 11.3–12.3 V DC Before switching on the line contactor, the soft-
– Then proceed to step 3 ware checks the voltage of the power bridge with-
• If: The reading is less than 11.3 V DC out driving it. The software expects the voltage to
be at a steady state value. If it is too low, this alarm
occurs.
Step 3: Check the wiring condition and connections
All vehicle movement is disabled
between CA202-3 and CA202-4 (ECR1) and CA401-1
and CA401-4 on Access 3™. Step 1: Follow the procedure for Event Code 304.
• If: The connections are OK
Event Code 315
Step 4: Check the ECR1 voltage between CA401-2 A hardware or software defect has been detected.
(+) and CA402-5 (-) on Access 3™. This alarm does not inhibit the machine opera-
• If: The reading is 11.3–12.3 V DC tions, but the vehicle works with the default values.
– Then check wiring condition and connections Step 1: Enter the Utilities menu (U.4) and perform a
between CA202-1 and CA202-2 and CA401-2 Clear EEPROM.
and CA401-5. Step 2: Recalibrate all the vehicle functions.
• If: The reading is less than or greater than Step 3: Apply any customer preferred Features and
11.3–12.3 V DC Performance settings.
– Then replace Access 3™ Step 4: Turn off the vehicle, and then turn on the ve-
hicle again.
Event Code 313 • If: The event does not return
Before switching on the line contactor, the soft-
ware checks the voltage of the power bridge with- • If: The event returns
out driving it. The software expects the voltage to – Then replace Access 3™
be at a steady state value. If it is too low, this alarm
occurs. Event Code 316
Step 1: Check the connections of the motor and
power cables. A complete parameters set restore was made since
the vehicle was last turned off.
• If: Damage or disconnects are found in the connec-
tions Step 1: Follow the procedures for Event Code 315.
– Then replace or repair the motor cables
• If: No disconnects are found
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All vehicle movement is disabled +BV Missing at CA407-1
Step 1: Follow the procedures for Event Code 301. All vehicle movement is disabled
Step 1: Check the connection of CA407-1.
Event Code 318 • If: The connection is good
All vehicle movement is disabled. – Then continue to step 2
Step 1: Follow the procedures for Event Code 301. • If: The connection is bad
– Then repair the connection
Event Code 320
Step 2: Check FU6.
Access 2/3 detects that the ALM2 driver is shorted. • If: FU6 is blown
All vehicle movement is disabled. – Then replace FU6
Step 1: With the key off and battery unplugged, dis- • If: The fuse is not blown
connect the red and green wires from the ALM2. Con-
nect the battery and turn on the vehicle.
Step 3: Check the circuit between FU6 and CA407.
• If: The event changes
• If: The circuit is good
– Then replace ALM2
Step 2: Disconnect CA408 at Access 3™ and
CA603. With the ALM2 coil wires (red and green) dis- The left brake (BRK2) is open.
connected, check the resistance between CA603-2 To release the brakes, 24 V is applied to the brake coil
and CA408-1. momentarily. All vehicle movement is disabled.
• If: Resistance is detected Note: Access 2/3 and Access 3™ supply the negative
– Then repair shorted wiring between CA603 or voltage to the brake attached to the motor that each is
CA408 and the ALM2 coil driving. They supply the positive voltage to the brake
• If: There is an open circuit (O/L) on the opposite motor.
– Then replace Access 3™ Step 1: Connect the DVOM to CA403-1 (+) on
Access 2/3 and CA407-5 (-) on Access 3™. Enter the
Utilities menu U2.2 Tester BRK2, press Enter and re-
Event Code 321 cord the voltage displayed.
The temperature of the left traction motor (M2) is • If: The voltage is 15–26 V DC
out of range. – Then continue to step 2
Step 1: Turn on the vehicle. Go to the Analyser Menu • If: The voltage is less than 15 V DC
A3.2 (M2 temperature) and record the reading.
– Then determine which voltage polarity is missing
• If: There is no temperature displayed or the tem- and replace appropriate module
perature is less than 150°C (302°F)
Step 2: Connect DVOM to wires 2995 (+) and 5925
– Then check the wires between Access 3™ and (-) at BRK2. Enter the Utilities menu U2.2 Tester BRK2,
the M2 thermal sensors. press Enter and record the voltage displayed.
• If: The temperature is greater than 150°C (302°F) • If: The voltage is 15–26 V DC
– Turn off the vehicle, then turn on the vehicle – Then replace BRK2
again and monitor event frequency
• If: The voltage is less than 15 V DC
• If: The alarm occurs permanently
– Then repair the wiring between CA407-5,
– Then replace Access 3™ CA403-1 and BRK2
Note: If the vehicle operates, this could be a random nui-
sance event. Monitor the event frequency. If it gradually
increases for no apparent reason, replace Access 3™.
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The K2 coil driver or the brake (BRK2) driver has One or more on/off valve drivers is not able to drive
shorted. the load (cannot close).
All vehicle movement is disabled. Step 1: Follow the procedures for Event Code 300.
Step 1: Turn off the vehicle. Disconnect wire 5919
from the K2 coil. Connect the battery and turn on the Event Code 330
vehicle.
Before switching on the line contactor, the soft-
• If: The event changes ware checks the power bridge. It expects the volt-
– Then replace the K2 coil age of the power capacitors not to decrease. If the
• If: The event returns voltage decrease happens, this alarm occurs.
– Then proceed to step 2 All vehicle movement is disabled.
Step 2: Disconnect CA403 and CA407 on Step 1: Follow the procedures for Event Code 304.
Access 3™. With the K2 coil wire 5919 disconnected,
check the resistance between CA403-3 and CA407-5. Event Code 331
The driver of one of the low side outputs is shorted.
– Then repair the shorted wiring between CA403 The number shown in the alarm label identifies the
and the LC coil, and continue to step 3 driver.
• If: There is an open circuit. Step 1: Follow the procedures for Event Code 300.
Step 3: Turn off the vehicle and unplug the battery. Event Code 333
Disconnect wire 5925 from the brake (BRK2). Connect Step 1: Turn off the vehicle, and then turn on the ve-
the battery and turn on the vehicle. hicle again.
• If: The event changes • If: The event clears
– Then replace BRK2 – Then check that the Features and Performance
• If: The event returns settings are correct and perform C1 and C2 cali-
– Then continue to step 4 brations
Step 4: Disconnect CA403 on Access 2/3 and • If: The event does not clear
CA407 on Access 3™. With the BRK2 wires (5926 and – Then replace Access 3™
2995) disconnected, check the resistance between Note: If the vehicle operates, this could be a random
CA407-5 and BRK2. nuisance event. Monitor the event frequency. If it grad-
Note: This test is looking for a short in the wiring. High ually increases for no apparent reason, replace
resistance or an open circuit is normal due to the di- Access 3™.
odes in the harness.
• If: A short is found Event Code 334
– Then repair the wiring between CA403 and BRK2 All vehicle movement is disabled.
• If: No short is found Step 1: Clear the event by clearing the EEPROM in
– Then replace Access 2/3 Access 3™ using the Utilities menu (U4).
Step 2: Recalibrate all vehicle functions.
Event Code 327 Step 3: Apply any customer preferred settings in the
All vehicle movement is disabled. Features and Performance menus.
Step 1: Follow the procedures for Event Code 327. Step 4: Turn off the vehicle, and then turn on the ve-
hicle again.
Event Code 328 • If: The event does not return
All vehicle movement is disabled – Then return the vehicle to service
Step 1: Follow the procedures for Event Code 300. • If: The event returns
Step 5: Then replace Access 3™
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ELECTRICAL SYSTEM
Event Codes

nuisance event. Monitor the event frequency. If it grad-
Event Code 342
ually increases for no apparent reason, replace At start-up, the controller checks the battery volt-
Access 3™. age (measured on the key input pin A10) and veri-
fies that it is ±20% from the nominal value.
Event Code 335 All vehicle movement is disabled.
The Access 3™ software is not compatible with the Step 1: Follow the procedures for Event Code 303.
Access 3™ module.
Step 1: Follow the procedures for Event Code 334. The outputs of the amplifiers (used to measure the
motor voltage) are checked. This alarm occurs
Event Code 337 when voltage signals are greater than 3 V or less
than 2 V at the input.
The EB coil driver is not able to drive the load. The
device itself or its driving circuit is damaged.
Step 1: Follow the procedures for Event Code 325. Event Code 344
Event Code 338 The Access 3™ internal memory reverts to factory
settings.
An acquisition of the current gains is occurring.
Note: The vehicle will function using the factory default
Step 1: Follow the procedures for Event Code 334. settings.
Event Code 339 hicle again.
Access 3™ cannot communicate with Access 1. • If: The event clears
All vehicle movement is disabled. – Then verify that the features and performance
settings are correct for the application and per-
form C1 and C2 calibrations
Event Code 341 • If: The event does not clear
The Access 3™ temperature is out of range.
Note: The vehicle may continue to operate, but perfor- nuisance event. Monitor the event frequency. If it grad-
mance may be reduced to manage the thermal limits of ually increases for no apparent reason, replace
the controller. Access 3™.
Step 1: Check the Access 3™ temperature using the
Analyser A3.4 ACCESS 3 TEMP menu. Event Code 345
• If: The temperature is 85°C (185°F) or greater
The EB driver is shorted or the microcontroller de-
– Allow the vehicle to cool off for 15 min and then
tects a mismatch between the output setpoint and
check if the module cools, if not continue to step 2
the driver voltage measured on the EB output.
• If: The temperature is less than 85°C (185°F)
hicle again Event Code 346
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ELECTRICAL SYSTEM
Event Codes
Event Code 400 – Then replace Access 4
This alarm is a safety-related test that checks the Event Code 402
correct operation of the software.
Error is detected in eeprom or in eeprom manage-
All functions are blocked.
ment. This alarm does not inhibit the machine op-
Step 1: Enter the Utilities menu (U.4) and perform a erations, but the vehicle works with the default
Clear EEPROM. values.
Step 2: Recalibrate all vehicle functions. Step 1: Follow the procedures for Event Code 400.
Step 3: Apply any customer preferred Features and
Performance settings. Event Code 403
hicle again. This alarm inhibits the machine operations.
• If: The event does not return Step 1: Follow the procedures for Event Code 400.
Event Code 404
Step 1: Follow the procedure for Event Code 400.

CAN communication does not work.
Access 4 has detected an under or overvoltage
condition at the key switch (KYS) input. All vehicle movement is disabled.
Note: The overvoltage threshold is 65 V DC and the Step 1: Follow the procedure for Event Code 101.
undervoltage threshold is 15 V DC. If this event occurs
when the vehicle is turned on, idle or a traction request Event Code 406
has been made, an undervoltage condition is likely. If
this event occurs during the motor operation, an over- Access 4 found another module to be presenting
voltage condition is likely. The battery condition and an event.
state of charge should be considered. Step 1: Check the other event codes present in
Step 1: Check the voltage between the B-NEG termi- Event History.
nal and CA102-1 on Access 4, with the vehicle turned • If: The event is not resolved by troubleshooting the
on and the operator on the vehicle. other codes
• If: The voltage is less than 15 V DC or greater – Then replace Access 4
than 65 V DC
• If: The voltage is between 15 V DC and 65 V DC The Access 4 software is not compatible with the
– Then replace Access 4 Access 4 module.
Step 2: Check the voltage between CA103-2 and the All vehicle movement is disabled.
B-NEG terminal on Access 4. Step 1: Install the correct software version in the su-
• If: The voltage is less than 15 V DC or greater pervisor microprocessor.
than 65 V DC Step 2: Clear the event by clearing the EEPROM in
– Then proceed to step 2 Access 4 using the Utilities menu (U4).
• If: The voltage is between 15 V DC and 65 V DC Step 3: Recalibrate all vehicle functions.
– Then replace Access 4 Step 4: Apply any customer preferred Features and
Step 3: Check the circuit between CA111, the left Performance settings.
mast cable, CA609, DTS, CA601 and FU3. Step 5: Turn off the vehicle, and then turn on the ve-
• If: The circuit is bad hicle again.
– Then repair or replace the wiring • If: The event does not return
• If: The circuit is good – Then return the vehicle to service
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ELECTRICAL SYSTEM
Event Codes
• If: The event returns • If: The reading is XX V DC

– Then replace Access 4 – Then check the sensors. If LHS reads on con-
tinue to step 4. If RHS reads on, continue to
Event Code 408 step 5.
All vehicle movement is disabled. • If: The reading is less than XX V DC
Step 1: Follow the procedures for Event Code 400. – Then continue to step 6
Step 4: Turn off the vehicle and disconnect CA301
Event Code 409 and CA102 (Access 4). Check the resistance between
CA301-10 and CA102-17. Check the resistance be-
The wrong software version is on the supervisor tween CA301-9 and CA102-10.
microprocessor. • If: The wiring has a short
All vehicle movement is disabled. – Then repair or replace the wiring
Step 1: Follow the procedures for Event Code 407. • If: The wiring is OK
– Then replace the left-hand sensor (LHS).
Event Code 412 • If: The event continues
There is a mismatch between the two encoders – Then replace Access 4
present on the right motor (M1). Step 5: Turn off the vehicle and disconnect CA303
All vehicle movement is disabled. and CA102 (Access 4). Check the resistance between
Step 1: Block the drive wheels off the floor (see Con- CA303-10 and CA102-16. Check the resistance be-
trol of Hazardous Energy section in the Service and tween CA303-9 and CA102-9.
Parts Manual for proper blocking procedures). Turn on • If: The wiring has a short
the vehicle and enter the Analyser menu A2.10 M1 – Then repair or replace the wiring
Speed, in the proper operator position, gates open, re-
quest full forward travel. Record the RPM. • If: The wiring is OK
• If: The reading is 3,200–3,260 RPM – Then replace the right-hand sensor (RHS).
– Then continue to step 2 • If: The event continues
• If: The reading is not between 3,200–3,260 RPM – Then replace Access 4
– Then replace Access 2/3. Step 6: Check the wiring between CA101-35 and
CA301-8 and between CA102-3 and CA303-7.
Step 2: Enter the Analyser menu A4.26 M1 Speed, in
the proper operator position, request full forward travel. • If: The wiring has a short
Record the RPM. – Then repair or replace the wiring
• If: The reading is 3,200–3,260 RPM • If: The wiring is OK
– Then continue to step 2 – Then replace Access 4
• If: The reading is not between 3,200–3,260 RPM
– Then replace Access 4.
Event Code 414
The sunlight detection circuit for the left-hand sen-
Event Code 413 sor is activated.
The presence sensor input to Access 4 is incor- Step 1: Follow the procedure for Event Code 413.
rect.
Step 1: Enter the Analyser menu. Scroll to A4.20
Event Code 415
LHS and place your left hand in normal operating posi- This alarm does not inhibit machine operation but
tion. Record the reading. the default parameters are used.
Step 2: Enter the Analyser menu. Scroll to A4.19 Step 1: Follow the procedures for Event Code 400.
RHS and place your right hand in the normal operating
position. Record the reading. Event Code 416
Step 3: Check the voltage between CA301-8 (-) and
CA303-7 (+). Step 1: Follow the procedures for Event Code 400.
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ELECTRICAL SYSTEM
Event Codes

Access 4 detects that the emergency switch (EDS) Access 4 detects that the K3 relay coil is shorted.
is activated. Step 1: Turn off the vehicle. Remove wire 5906 from
All vehicle movement is disabled. the K3 relay coil. Turn on the vehicle.
Step 1: Check the position of the EDS. • If: If the event code changes or goes away
• If: The EDS is activated – Then replace the K3 relay
– Then deactivate it • If: If the event returns
• If: The EDS is not activated – Then repair or replace the wiring between
– Then continue to step 2 CA101-33 and K3 relay coil
Step 2: Connect a DVOM to CA101-20 (+) and • If: The wiring is OK
CA102-2 (-). With the vehicle turned on, check the volt- Step 2: Then replace Access 4
age.
• If: The reading is less than 22 V DC Event Code 423
– Then repair the circuit between EDS2, CA111, Access 4 detects a short in either the PLSL circuit
CA609 and CA101 or the ALM3 circuit.
• If: The reading is 22–26 V DC Step 1: Turn off the vehicle and remove wire 29143
– Then replace Access 4 from CA114-5. Turn on the vehicle.
• If: The event code changes or goes away
Event Code 418 – Then replace the PLSL.
The side gate open input is activated. • If: The event returns: connect wire 29143 into
Step 1: Follow the procedures for Event Code 219. CA114-5 and continue to step 2.
Step 2: Turn off the vehicle and remove wire 5931
Event Code 419 from ALM3. Turn on the vehicle.
All functions are blocked. • If: The event code changes or goes away
Step 1: Follow the procedures for Event Code 400. – Then replace the ALM3.
Event Code 420 – Then check the wiring between Access 4 and
PLSL and ALM3 for shorts
This alarm signals that an undervoltage has been
• If: The wiring is OK
detected at the key input.
Step 1: Follow the procedures for Event Code 401. Event Code 424
Event Code 421 A hardware watchdog is present inside to synchro-
nise the microcontrollers.
Access 4 detects that the K4 relay coil is shorted.
Step 1: Turn off the vehicle. Remove wire 5905 from
the K4 relay coil. Turn on the vehicle.
• If: If the event code changes or goes away Event Code 425
– Then replace the K4 relay
• If: If the event returns Error is detected in eeprom or in eeprom manage-
ment. This alarm does not inhibit the machine op-
– Then repair or replace the wiring between erations, but the vehicle works with the default
CA101-34 and K4 relay coil values.
• If: The wiring is OK Step 1: Follow the procedures for Event Code 400.
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ELECTRICAL SYSTEM
Event Codes
Event Code 426 • If: The readings do not match

– Then check the wiring for the STR CMD circuits
This warning appears when the controller restored • If: The readings match
the default values.

This alarm inhibits the machine operations. CAN communication is not functional.
Step 1: Follow the procedures for Event Code 400. All vehicle movement is disabled.
Step 1: Check the CAN connection. Make sure that
Event Code 428 all the controllers are present on the CAN line.
• If: There is a short or disconnect
There is a mismatch between the two encoders
– Then replace the wiring
present on the left motor (M2).
• If: There are no issues with the wiring
Step 1: Block the drive wheels off the floor (see Con-
trol of Hazardous Energy section in the Service and
Parts Manual for proper blocking procedures). Turn on Event Code 432
the vehicle and enter the Analyser menu A3.1 M2
The Access 4 software is not compatible with the
Speed, in the proper operator position, gates open, re-
Access 4 module.
quest full forward travel. Record the RPM.
• If: The reading is 3,200–3,260 RPM
• If: The reading is not between 3,200–3,260 RPM Event Code 433
– Then replace Access 3™.
There is an error on the led emitter circuit.
Step 2: Enter the Analyser menu A4.27 M2 Speed, in
the proper operator position, request full forward travel. All vehicle movement is disabled.
Record the RPM. Step 1: Follow the procedures for Event Code 413.
• If: The reading is 3,200–3,260 RPM
– Then continue to step 2 Event Code 434
• If: The reading is not between 3,200–3,260 RPM There is a mismatch on the left-hand sensor (LHS)
– Then replace Access 4. input between Access 2/3 and Access 3™.
Event Code 429
Step 1: Follow the procedures for Event Code 400. There is a mismatch on the right-hand sensor
(RHS) input between Access 2/3 and Access 3™.
Event Code 430 Step 1: Follow the procedures for Event Code 413.
Access 4 detects a mismatch between the
STR_CMD inputs. Event Code 438
All vehicle movement is disabled. Access 4 detects a short in the driver circuit of ei-
Step 1: Turn on the vehicle and enter the Analyser ther K4, K3, PLSL or ALM3.
menu A4.22 STRCMD1, in the proper operator position Step 1: Follow procedures for Event Codes 421, 422,
and the gates open, request full right turn, neutral and 423 until the issue is found.
full left turn. Record the voltage for each.
Step 2: Enter the Analyser menu A4.23 STCMD2, in
the proper operator position, request a full right turn,
neutral and a full left turn. Record the RPM readings.
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ELECTRICAL SYSTEM
Event Codes
Event Code 439

Access 4 detects a short in the driver circuit of ei-
ther K4, K3, PLSL or ALM3.
– Follow procedures for Event Codes 421, 422,
423 until the issue is found.
Event Code 440

Access 4 detects a short in the driver circuit of ei-
ther K4, K3, PLSL or ALM3.
– Follow procedures for Event Codes 421, 422,
423 until the issue is found.
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ELECTRICAL SYSTEM
Service Panel
Service Panel
3
2
6
4
Fig. 1 (30467)
1 AC inlet Indicator lights for the battery
2 Charger LEDs charger
3 Push/Drive switch, DTS
Three indicator lights on the service panel monitor the
4 Elevation control switch, ECS battery charging status. The colours of the lights indi-
5 Emergency disconnect switch, EDS2 cate the following:
6 Emergency raise/lower switch, ERLS • Red - Abnormal charge
• Yellow - Charging
AC inlet
• Green - Charge complete
The AC inlet is provided so that the battery charger can
When the battery charger is initially plugged in, it per-
be plugged into a 125 V, 15 A (minimum) AC outlet.
forms a diagnostic test. All three indicator lights flash
Make sure the cord is in a location where it is not
three times, and then each indicator light flashes indi-
stepped on, tripped over or otherwise subject to dam-
vidually. After a 3–5 s delay, the battery charger turns
age or stress. Check the extension cord for the follow-
on and the yellow light illuminates. After charging is
ing:
complete, the yellow indicator light turns off and the
• The plug pins are the same number, size and shape green indicator light turns on.
as the inlet plug of the battery charger
If charging is not complete within 16–20 hr or if an over-
• The extension cord wire is in good condition current condition occurs, the red indicator light illumi-
• The size of the wire can safely handle a load nates. To clear it, unplug the battery charger and then
plug in the battery charger again to restart it.
M4.8-2360-300 Crown 2016 PF27518
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ELECTRICAL SYSTEM
Service Panel
If shorted battery cells are detected during a charge cy- • Steering

cle, the red indicator light flashes on for 2 s and off for 1. Put the switch in the Base position.
1 s. For additional information, see the Battery section
2. Make sure that the emergency raise and lower
switch (ERLS) on the service panel is active.
Push/Drive switch (DTS) 3. Return the switch to the Platform position for nor-
mal operation.
This switch does not require adjustment.
WARNING Emergency disconnect switch
A vehicle without the ability to brake can be dan- (EDS2)
gerous.
Severe injury or death can result. Activating EDS2 removes power from the emergency
disconnect contactor, which opens up its contact and
 See SAFETY / Control of Hazardous Energy / Tow- removes power from the lift, lower and traction circuit.
ing the vehicle for the correct towing procedures.
1. Push and turn EDS2 clockwise until the switch re-
 Be careful when the Push/Drive switch is in the leases.
Push position.
2. To power up the vehicle again, push and turn
• The vehicle is free to move. EDS2 anti-clockwise.
• The brake pedal has no effect on the brake. 3. Cycle the key switch off and on before operating
• The vehicle does not have traction. the vehicle.
• There is no steering control. This switch requires no adjustment. For more informa-
 Do not park on a grade. Releasing the brake on the tion, see the Switches section in the Service and Parts
towed vehicle while on an uneven surface can Manual.
cause the vehicle to roll.
 Do not push the vehicle while the operator is on the
Emergency raise and lower switch
platform. (ERLS)
 Do not push the vehicle at a speed exceeding When the elevation control switch is in the Base posi-
3.2 km/h (2 mph) if the traction motors are con- tion, lowering and raising the platform is controlled by
nected to the electrical circuit. the emergency raise and lower switch. This switch
does not require adjustment.
With the switch in the Drive position, normal operation
of steering and traction is possible. To push or tow the
vehicle, flip the switch to the Push position. The Push
position releases the brakes electrically and disables
the following functions:
• Traction
• Steering
• Lifting
• Lowering
Make sure that the traction or towing speed does not
exceed 3.2 km/h (2 mph) to prevent damage to the
controller.
For normal operation, the switch must be returned to
the Drive position. This switch does not require adjust-
ment.
Elevation control switch (ECS)
In the Base position, ECS disables the following func-
tions:
• Traction
Crown 2016 PF27518 M4.8-2360-301
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ELECTRICAL SYSTEM
Service Panel
Notes:
M4.8-2360-501
230
BRAKE SYSTEM
231
Notes:
232
BRAKE SYSTEM
Brake System
Brake System Parking brake

The parking brake consists of a 12 V electric brake at-
Service Brake tached to each traction motor and is energised by
Access 2/3 and Access 3™.
Power is supplied to the brake through the following
actions:
• Depressing the DMSR and DMSL switches
1 • Engaging the LHS and RHS proximity sensors
• Supplying an input and a steer or travel command
to Access 3™
 These actions cause Access 2/3 and
Access 3™ to enable drives that release the
brakes.
When the operator releases the DMSR switch, DMSL
switch, LHS proximity sensor, or RHS proximity sensor
Access 3™ electronically brakes and stops the vehicle.
The coil in the parking brake de-energises 1.5 s after
the calculated stop. The springs force armatures inside
of the brake to press the lining assemblies against the
rotor and apply the parking brake.
Note: The parking brake is never applied before the
calculated stop time unless a service event occurs or
the emergency disconnect is activated.
Checking the parking brake for wear
Because the parking brake is not normally applied
Fig. 2 (30472) while the vehicle is moving, it has minimal wear. Check
1 Brake the air gap if you notice the function of the brake declin-
ing.
Regenerative brakes 1. Turn off the vehicle.
The vehicle uses two types of electronic brakes. When 2. Apply the brake.
travelling at higher speeds, the vehicle uses regenera- 3. See Figure 3. Use a feeler gauge to measure the
tive brakes. At lower speeds, the vehicle uses active air gap (1) between the coil body (2) and the arma-
brakes. ture plate (3).
The system controller goes into electronic brake mode 4. Replace the parking brake if the wear exceeds
when the twist grip is in neutral or put in the opposite 0.2 mm (0.008 in). The brake is not adjustable.
direction of travel. In electronic brake mode, the motors
act as generators driven by the inertia of the vehicle.
When the generated voltage is greater than the battery
voltage, the system controller places the battery in se-
ries with the motors. The battery receives a charge
from this process and provides an electrical load on the
motors causing them to slow down. When the vehicle
speed slows to the point that the generated voltage is
less than the battery voltage, the vehicle switches to
active brakes.
Adjustment for the electronic brakes is the deceleration
rate. Settings and procedures for these adjustments
are in Menu Settings.
Crown 2016 PF27520 M5.0-2360-100
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BRAKE SYSTEM
Brake System
2
1
Fig. 3 (30473)
1 Air gap between the coil body and the armature plate
2 Coil body
3 Armature plate
Determining the maximum stopping distance of

the vehicle
Note: This procedure is not for parking brake-assisted
stops.
1. Move the vehicle to a level, smooth, dry concrete
surface.
2. Make sure that the load deck and tray are empty.
3. Make sure that the platform does not exceed
510 mm (20 in).
4. Travel in the load deck first direction at 6 km/h
(4 mph) with the gates open and the vehicle in rab-
bit mode.
In these conditions, the maximum stopping distance of
the vehicle is 1,270–1,780 mm (50–70 in).
To adjust the stopping distance, see Decel Rate in the
Menu settings. Decreasing the value of this setting in-
creases the deceleration force and shortens the stop-
ping distance. If the stopping distance cannot be
achieved due to application conditions, reduce the
maximum allowable speed (see Max Speed in the
Menu settings) until the stopping distance can be
brought into acceptable range.
M5.0-2360-101 Crown 2016 PF27520
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LIFTING MECHANISM
235
Notes:
236
LIFTING MECHANISM
Mast
Mast 1. See Figure 5. Use a wire hook (1) to bring the

chain into the platform.
Platform chain anchor assembly
See Figure 4. See LIFTING MECHANISM PARTS / Lift
Chains for part numbers.
4
3 1
5
3 Fig. 5 (30742)
2. See Figure 6. Place the chain on the end of the
2 wire and pull the chain into the platform (1). Then
4 route the chain out of the platform (2).
1
7
7
6
1
Fig. 6 (30743)
1 Insert chain
6
2 Exit chain
3. See Figure 7. This view is from the bottom of the

Fig. 4 (30741)
platform. The chain is being routed before the in-
stallation of the chain anchor.
1 Cotter pin
2 Nut
3 Switch plate
4 Washer
5 Spring
6 Chain pin
7 Chain anchor sub
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LIFTING MECHANISM
Mast
8. Insert the chain anchor through the platform and

into the anchor block.
9. Install a spring, washer and one nut onto the chain
anchor. Thread the nut down, enough to install a
switch plate and another nut.
10. Tighten the bottom nut until the switch plate is low
2
enough to install the previously subbed chain an-
chor switches.
11. The chain anchor switches are routed behind the
3 floorboard supports and secured, from the outside,
1 with two screws (P/N 060014-079), on each side.
2
Fig. 7 (30744) 6
3
1 Chain from the mast 4
2 Chain enters the platform
3 Chain exits the platform
5
See Figure 8.
4. Make sure that the chain remains straight and not
kinked.
5. Place the chain anchor (3) on the end of the chain.
6. Insert the chain pin (1) through the chain anchor (3)
and the chain. Fig. 9 (30746)
7. Secure the chain pin (1) with the cotter pin (2). No- 1 Left side
tice the orientation of the chain anchor (3). When
2 Gap between the switch and switch plate
installed, the chain is against the front wall of the
3 Nut
platform.
4 Washer
5 Spring (inside the anchor block)
6 Left chain anchor switch
1 2
Fig. 8 (30745)
See Figures 9 and 10.
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LIFTING MECHANISM
Mast
13. See Figure 10. Tighten the second nut against the
switch plate and install a cotter pin in the chain an-
chor.
2
1 14. See Figure 12. The mounting holes for the chain
3 anchor switch are shown on the outside of the plat-
5 4 form on the right. The left side is a mirror image.
Fig. 10 (30747)
1 Right side
2 Cotter pin
3 Nut Fig. 12 (30748)
4 Switch plate
Chassis chain anchor assembly
5 Right chain anchor switch
See Figure 13. See LIFTING MECHANISM PARTS /
6 Floorboard support
Lift Chains for part numbers.
12. See Figure 11. There should be a gap between the
switch plate and the switch after assembly. Make
sure that the gap between the switch and the
switch plate is smaller (1) than the gap between the
chain anchor block and the block mounted on the
platform (2).
4
1
1
2
3
Fig. 13 (30750)
1 Switch plate
2 2 Nut
3 Cotter pin
4 Chassis
1. See Figure 14. Slide the switch plates (1) onto the
chain anchor threaded rods. The switch plates rest
Fig. 11 (30749) against the existing nuts.
1 Smaller gap
2 Larger gap
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LIFTING MECHANISM
Mast
1
2
Fig. 14 (30751) Fig. 16 (30753)
2. Thread the outside nuts onto the rods and tighten 6. See Figure 17. Install the cotter pins with a needle
the nuts up to the switch plates. nose plier.
3. See Figure 15. Use a 3/4 in wrench to hold the
chain anchor parallel to the chassis floor. Tighten
the nut against the switch plate using a 9/16 in
wrench.
Fig. 17 (30754)
Mast reshimming (without removing

the mast assembly from the vehicle)
Fig. 15 (30752) A procedure for reshimming the mast on WAV60 series
See Figure 16. vehicles can reduce the downtime and the labour as
most of the reshimming is performed at the top of the
4. On the left side, the switch plate rides up while mast.
tightening. Hold down the switch with your left
thumb while also holding the 3/4 in wrench on the Recommended Tools and Equipment:
chain anchor. • Common hand tools
5. Tighten the outside nut and adjust the chain an- Approximately procedure time: 1 hr
chor to be parallel to the chassis floor. Make sure
that the gap between the switch and the plate is
smaller (1) than the gap of the chain anchor and
the block mounted on the platform (2).
M7.0-2360-004 Crown 2016 PF27485
240
LIFTING MECHANISM
Mast
Parts needed to complete this procedure are:
Part No. Description Qty.

1
120283-001 Shim, 0.381 mm (0.015 in) thick 6
(black)
2
120283-002 Shim, 0.635 mm (0.025 in) thick 4
(gold)
120283-003 Shim, 0.889 mm (0.035 in) thick 2
(silver)

1. Follow all the safety procedures. See the SAFETY Fig. 19 (21266-01)
chapter. 1 1.3 mm (0.050 in) New land width
2. Wear the appropriate items for personal safety. 2 If the land is worn into the groove, replace the wear block
3. Move the vehicle to your work area on a level floor. 3. See Figure 20. Insert the prybar (2) between the
4. Fully lower the platform. second and third stage as shown. All the lateral
5. Turn off the vehicle. play moves to one side of the mast.
6. Disconnect the batteries. 4. Loosen the shim screw (4).
7. Secure the work area. 5. Insert the additional shims (P/N 120283-001,
120283-002 or 120283-003) in any combination,
8. Lockout/tagout the vehicle. See the SAFETY /
into the area shown (3). The additional shims slide
Control of Hazardous Energy / Lockout/Tagout
in by hand and fit snug.
section.
9. Put the chocks against the wheels.
Replacing or adding shims 5
1 3
1. See Figure 18. Remove the mast cap (1).
2
4
1
3
6
Fig. 20 (30441)
1 Top of the mast
Fig. 18 (30451)
1 Mast cap 2 Insert prybar
3 Shim
2. See Figure 19. Inspect the land area on the wear 4 Loosen shim screws
guides. When new, the land width is 1.3 mm
5 Nuts - torque 54 Nm (40 ft lb)
(0.05 in) (1). If the land area is worn into the
groove, replace the wear guide (2). 6 Land wear indicator
Note: To find the correct combination of shims, remove

the existing shims and start again with a new combina-
tion.
Crown 2016 PF27485 M7.0-2360-005
241
LIFTING MECHANISM
Mast
6. Once the correct shim combination has been

found, remove the shim retaining screw and se-
cure the additional or replacement shims.
7. See Figures 21, 22 and 23. Repeat steps 3 to 7 for 1
the remaining shims in the top of the mast.
8. Connect the batteries and elevate the platform 3
from the service panel. 4
9. The platform should raise and lower freely without 2
binding.
Note: If additional shimming is required, use this same 3
procedure on the bottom shims and guides. Shims
needed are:
Part No. Description Qty. Fig. 22 (30448)

1 Top of the mast
120284-001 Shim, 0.381 mm (0.015 in) thick 6
(black) 2 Insert prybar
3 Shim
120284-002 Shim, 0.635 mm (0.025 in) thick 4
4 Loosen shim screws
(gold)
120284-003 Shim, 0.889 mm (0.035 in) thick 2
(silver)
2
1
2 3 3
4
4 3
5 4
Fig. 23 (30449)
1 Top of the mast
Fig. 21 (30447) 3 Shim
1 Top of the mast
4 Insert prybar
3 Land wear indicator 10. Lower the platform.
4 Shim 11. Disconnect the batteries.
5 Insert prybar 12. Verify that all the shim screws are secure.
13. See the INSPECTION AND LUBRICATION / Lu-
brication and Adjustment section to lubricate the
top part of the mast.
14. Install the mast cap.
M7.0-2360-006 Crown 2016 PF27485
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LIFTING MECHANISM
Mast

1. Remove the chocks from the wheels.
2. Remove the lockout/tagout device.
4. Raise the load tray. 1
Mast disassembly 2

chapter.
7. Secure the work area. Fig. 24 (30495)
8. Lockout/tagout the vehicle. See the SAFETY / 1 Strap placement platform
Control of Hazardous Energy / Lockout/Tagout 2 Mast cap
section.
Accessing the mast WARNING
See Figure 24. A vehicle or mast that falls can cause severe injury
1. Attach the straps to the hoist and the platform. or death.
2. Disconnect the connector for the DMSR and DMSL If the capacity of the lift device, straps or chains, or
switches located below the floorboard. composite or hardwood blocks cannot hold the main-
frame, platform and load handler weight, the vehicle
3. Remove the floorboard and the mast cap (2) to ac-
could fall.
cess the wires.
 Read the instructions in the SAFETY / Control of
Hazardous Energy / Lifting and Blocking chapter
before you begin maintenance.
 Do not put fingers, hands, arms or feet through the
mast.
 Do not put fingers, hands, arms or feet at pinch
points.
 Make sure that the lift device is sufficiently rated to
lift the necessary parts of the mast.
 Make sure that the blocking material is sufficiently
rated to support the necessary vehicle weight.
 Never work under or near a vehicle without suffi-
cient and secure blocks.
 Always block the masts when working on the masts
in an elevated position, even though connected to a
hoist.
4. Raise the platform with a hoist. Use a composite or

hardwood block to block the platform.
Crown 2016 PF27485 M7.0-2360-007
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LIFTING MECHANISM
Mast
Removing the third stage mast

See Figure 25.
1. Disconnect the wire harnesses.
2. Remove the cable clamps on either side of the plat-
form mast at the bottom of the platform.
3. Pull the wire harnesses and the plugs through the
holes in the bottom right and left sides of the plat-
form mast.
4. Remove the guides (4) and the shims (5) from the
front and right side of the platform mast.
5. Remove the guides (1, 2, 3) from the rear and left
side of the platform mast.
6. Unfasten the chain anchor (6, 7) for the primary
chain from the third stage mast.
7. Remove the secondary chain anchors from the
blocks on the platform mast.
8. Detach the chain from the chain anchors.
9. Remove the screws and the cable track from the
platform.
10. Pull the cable track partially out from the bottom of
the platform.
11. Use the hoist to raise the platform from the vehicle.
Do not pinch or cut the control cables.
12. Remove the guides from the top of the third stage
mast.
13. Remove the screws from the other end of the cable
track.
14. Remove the cable clamps on the third stage mast.
15. Remove the cable guides from between the sec-
ond and third stage masts.
16. Direct the cables so they are straight down from
the pulleys, between the second and third stage
masts.
17. Remove the remaining guides from the third stage
mast.
18. Remove the third stage mast.
M7.0-2360-008 Crown 2016 PF27485
244
LIFTING MECHANISM
Mast
(a) Platform
(b) Third stage mast
(c) Torque to 37–51 Nm (27–37 ft lb)
5
(a)
(b)
8
(c)
0
7
5 5
4
2
5
1 4
Fig. 25 (30494)
Crown 2016 PF27485 M7.0-2360-009
245
LIFTING MECHANISM
Mast
Removing the second stage mast

See Figure 26.
1. Remove all the shims (4) from the top of the first
and second stage masts.
2. Remove the guides (8, 9) from the top of the sec-
ond stage mast.
3. Move the wire harnesses to the back of the second
stage mast.
4. Unloop the chain from the pulley and place it in the
back of the chassis. Make sure that there are no
kinks in the chain.
5. Remove the hydraulic line and the velocity fuse
from the base of the lift cylinder. Catch any hydrau-
lic oil that runs from the hydraulic line.
6. Remove the two screws (10) that attach the lift cyl-
inder and the yoke to the second stage mast.
7. Carefully remove the lift cylinder and the yoke by
lifting it out the top of the first stage mast.
8. Use the hoist and the strap to lift and block the sec-
ond stage mast with a composite or hardwood
block.
9. Remove the guides (6) and the shims (7) from the
bottom right and rear sides of the second stage
mast.
10. Remove the guides (5) from the bottom front and
left sides of the second stage mast.
11. Place the control cables inside the first stage mast
to protect them while removing the second stage
mast.
12. Use a hoist to raise the second stage mast off the
top of the first stage mast.
13. Remove the guides (1, 2, 3) from the top of the first
stage mast.
M7.0-2360-010 Crown 2016 PF27485
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LIFTING MECHANISM
Mast
10 (a) Second stage mast

(b) Chassis
0
(d)
(c) (c) Yoke
(d) Torque to 37–51 Nm (27–37 ft lb)
8
9 2
3 1
(a)
8
3
(b)
7
6
7
Fig. 26 (30497)
Crown 2016 PF27485 M7.0-2360-011
247
LIFTING MECHANISM
Mast
Mast assembly
WARNING
Recommended Tools and Equipment:
• Shim gauge (P/N 125535) A vehicle or mast that falls can cause severe injury
• Shim gauge (P/N 125539) or death.
If the capacity of the lift device, straps or chains, or
• Shim gauge (P/N 133403)
composite or hardwood blocks cannot hold the main-
Preparing to install the mast assembly frame, platform and load handler weight, the vehicle
See Figure 26. could fall.
1. To remove dirt and grease, clean the outside of the  Read the instructions in the SAFETY / Control of
first stage mast with a shop rag. Also clean the in- Hazardous Energy / Lifting and Blocking chapter
side and the outside of the second stage mast and before you begin maintenance.
the third stage mast. Clean inside the platform  Do not put fingers, hands, arms or feet through the
mast. mast.
2. Apply grease (P/N 063002-024) to the top 150–  Do not put fingers, hands, arms or feet at pinch
200 mm (6–8 in) of the inside four corners of the points.
second, third and platform stage masts.  Make sure that the lift device is sufficiently rated to
3. Inspect the guides for wear. New guides have an lift the necessary parts of the mast.
integrated 1.3 mm (0.050 in) land to indicate wear.  Make sure that the blocking material is sufficiently
If the land is worn away to the groove or if the guide rated to support the necessary vehicle weight.
surfaces have deep grooves in them, replace the
 Never work under or near a vehicle without suffi-
guide.
cient and secure blocks.
4. Install the guides (1, 2, 3) back onto the first stage
 Always block the masts when working on the masts
mast. Do not install any shims now.
in an elevated position, even though connected to a
5. Place the control cables inside the first stage mast hoist.
to protect the cables from being cut.
Installing the second stage mast 2. Attach the two front guides and the guide (7) for the
1. Use the hoist to slide the second stage mast over left side to the bottom of the second stage mast. Do
the first stage mast. Use a composite or hardwood not overtighten the screws in any of the guides.
block to block the second stage mast. 3. See Figure 27. Use the shim gauge (P/N 125535)
to check the spacing at the lower rear and right
side of the mast, between the first and second
stage. When checking with the gauge, do not use
the number that is partially covered, use the next
highest number. Example: If the number 7 is par-
tially covered, as shown in Figure 27, then use the
number 8 as the guide (4). Next, see the shim chart
to find the correct combination of the shims re-
quired.
M7.0-2360-012 Crown 2016 PF27485
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LIFTING MECHANISM
Mast
1 Shim gauge (P/N 125535)

Gauge Shims Thickness 2 Top shim gauge (P/N 125539 and 133403)
Reading Required 3 Mast
4 Gauge reading would be 8
mm in
5 Bottom shim, black 0.381 mm (0.015 in) thick
1 No shims 0.000 0.000 (P/N 120284-001)
Bottom shim, gold 0.635 mm (0.025 in) thick
2 One Black 0.381 0.015 (P/N 120284-002)
Bottom shim, silver 0.889 mm (0.035 in) thick
3 One Black 0.381 0.015 (P/N 120284-003)
4 Two Black 0.762 0.030 6 Top shim, black 0.381 mm (0.015 in) thick
(P/N 120283-001)
5 One Silver 0.889 0.035 Top shim, gold 0.635 mm (0.025 in) thick
(P/N 120283-002)
6 Three Black 1.143 0.045 Top shim, silver 0.889 mm (0.035 in) thick
(P/N 120283-003)
7 Two Black, One Gold 1.397 0.055
8 Two Gold, One Black 1.651 0.065 See Figure 26.
4. Determine the correct number of shims (7) re-
9 Two Silver 1.778 0.070
quired. Install the shims and the guides (6) on the
10 Two Black, Two Gold 2.032 0.080 bottom right and back of the second stage mast.
11 Three Gold, One Black 2.286 0.090 5. Remove the composite or hardwood block and
lower the second stage mast. Position the control
cables to the front of the mast.
6. Install two gold shims (7) on the top left side of the
first and second stage mast. The shims go be-
tween the left front guide (2), the rear guide (3) and
the first stage mast with the tabs facing in. If two
2 gold shims do not go into place easily, use one
1 black and one gold shim. If those shims do not fit,
then go up the shim list until the proper shim fit is
found.
7. Insert the gauge (P/N 125535) into the top right
side of the mast between the first and second
stage mast. Select the correct shims from the
chart. Attach the shims to the right front guide (1),
the rear guide (3) and install the assembly on the
top right side of the first stage mast.
8. Insert the gauge (P/N125535) into the top rear of
3
the mast between the first and second stage mast.
Select the correct shims from the chart. Attach the
shims to the rear guides (3) and install the assem-
bly on the back of the mast. Do not put any shims
4 on the right front guide (1) and the left front guide
(2) at the front.
Adding the cylinder and the yoke assembly
1. Use the hoist to position and install the cylinder and
5 6 the yoke assembly back into the mast.
2. Bolt the yoke to the second stage mast.
3. Put the chain and the control cables over the
proper corresponding pulleys on the yoke.
Fig. 27 (21264-01)
Crown 2016 PF27485 M7.0-2360-013
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LIFTING MECHANISM
Mast
4. Attach the chain to the front of the mast and the 9. Insert the shim gauge (P/N 125535) between the
control cables to the back of the mast. third stage and the platform mast at the bottom
5. Install the top guides (8, 9) on the top of the second back of the vehicle.
stage mast. 10. Using the lowest visible number, select the appro-
priate shims from the shim chart. Install the mast
Installing the third stage mast
guides and the shims at this location.
See Figure 25.
11. Lower the platform until the lift chains support the
1. Use a hoist to install the third stage mast over the platform.
second stage mast. Do not pinch the control cables
12. Insert two shim gauges (P/N 133403), one on each
during the assembly.
side, between the third stage and the platform
2. Block the platform with a composite or hardwood mast.
block.
13. Adjust the heights of each gauge so that the lowest
3. Position the control cables in the guides. Install the visible number is the same on each side or within
guides (2, 4) on the lower back of the third stage one increment of each other. Select the appropri-
mast. ate shims from the shim chart.
4. Install the chain anchor (6) to the third stage mast. 14. To install the top guides and shims, connect the
5. Attach the guide (3) for the left side to the third batteries. Raise the mast until the countersunk
stage mast. holes are visible and accessible from inside the
6. Use the shim gauge (P/N 125539) to check the bot- mast.
tom front of the mast. Use the shim gauge (P/N 15. Install the guides and shims on the top left and right
125535) to check the bottom right of the mast. De- sides. Install the screws from the inside of the third
termine the shims required between the second stage.
and third stage mast. 16. Insert the shim gauge (P/N 125535) to the back of
7. Install the correct number of shims (7, Figure 26) the mast, between the third stage and the platform
and guides (5, Figure 25) on the front of the third mast.
stage mast. 17. Using the lowest visible number, select the appro-
8. Install the correct number of shims (7, Figure 26) priate shims from the shim chart. Install the mast
and guides (4, Figure 25) on the right side of the guides and the shims.
third stage mast. 18. Route the cables through the holes on either side
Installing the platform mast of the third stage mast and the bottom of the plat-
form. Make sure that the cables are seated in the
1. Push up the cables into the third stage mast.
guides.
2. Pull the cables tight and secure with a clamp (8).
19. Remove the composite or hardwood block and
3. Install the two slides to the chain sheave pulley as- lower the mast. Do not pinch or cut the cables.
sembly.
20. Remove the straps from the platform.
4. Before installing any slides, install the platform
mast over the third stage. Lower the platform mast Completing the mast assembly
approximately 2/3 the length of the third stage. 1. Install the cables into the mating connectors on the
5. Using the shim gauge (P/N 133403), insert one right and left side of the bottom of the platform.
gauge into each side of the bottom of the mast be- 2. Secure the control cables with the cable clamps
tween the platform mast and the third stage. (24) on the right and left side of the mast.
6. Adjust the heights of each gauge so that the lowest 3. Replace the floorboard.
visible number is the same on each side or within 4. Plug in the connector for the DMSR and DMSL
one increment of each other. Select the appropri- switches located beneath the lower back part of
ate shims from the shim chart. the floorboard chassis.
7. Install the mast guides and the shims. 5. Use a thicker gauge (P/N 125539) to check the
Note: The cable tracking on the third stage must be area between the top back second and third stage
installed before the installation of these guides. mast. Select and install the shims.
8. Install the front guides at the bottom of the plat- 6. Connect the batteries.
form. Do not install any shims now.
M7.0-2360-014 Crown 2016 PF27485
250
LIFTING MECHANISM
Mast
7. Use the remote at the front of the vehicle, then

raise and lower the mast one complete cycle.
8. With the mast lowered, check the oil in the hydrau-
lic reservoir. Fill as needed.
9. Raise and lower the mast through five or more cy-
cles, then raise the mast completely.
Note: At the top front of the first stage mast, there is a
slotted hole and a slot in the second stage mast. The
bleed screw on the lift cylinder is directly behind those
slots.
10. Use a screwdriver to loosen the bleed screw about
one half-turn. When the hydraulic oil starts to seep
out, tighten the bleed screw.
11. Apply grease (P/N 063002-024) to the sides of the
mast in the path of the guides.
12. Lower the mast and check the hydraulic oil level in
the reservoir, fittings and connections. Make sure
that there are no leaks.
13. Make sure that the platform height is adjusted
properly.
14. Adjust the control cable tension. See the ELEC-
TRICAL SYSTEM / Control Cables section.
15. Adjust the chain tension. See Platform chain an-
chor assembly in this section.
16. Replace the load deck and the mast cap (2,
Figure 24).
Crown 2016 PF27485 M7.0-2360-015
251
LIFTING MECHANISM
Lift chains
Lift chains Cleaning and Lubrication

Planned maintenance for lift chains Cleaning the lift chains
The lift chains are important components on your vehi-
cle. Lift chain maintenance is necessary for the safe
operation of your vehicle. It is necessary to do intermit- WARNING
tent maintenance on the lift chains for the maximum Incorrect cleaning can cause cracks in the lift
service life. Incorrect maintenance intervals can de- chains.
crease performance. A lift chain with cracks can result in severe injuries or
death.
Do not clean lift chains with steam, cold cleaning
WARNING agents, or agents that cause corrosion. These items
damage the lift chains.
Falling loads can cause injury.
 Clean the lift chains only with Crown Chain and Ca-
Lift chains, chain anchors, chain pins, and their attach-
ble Lube (P/N 363107-001) or Crown Premium
ments are safety components. Failure of these compo-
Chain and Cable Lube (P/N 363115-001).
nents can cause the platform and load to fall, resulting
in severe injuries or death.
Note: The initial factory lubricant on the lift chains pre-
 Replace damaged lift chains and their components
vents corrosion. Do not clean or remove the lubricant
with original spare parts before you return the vehi-
from the new lift chains. See the Inspection and Lubri-
cle to operation.
cation section for the applicable lubricant and planned
 Always replace lift chains in pairs. maintenance intervals for your vehicle.
Note: The frequency of lubrication changes with the
conditions of operation and environment.
CAUTION Lubrication
Lubricate the lift chains at the specified maintenance
Health risk intervals for maximum service life. A layer of lubricant
Cleaning agents, lubricants and solvents can damage between the chain components and on all lift chain sur-
your health. faces is necessary to:
 Obey the safety instructions of the manufacturer • Decrease the wear on the joint
when you handle solvents and lubricants.
• Prevent corrosion
• Decrease the frequency of turned pins
• Decrease tight joints in the roller chain
• Cause lift chain movement smoothness
• Decrease the lift chain tension
Recommended Tools and Equipment:
• Crown chain and cable lube (P/N 363107-001)
• Crown premium chain and cable lube
(P/N 363115-001)
Lubricating the lift chains
See the Inspection and Lubrication section for the ap-
plicable lubricant and planned maintenance intervals
for your vehicle.
Note: The frequency of lubrication changes with the
conditions of operation and environment.
1. Spray the lubricant onto the lift chain.
M7.5-2360-001 Crown 2016 PF27522 Rev. 3/20
01 Rev. 3/20
252
LIFTING MECHANISM
Lift chains
2. See Figure 28. Make sure that the oil goes into the – Place the end of the scale in the centre of a chain
lift chain joints (1). pin. Count down 24 pins and if the centre of that
 Lubrication on the chain and in the joints pre- pin has stretched to 314 mm (12 in.), the chain
vents wear and provides maximum service life. should be replaced.
Stret-
New
ched
Chain
Chain
Fig. 28 (16850-02)
Inspection
See the INSPECTION AND LUBRICATION section for
the applicable lubricant and planned maintenance in-
tervals for your vehicle. The inspection includes:
• Checking the lift chains for wear
• Checking the lift chains for other damage
Fig. 29 (34468)
Checking the lift chains for wear
4. Replace the lift chain if the lift chain has stretched
Recommended Tools and Equipment: more than 3% or will stretch more than 3% before
• Chain wear scale (P/N 106440) or steel tape meas- the next maintenance interval.
ure – Do not repair a chain by removing a worn section
As the lift chain bends on and off the pulleys, the joints of a lift chain and installing a new piece.
gradually wear. Material wears off the outside diameter – If the vehicle has a pair of lift chains, replace both
of the pin and the inside diameter of the holes for the lift chains at the same time.
pins on the inner plates. This action causes the chain
to stretch. – If a part of the lift chain is worn, replace both lift
chains at the same time.
Measuring the lift chains with a chain wear scale
Measuring the lift chains with a steel tape measure
1. Raise the platform high enough to expose the lift
1. Raise the platform high enough to expose the lift
chains.
chains.
2. Select a section of the chain that goes over a pulley
2. Select a section of the chain that goes over a pulley
during operation.
during operation.
3. See Figure 29. Measure the lift chain with a chain
3. See Figure 30. Measure the lift chain pitch (1) from
wear scale (1).
the centre to the centre of two chain pins of an
Note: The pitch is the distance between the pins. outer plate.
– Use Scale A for chains with a pitch of 12.7 mm
(0.5 in)
Crown 2016 PF27522 Rev. 3/20 M7.5-2360-002

01 Rev. 3/20
253
LIFTING MECHANISM
Lift chains
3. Calculate the % of lift chain stretch (x).

% of lift chain stretch = [measured length/(new
length/100)]-100
Example: The lift chain pitch is 25 mm (1 in). The Chain

Wear Limits table shows that the “new length” for this
lift chain pitch is 305 mm (12 in). The measured length
with the steel tape measure is 309 mm (12.2 in).
x = [309 / (305 / 100)] - 100
x = 309 / 3.053 - 100
x = 101.3 -100
x = 1.3
In this example, the lift chain stretch is 1.3%.
4. See the Chain Wear Limits table. Replace the lift
chain if the lift chain has stretched more than 3% or
will stretch more than 3% before the next mainte-
nance interval.
– Do not repair lift chains by removing a worn sec-
tion of a lift chain and installing a new piece.
– If the vehicle has a pair of lift chains, replace both
lift chains at the same time.
– If a part of the lift chain is worn, replace both lift
Fig. 30 (34469) chains.
4. See the Chain Wear Limits table to find the pitch

value and check the number of chain links that are
necessary for the measurement.
Chain Wear Limits
Pitch Chain Links Length New Wear Limits
25.4 mm 12 305 mm 314 mm

(1 in) (12 in) (12.375 in)
19.05 mm 16 305 mm 314 mm
(0.75 in) (12 in) (12.375 in)
15.88 mm 20 318 mm 327 mm
(0.625 in) (12.5 in) (12.875 in)
12.7 mm 24 305 mm 314 mm
(0.5 in) (12 in) (12.375 in)
Checking the lift chain for stretch

1. On the lift chain, count the number of links listed in
the Chain Wear Limits table.
2. Measure the length (2, Figure 30) from the centre
of the first chain pin to the centre of the last chain
pin.
Note: The pitch is the distance between the pins.
M7.5-2360-003 Crown 2016 PF27522 Rev. 3/20
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254
LIFTING MECHANISM
Lift chains
Checking the lift chain for other damage
Lift Chain Inspection
Damage Example Damage and Symptom Cause Solution
Noise • 1. Check the chain elon-

Insufficient lubrication
• Mild squeaking to loud gation.
in the chain joints
creaking during opera- Note: When the chain  If the chain is within
tion goes over the pulley the the tolerance level,
movement in the joints clean and lubricate
causes friction. the chain.
 If the chain elonga-
tion is out of the tol-
erance level,
replace the chain.
Joint corrosion • Insufficient lubrication 1. Replace the chain.
• Red or brown colour (1) • Grease or oils that do 2. Lubricate the chain.
in the joint area not go into the joint 3. Increase the fre-
quency of the planned
maintenance intervals.
1
Surface corrosion • Insufficient lubrication1. Remove the corrosion

• Red or brown colour (2) or anti-corrosion from the chain with the
on the connecting • Increased frequency correct cleaning agent.
plates for planned mainte-  If this is not possi-
nance intervals is nec- ble, replace the
2 chain.
essary because of the
conditions in the oper- 2. Check the chain for pit-
ating environment ting (small dents on
the wear points) and
other corrosion.
 If you find other pit-
ting or corrosion, re-
place the chain.
Rigid joints • Insufficient lubrication 1. Replace the chain.
• The chain joints do not caused joint corrosion 2. Increase the fre-
easily go back to the quency of the planned
3 extended position. maintenance intervals.
Turned chain pins • Insufficient lubrication 1. Replace the chain.

4 • One or more chain pins Note: Turned chain pins 2. Increase the fre-
(4) turned. are a result of rigid joints. quency of the planned
Images and technical information provided with the kind permission of Rexnord Kette GmbH • www.rexnord.com
Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this chart.
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LIFTING MECHANISM
Lift chains
Loose chain pins • Insufficient lubrication 1. Replace the chain.

• One or more chain pins Note: Loose chain pins are 2. Increase the fre-
(5) are protruding. a result of rigid joints. quency of the planned
5 maintenance intervals.
Too much outer wear • The chain is not aligned 1. Measure the width of
• The outer plates (6) are correctly and is operat- the wear zone and cal-
worn down ing against mast sec- culate the percentage
tions or at the side of wear in relation to the
6 the pulley. overall width of the
• The lift chains tension plate.
is not equal  If the wear is
≥ 5% of the full
width, replace the
chain and correct
the incorrect align-
ment of the lift com-
ponents or the
pulleys.
 If the wear is
< 5% of the full
width, you must cor-
rect the incorrect
alignment of the lift
components or the
pulleys. You can
use the lift chain
again.
Nicks or distortion • The chain hits against 1. Remove the cause of
• Parts of the chain have parts of the mast the nicks or distortion.
nicks (7) or are dis- 2. Replace the chain
torted
Broken Plates • Fatigue crack because 1. Find and correct the

• The head section of the of overload cause of the overload.
plate is missing or the • Corrosion 2. Replace the chain.
8 crack is protruding.
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LIFTING MECHANISM
Lift chains
Broken pins • Pitting on the pins be- 1. Replace the chain.

• The outer plate (9) lifts cause of corrosion. Pit- 2. Increase the fre-
9 ting causes permanent
out a small distance quency of the planned
damage to the pin. maintenance intervals.
Note: These defects are
not easy to see in the initial
stages.
Contamination • Incorrect lubricant 1. Clean the chain and
10 • A thick layer of dirt used. check it for damage.
mixed with oil or grease • The chain was not  If the chain does not
(10) is on the chain cleaned before lubrica- have damage, lubri-
tion. cate it with the cor-
rect lubricant.
 Replace the chain if
it is damaged.
2. Increase the fre-
quency of the planned
• The chain came into 1. Replace the chain.
11 • Non-distorting brittle contact with hydrogen. 2. Check the operating
fracture (11), usually Note: Electrolysis always conditions for sources
only on the outer plate makes hydrogen. Solvents of hydrogen.
made with chlorine also 3. See the lift chain
emit hydrogen. cleaning instructions.
Chain elongation • Wear caused by move- 1. Replace the chain.
• The chain elongation ment in the joints. Note: Check if increasing
check found the chain Note: This is typical wear. the frequency of the
to be out of the toler- planned maintenance in-
ance level. tervals can increase the
life of the lift chain.
Replacing the lift chain 2. If the factory lubricant dried, soak the new lift
chains in heavy engine oil for a minimum of 30 min
1. Find the part number for the lift chain in the parts before you install them.
list in your service manual. Make sure that the re-
3. After you remove the existing lift chains from the
placement lift chain is applicable to your vehicle.
mast, carefully examine the chain anchors and pul-
Note: Replace the lift chains as a pair. You cannot eas- leys.
ily keep equal tension of the lift chain between a new
4. Replace the chain anchors that are broken, have
chain and an existing chain.
cracks in them, or are worn.
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LIFTING MECHANISM
Lift chains
5. Replace the pulleys that are worn and examine the 18. Put the chain on the chain anchor (1) and secure
pulley bearings for wear. with the new chain pin (2) and cotter pin (3).
6. Do not paint the new lift chains. 19. Adjust the chain anchors (1) to remove slack from
7. Install the new lift chains with new pins. Do not use the chains.
the existing pins. 20. Put two temporary 8 mm (0.31 in) shims on top of
8. After you connect the new lift chains to the chain the tube of the chassis.
anchors, adjust the chain tension for the correct  This automatically sets the platform height and al-
platform height. lows the cylinder cushion to operate properly.
 The correct tension and mast adjustment in- 21. Connect the batteries.
creases the chain service life.
22. Remove the composite or hardwood block, and
lower the platform completely on 8 mm (0.31 in)
Removing the lift chain shims using the chassis console.
For vehicles with a 2,995 mm (118 in) lift height 23. Turn off the vehicle.
1. Raise and block the third stage mast using a com- 24. Adjust the chain anchors at the same time until the
posite or hardwood block. platform rises 8 mm (0.31 in) from the shim plates.
2. Turn off the vehicle. 25. Raise the mast half way.
3. Disconnect the batteries. 26. Check the tension on the chain. Make sure that the
4. Remove the mast cap. chain is not loose.
5. Disconnect the connector for the DMSR and DMSL 27. Adjust the chain anchor on the loose chain until the
switches located below the floorboard chassis. tension feels equal.
6. Remove the floorboard. 28. Secure the chain anchor position with the nuts on
7. Remove the access covers and the H-frame (three the rear side (8).
pieces) from the vehicle. 29. Remove the shim plates.
8. See Figure 32. Loosen chain anchors (1), to allow 30. Install the H-frame, access covers, the floorboard
slack in the chain. and the mast cap.
9. Remove the cotter pin (3) and the chain pin (2) 31. Connect the connector for the DMSR and DMSL
from the chain anchor (1). switches located below the floorboard chassis.
10. Remove the screw (9) and lock washer (4) from the 32. Perform an operational check.
chain anchor (7).
11. Pull the chain anchor (7) and chains down below
the third stage mast about 150 mm (6 in). Use a
wood wedge between the third stage mast and
chain so that the chain is not pulled back up into
the mast.
1
12. Remove one retaining ring (5), pin (6) and chain (a)
anchor (7), from the existing chain.
13. See Figure 31. Connect the end of the new lift
chains (2) to the existing lift chains (1).
2
14. See Figure 32. Put the new chain on the chain an- (b)
chor (7) and secure with the new pin (6) and retain-
ing rings (5).
15. Remove the wood wedge and pull the chain (a) Old Chain
through the bottom (platform side) of the third (b) New Chain
stage mast.
Fig. 31 (34570)
16. Put the chain anchor (7) on the third stage mast
and secure with the screw (9) and lock washer (4).
17. Disconnect the new chain from the existing chain.
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TABLE OF CONTENTS
Lift chains
(a) Third stage mast

(b) Chassis
(c) 8 mm (0.31 in.) shim location
(d) Chain anchor and switch assembled
4
5
9
6
5
7
1 3
8
8
Fig. 32 (34520)
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LIFTING MECHANISM
Lift chains
Replacing the secondary chain 24. Attach the other end of the chain to the existing
chain with a wire.
For vehicles with a 2,995 mm (118 in.) lift height
25. Pull on the object at the end of the wire or spare
only
chain until the new chain is taut.
1. See Figure 33. Raise the platform from the service
26. Lower the third stage mast. When the primary
panel until the cable track mounting to third stage
chain is fully tensioned, make sure that the new
mast is visible.
chain goes over the pulleys until the third stage
2. Block the mast. mast stops.
3. Remove the cable track from the third stage mast. 27. Install the cable guides.
4. Pull the cable track down so that the studs are be- 28. Pull the cables tight over the studs and clamp to
low the mounting plate. the third stage mast while maintaining tension. See
5. Remove the blocks. section ELECTRICAL SYSTEM/Switches section.
6. Lower the platform to a height of 915 mm (36 in) 29. Install corner guides at the top of the third stage
above the ground. Measured from the ground to mast.
the top of the rear skirt. 30. Install the platform on the vehicle.
7. Block the mast. 31. Install the cable track in between the third stage
8. Turn off the vehicle. mast and the platform mast.
9. Disconnect the batteries. 32. Attach the cable track to the platform.
10. Disconnect CA101, CA102 and the cable clamps 33. Connect CA101 and CA102.
on the platform. 34. Remove slack in the dynamic cable into the plat-
11. Insert the cable down through the holes in the platform and install cable clamps.
form. 35. Install the shims on the lower left and ride side of
12. Remove the cable track from the platform. the platform.
13. Remove the chain from the platform chain anchors 36. Connect the batteries.
(1). 37. Raise the platform from the service panel.
14. Remove the guides and shims from the lower left 38. Block the platform.
and ride side of the platform.
39. Attach the cable track to the third stage mast and
15. Remove the cable clamp from the left and ride side mounting plate.
of the third stage mast.
40. Remove the blocks.
16. Pull the cable and track down from in between the
41. Install the covers.
platform and the third stage mast.
42. Perform an operational check.
17. Using the straps and a crane, lift the platform off of
18. Remove the guides and shims between the third
and second stage masts, top and bottom, including
J-shaped groove table guides.
19. Attach another equal length section of chain or
wire to the end of each chain.
20. Attach the third stage lifting tool or similar across
the top of the third stage mast.
21. Lift the third stage mast until the secondary chain
mounts on the second stage mast is visible.
22. Remove the cotter pin (2) and mounting pin (3)
from the second stage mast for each chain.
23. Attach one end of the new chain to the second
stage mast using a mounting pin (3) and cotter pin
(2).
M7.5-2360-008 Crown 2016 PF27522 Rev. 3/20
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LIFTING MECHANISM
Lift chains
2
3
2
2
1
2
Fig. 33 (34522)
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LIFTING MECHANISM
Lift chains
Disconnecting the leaf chain

See Figure 34.
Preparing the work area
To minimise the risk of damage done to the chain, use
the following equipment:
• A sturdy surface with an opening slightly greater
than the diameter of the pin and thick enough for
the pin (4) to extend beneath the work surface
• A flat washer (2) with an inside diameter slightly
greater than the diameter of the pin and a height
equal to the head height of the pin
• A grinding wheel (3)
• A pin punch with a diameter slightly less than the
pin diameter
• A hammer or press
Disconnecting the leaf chain
1. Use the grinding wheel to remove the top head of
the pin (4) flush with the pin link plate (1). Do not do
damage to the pin link plate.
2. Put the support ring (2) above the opening of the
work surface.
 Make sure that the support ring holds the pin link
plate (1) on the bottom. This action prevents
damage to the lift chain components while you
push the pin through the chain.
3. Put the lift chain on its side and seat the pin in the
support ring (2).
4. Remove the pin from the lift chain through the pin
link plate (1) on the top.
1
4
Fig. 34 (16851-02)
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CYLINDERS
263
Notes:
264
CYLINDERS
Cylinders
Cylinders
WARNING
High-pressure compressed air.
WARNING There is a risk of injury from high-pressure compressed
air.
High-pressure fluids can go through the skin and cause  Wear eye and face protection when you use com-
severe injury. High-pressure fluid that goes into the pressed air to clean components.
when the skin looks normal. There is a delayed start of Preparing the vehicle for maintenance
pain and severe tissue damage occurs.
 Release the pressure before you disconnect the hy- chapter.
draulic plumbing.
pressure.
high-pressure fluids. 5. Turn off the vehicle.
 To examine for leaks, use a piece of cardboard or 6. Secure the work area.
paper. Do not use your hand. 7. Lockout/tagout the vehicle. See the SAFETY /
 You must immediately get medical aid from a spe- Control of Hazardous Energy / Lockout/Tagout
cialist who has experience with this type of injury. section.
9. Remove the cover from the mast cap (1).
10. Remove the bridge (2) from the second stage
mast.
BA
1 2
3
3
CA101
CA102
D D
C
Fig. 35 (30502)
Crown 2016 PF27514 M8.0-2360-001
265
CYLINDERS
Cylinders
11. Turn on the vehicle. 10. Remove the retaining ring (3) from one side of the
12. See Figure 3. Raise the platform. Block (8) the chain anchor assembly. Slide the pin (4) out and
platform using two 100 x 100 mm (4 x 4 in) equal remove the chain anchor. Do not let the chains pull
length composite or hardwood blocks approxi- up through the mast.
mately 180–205 mm (7–8 in) long. 11. Use a piece of wire 1,220 mm (48 in) long to tie the
13. Turn off the vehicle. ends of the chain together.
14. Remove the load deck. 12. Slowly feed the chain back through the third stage
mast.
13. Pull the chains out of the top of the mast and lay
Releasing hydraulic pressure them over to the back.
See Figure 36. Release the hydraulic pressure from Note: Use a Crown wear scale (P/N 106440) to inspect
the system with the manual lowering valve (1) on the the lift chains. Follow the instructions in the LIFTING
end of the solenoid valve (SV1) (2). MECHANISM / Lift Chains section.
Removing the cylinder
1. Place shop rags at the bottom of the lift cylinder.
2. Remove the hydraulic line.
3. Clean up any oil that runs out of the cylinder or the
hydraulic line.
4. Pull up the slack in the control cables through the
2 top of the mast and remove the cables from the
yoke. Do not pull the control cable plugs up into the
mast.
5. See Figure 37. Remove the two screws (7) that
hold the yoke assembly to the second stage mast.
1
6. Note the orientation of the yoke in the mast. Pull up
on the yoke until the cylinder ram is fully extended.
7. Continue to lift the cylinder from the mast, rotating
as required for removal. Make sure that the ram
Fig. 36 (30503) does not drop down into the cylinder while remov-
Preparing the cylinder for removal ing it from the mast to prevent a larger oil spill.
1. Unplug the connector for the DMSR and DMSL
switches located below the floorboard.
2. Remove the floorboard and set aside.
3. Place a mark on the cable evenly with the rear end
of each cable clamp (3) using a marker or piece of
tape.
4. Remove the cable clamps.
5. Unplug connectors CA101 and CA102.
6. Pull the cables down through the floorboard next to
7. See Figure 37. Remove the inspection plate (6).
8. Remove the two screws (1) holding the chain an-
chor (2) from the lower third stage mast.
9. Pull the lift chain (5) down through the third stage
mast to completely expose the chain anchor.
M8.0-2360-002 Crown 2016 PF27514
266
CYLINDERS
Cylinders
(a)
B 3 5
A
4 1
3
2
8
6
9
Fig. 37 (30478)
(a) Third stage mast
Disassembling the cylinder

1. Remove the yoke assembly by driving out the roll
pin.
2. To disassemble the cylinder, use a spanner
wrench and turn the cap anti-clockwise to unscrew
it from the cylinder tube.
3. Carefully remove the ram assembly from the cylin-
der bore. Make sure that the ram does not touch
any sharp edges.
Crown 2016 PF27514 M8.0-2360-003
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CYLINDERS
Cylinders
CAUTION
1 You can damage the seals by using incorrect tools.
 Do not use a screwdriver or equivalent tools.
 Use plastic or soft metal (brass, aluminium) tools
without burrs or sharp edges.
127 mm
(5 in)
Fig. 39 (2292-01)
4
CAUTION
Seal seating areas with burrs, nicks and dirt cause
the seal to deform and lose its sealing ability.
Seal failures result.
 Closely inspect the seal seating areas before the
new seal is installed.
 Check for burrs, nicks and dirt on the seal seating
area.
Fig. 38 (6203-02)
Installing the seals
1 Cap
Special tools and equipment:
2 Spanner wrench
3 Ram
• Installation tool
4 Cylinder Note: The installation tool is made of a soft metal or
machined-smooth hard plastic. The tool must be free of
4. See Figure 39. Use a hooked tool to remove the burrs. It has a fixed steel pin (Pin 1) and two movable
rod seal from inside the cap. pins (Pin 2 and Pin 3). This tool is required for this in-
5. Remove the rod wiper ring. stallation method.
6. Thoroughly clean the area where the seal seats.
Remove any burrs, dirt or seal debris before install-
ing the new seals.
M8.0-2360-004 Crown 2016 PF27514
268
CYLINDERS
Cylinders
1 Pin 1
2 Pin 2
4
3 3 Pin 3
5. See Figure 42. Slightly remove pin 3 so the u-cup

loop snaps into the installation groove.
3
1
1
2
Fig. 40 (1902S-02)
1 Pin 1
2 Pin 2
3 Pin 3 2
4 Tool body
Fig. 42 (1904S-02)
1. Before installation, apply light lubrication to the 1 Pin 1
seal and the installation groove. Use the same oil
2 Pin 2
that is used later in the cylinder.
3 Pin 3
2. See Figure 40. Slip the u-cup over pin 1 (the fixed
pin) and bend it over pin 2 as shown. 6. See Figure 43. Slightly remove pin 2 to snap the u-
3. Continue to bend the u-cup until pin 3 can be cup completely into the installation groove.
pushed through the u-cup loop, which locks the u-
cup in position.
4. See Figure 41. Insert the installation tool with the 3
mounted u-cup into the cylinder bore until aligned
with the u-cup installation groove.
3 1
Fig. 43 (1905S-02)
1 1 Pin 1
2 Pin 2
3 Pin 3
7. Remove the installation tool.
Fig. 41 (1903S-02)
Crown 2016 PF27514 M8.0-2360-005
269
CYLINDERS
Cylinders
CAUTION
You can damage seals and packings. 1 3
Be careful when installing new seals and packings.
 Carefully insert the cylinder cap.
 Prevent threads and sharp edges from damaging
new seals and packings. 4 2
(b)
8. After the packings and the seal are in place and the
ram has been installed, attach the cap. (a)
1
Installing the cylinder
1. Replace the yoke on the cylinder.
2. See Figure 45. Tighten the cable tension screw (1) 2
until the tension bracket (2) touches the chassis.
3. Position the cylinder and the yoke by turning the
cylinder until the port is pointing 45° to the left of 2
the front of the mast. 3
3
4. Slide the cylinder down into the mast.
5. After the cylinder is installed in the mast, rotate the Fig. 44 (30619)
cylinder back to align the port with the hole in the (a) To the manifold assembly
lower mast.
(b) Torque sequence
6. Continue to lower the ram and the yoke assembly
into the mast. Make sure that the cables are in the After installing the cylinder
proper position on the pulleys before the yoke 1. Pull down the control cables on the plug end and
slides into the third stage mast. Do not damage the feed them back up through the floorboard.
control cables during the procedure. 2. See Figure 37. Secure the control cables with ca-
7. Connect the yoke assembly to the second stage ble clamps (3). Make sure that the marks previ-
mast with two 3/8 inch screws (4). ously put on the cables are in their respective
8. Connect the hydraulic line. Torque to a maximum positions.
of 27 Nm (20 ft lb). 3. See Figure 45. Plug the cable connectors CA101
9. See Figure 44. Assemble the tube (1) with the and CA102 back into their mating connectors on
flanges (2) to the mast cylinder with the screws (3). the right and left sides of the platform.
Hand-tighten the screws according to the torque 4. Feed the chains down through the mast between
sequence. the second and third stages and out the bottom of
10. Torque the screws (3) to 26–28 Nm (19–21 ft lb). the platform.
5. Connect the chain to the anchor with a pin and
clips. Secure the chain anchor to the third stage
mast with two screws.
6. Loosen the cable tension screw (1) until the cotter
pin (3) touches the tension bracket to put the ten-
sion back on the control cables.
Note: Removing the cable tensioner bracket allows for
better access to the screws on the flange fitting. Re-
tension the cables when you install them again.
7. Install the floorboard.
8. Plug the connectors for DMSR and DMSL switches
into the mating connectors below the floorboard.
M8.0-2360-006 Crown 2016 PF27514
270
CYLINDERS
Cylinders
10. Use the service panel to raise the platform com-

pletely.
WARNING
A platform that falls or lowers can cause injury or
death.
Do not operate the lift or lower cycle from the platform
before cycling per the instructions.
 When removing wood or composite blocks, raise
the platform completely before lowering to prevent
the platform from dropping quickly.
11. Remove the blocks and lower the platform com-

pletely.
12. Install the bridge. Torque the screws to 54 Nm
(40 ft lb).
13. Install the mast cap, inspection plate and load
deck.
14. Bleed the cylinder. See Bleeding the cylinder in
this section.
Crown 2016 PF27514 M8.0-2360-007
271
CYLINDERS
Cylinders
A
B
Fig. 45 (30479)
Bleeding the cylinder 3. Raise and lower the mast by using the remote
After the cylinder is installed on the vehicle, but before Raise and Lower switch on the service panel
the vehicle can be operated, air must be bled from the through one complete cycle.
hydraulic system. 4. With the platform fully lowered, check the hydraulic
1. Make sure that the platform is empty. reservoir and fill as required.
2. Set the elevation control switch (ECS) on the ser- 5. Raise and lower the platform through the complete
vice panel to the Base position. cycle at least five more times.
M8.0-2360-008 Crown 2016 PF27514
272
CYLINDERS
Cylinders
Note: Raising and lowering the platform forces any air

trapped in the system to the top of the cylinder.
6. Raise the platform completely.
7. Expose the bleed screw through the access hole in
the masts.
8. Carefully loosen the small bleed screw, at the top
of the cylinder, until all air escapes and only oil con-
tinues to flow from the screw.
9. Tighten the screw.
10. Wipe off all excess oil.
11. Lower the platform and place the ECS in the plat-
form position on the service panel.
Cylinder summary
The hydraulic system is designed to eliminate mechan-
ical damage even if the fittings become loose. Occa-
sionally, a slight drift of the platform assembly occurs.
Drifting can be due to internal leakage in the packing
and leakage in the solenoid or check valve. To seat
these valves properly when drifting occurs, raise and
lower the platform to flush out any foreign material from
the valve seat. If there is excessive oil loss, check the
system for leaks.
Crown 2016 PF27514 M8.0-2360-009
273
CYLINDERS
Cylinders
Notes:
M8.0-2360-009
274
PLATFORM
275
Notes:
276
PLATFORM
Platform
Platform
Load tray
The load tray is designed to carry a maximum load of
90 kg (200 lb). It can be adjusted up or down to four
different horizontal positions. For better access to the
load deck, lock the load tray in the full vertical position.
Operation
See Figure 46.
Moving the load tray into a different position
1. Rotate the tray upwards approximately 70° to re-
lease the locking pin (21).
2. Move the tray up and down as needed.
Locking the load tray into position
1. Rotate the tray to the horizontal position.
2. Push down on the back of the tray to check that the
locking pin is at the bottom of the retaining slot.
Crown 2016 PF27525 M9.0-2360-001
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PLATFORM
Platform
23
13 14
(b) (a)
23 6
22
21
20
13
1 19
14 18
17 16
8 15
2
7
3 6
10
9 11
8
12
5
4
1 Track 13 Ball bearing

2 Screw 14 Nylon spacer
3 Nut 15 Bumper
4 Bottom plate 16 Flatwasher (a) 180° rotated view
5 Screw 17 Spacer (b) Platform mast
6 Carriage 18 Compression spring
7 Pin 19 Flatwasher
8 Retaining ring 20 Screw
9 Link 21 Locking pin
10 Link pin 22 Compression spring
11 Retaining ring 23 Extension spring
12 Tray
Fig. 46 (30476)
M9.0-2360-002 Crown 2016 PF27525
278
PLATFORM
Platform
Locking the tray in the full vertical position 6. Assemble the spring cushion (15–20) to the car-
1. Fully rotate the tray upwards. riage (6).
2. Lower the tray until it touches the spring cushion. 7. Use the pins (7) and retaining rings (8) to install the
Push down on the tray to activate the spring cush- load tray (12) on the carriage (6).
ion. 8. Use one pin (10) and two retaining rings (11) to in-
3. Push the load tray under the lip on top of the track. stall the links (9) on the locking pin (21).
4. Let the load tray spring back up and lock into posi- 9. Install the extension springs (23) on the carriage
tion. (6).
Note: Do not install the extension spring when the load
Disassembling the load tray
tray is in the fully down position.
See Figure 46.
10. Install the load tray (12) assembly into the bottom
1. Raise the platform approximately 610 mm (24 in). of the track.
2. Turn off the vehicle. 11. Connect the extension springs (23) to the top of the
3. Lock the load tray in the second position down to track (1).
access the springs (23). 12. Use two screws (5) to secure the bottom plate (4)
4. Remove the flat head screws (5). to the track.
5. Remove the bottom plate (4). 13. Check the operation of the tray assembly.
6. Remove the retaining rings (11) from the pins (10)
to remove the locking pin (21).
7. Remove the pins from the links (9).
8. Remove the retaining ring (8) from the pin (7) to
access the load tray.
9. Remove the pin and the load tray (12) from the car-
riage.
10. Remove the bumper (15) from the screw (20).
Note: Do not remove the spring cushion assembly
when the load tray is in the fully down position.
11. Remove the spring cushion assembly from the bot-
tom of the carriage.
12. Remove the ball bearings (13) and nylon spacers
(14).
13. Remove the screws (2) and nuts (3) to remove the
track (1). Do not drop the screws down the mast.
Assembling the load tray
See Figure 46.
1. Raise the platform approximately 610 mm (24 in).
3. Use four screws and two nuts to install the track (1)
on the third stage mast. Torque the screws to
36.5–50.5 Nm (27–37 ft lb). Do not drop the
screws down the mast.
Note: The ball bearings (16) are already lubricated and
do not require additional lubrication. The outside of the
bearing, which runs on the track, is intended to run dry
without lubrication.
4. Install the ball bearings (13) on the carriage.
5. Secure the bearings with the nylon spacers (14).
Crown 2016 PF27525 M9.0-2360-003
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PLATFORM
Load Tray
Load Tray
Powered load tray
• The load tray is designed to carry a maximum load
of 90 kg (200 lb).
• A packet of grease (P/N 063002-065) is included for
use on the actuator screw.
Disassembling the powered load tray
See Figure 47.
3. Remove the two retaining rings (30) from the pin
(31) through the load tray (29).
4. Remove the pin and the load tray.
5. Remove the four screws (4) and the four flat wash-
ers (5).
6. Remove the screw (6) that connects the lower
cover (7) to the front cover (8).
7. To remove the front cover (8), remove the screw
(6) that connects the cover to the track (1).
8. Disconnect the actuator sub-assembly (25) from
the wiring harness (9).
9. Remove the four spacers (27) from the actuator
sub-assembly.
10. Remove the four bearings (28) from the actuator
sub-assembly.
11. Remove the two retaining rings (12) and the pin
(13) from the two mounting blocks (16) and the ac-
tuator sub-assembly.
12. Remove the actuator sub-assembly from the track.
13. Remove the four screws (14) and four flat washers
(15) from the track and mounting blocks.
14. Remove the two mounting blocks.
15. Remove the four screws (18) from the two switch
assemblies (19).
16. Remove the two switch assemblies from the track.
17. Remove the two screws (P/N 120544-003) from
the mast cap.
18. Remove the mast cap from the top of the mast.
19. Remove the four screws (2) and four nuts (3) from
the track. Do not drop the screws down the mast.
20. Remove the track from the mast.
21. Remove the four screws (17) from the switch
plates (20) and threaded blocks (21).
22. Remove the two switch plates and two threaded
blocks.
M9.0-2360-550 Crown 2016 PF27527
280
PLATFORM
Load Tray
1 Track 16 Mounting block 30 31

2 Screw 17 Screw 29
3 Nut 18 Screw A
4 Screw 19 Switch assembly
5 Flatwasher 20 Switch plate
6 Screw 21 Thread block
(a)
7 Cover 22 Bearing
8 Cover 23 Flatwasher
1
9 Wire harness 24 Retaining ring 21
10 Connector 25 Actuator assembly
(d)
11 Connector insert 26 Actuator ball screw 22
0
17 2
12 Retaining ring 27 Spacer
23
13 Pin 28 Bearing
14 Screw 29 Load tray 24
15 Flatwasher 30 Retaining ring
31 Pin
LMS1
19
(b)
25
0
6
(e)
C
0
27 28 3
(a) Platform mast 18
(b) Torque to 7–9 Nm LMS2
(5–7 ft lb) (c) 19
0
(c) Torque to 26–34 Nm 8 14 21

(19–25 ft lb)
A
(d) Torque to 3–4 Nm
15
(27–35 in lb)
20
(e) Torque to 0.3–0.6 Nm 17
(3–5 in lb)
0
(d)
(c)
0
4 (b) 12
16
0
6 16 26
M4
5
7
13
12
MOV1 15
5 B C
(c) 9 CA115 14
0
10
0
(c)
4
11
B
Fig. 47 (30501)
Crown 2016 PF27527 M9.0-2360-551
281
PLATFORM
Load Tray
Assembling the powered load tray

See Figure 47.
3. Use four screws (17) to install the two switch plates
(20) and the two threaded blocks (21) on the track.
Torque the screws to 3–4 Nm (27–35 in lb).
4. Use four screws (2) and four nuts (3) to install the
track (1) on the third stage mast.
5. Use two screws (P/N 120544-003) to install the
mast cap on the top of the mast.
6. Use four screws (18) to install the two switch plate
assemblies (19) on the track. Torque the screws to
0.3–0.6 Nm (3–5 in lb).
7. Attach the two mounting blocks (16) to the track
with four flatwashers (15) and four screws (14).
Torque the screws to 26–34 Nm (19–25 ft lb).
8. Insert the pin (13) through the assembly and the
two mounting blocks to install the actuator sub-as-
sembly (25) on the track.
9. Install the two retaining rings (12) to both ends of
the pin.
Note: The ball bearings (28) are pre-lubricated and do
not require further lubrication. The outside of the bear-
ing, which runs on the track, is intended to run dry with-
out lubrication.
10. Attach the four bearings (28) to the actuator sub-
assembly. Secure the bearings with four spacers
(27).
11. Connect the actuator assembly to the wiring har-
ness (9).
12. Use a screw (6) to install the cover (8) on the track.
Torque the screw to 7–9 Nm (5–7 ft lb).
13. Use four flat washers (5) and four screws (4) to in-
stall the lower cover (7) on the track. Torque the
screws to 26–34 Nm (19–25 ft lb).
14. Use a screw (6) to secure the two covers together.
Torque to 7–9 Nm (5–7 ft lb).
15. Insert the pin (31) through the load tray and actua-
tor assembly to secure the load tray (29).
16. Install the two retaining rings (30) on the pin.
17. Check the operation of the tray assembly.
M9.0-2360-552 Crown 2016 PF27527
282
SCHEMATIC DIAGRAMS
283
Notes:
284
SCHEMATIC DIAGRAMS
Introduction to Diagram Use
Introduction to Diagram Use • The terminal board and connector numbers are in
sequence on each page. A wire address with a con-
nector number or terminal board number shows
Electrical Diagram which direction to look in the electrical diagrams for
• The power-up electrical diagram shows the circuits the other end of the wire. When the wire goes to a
that operate the truck (for example, CAN interface, component and not a terminal board or connector,
Access 1 2 3®, the contactor and other compo- the pictorial shows a terminal board to refer to. This
nents). terminal board is not a solid line and has the termi-
• The circuits that do not operate the truck are on the nal board number in parentheses. This terminal
pictorials (for example, freezer condition, the wire board is not on the truck.
guidance system, lights and other components). • The input and output arrows could be on terminal
• When you use the electrical diagrams, the lower boards and connectors. These show if the wire
terminal board or connector numbers are to the transmits input or output signals. This helps to iden-
front of the section. The numbers increase the fur- tify the source of the signal or voctage.
ther you go into the diagrams. For example: a con- • Each page includes a section of the truck. When a
nector that starts with a 2 could be on DIA-7332- feature is on the truck that is not standard, a new
032, while a connector that starts with a 4 could be page includes the standard and feature wires. Only
on DIA-7332-033. one page of the truck section is necessary for the
applicable truck setup.
Pictorials • Wires that you identify by colour and not by number
• The terminal board and connector numbers on the are usually wires from a different manufacturer.
pictorials are in two different groups: power unit and • The page titles, which are at the start of the electri-
platform. The power unit terminal boards and con- cal diagrams, show the section of the truck wires on
nectors are: each page.
– 200s
– 400s
– 600s
– 800s.
The platform terminal boards and connectors are:
– 100s
– 300s
– 500s
– 700s
– 900s.
• The wires start at a specified location (for example,
the distribution board) and the connection points
start from the lowest number. The next connection
point from the distribution panel is with the next
group of 100s and continue for each connection
point away from the specified location.
Crown 1991 PF8974-1 Rev. 6/12 DIA-ITD-001

03 Rev. 6/12
285
SCHEMATIC DIAGRAMS
Electrical Diagrams
Electrical Diagrams
This electrical diagram index contains the electrical di-
agrams that are applicable to your vehicle. See the end
of this section for wire colour codes, power cable codes
and electrical diagram symbols.
Electrical Diagrams Index
Title Page Number Revision
Vehicle Schematic DIA-2360-019

Platform, Access 4 DIA-2360-020
InfoLink®, Motorised Load Tray DIA-2360-021
Access 2, Access 3™ DIA-2360-022
Chassis, M1, M2 DIA-2360-023
Power Cables DIA-2360-024
Wire Harnesses DIA-2360-025
Wire Colour-Codes and Schematic Symbols DIA-2360-026
DIA-2360-018 Crown 2020 PF28300 Rev. 2/20
286
SCHEMATIC DIAGRAMS
Vehicle Schematic
Vehicle Schematic
A B C
LEFT TRACTION MOTOR
ACCESS 4
D3
RIGHT TRACTION MOTOR
ACCESS 4
M1-9
M1-5
M1-7
M1-8
M1-3
M1-4
M1-6
M1-10
TO
D2
TO
BRK2 D5
LH
+
1 1234
D12 ECR3
1234 1
COMMON
CHAN A
CHAN B
ECR4
COMMON
CHAN A
CHAN B
+BV
+BV
K5 K5
M2 M1
ECR2 D4
BRK1 ECR1
COMMON
COMMON
RH
CHAN A
CHAN A
CHAN B
CHAN B
+
+BV
+BV
TS2 D7 TS1
+t°
1234 D6 +t°
1234
M2-5
U V W D3 D6 D2 D5 D1D4 D11
B1 B5 B1 B5 U V W D3 D6 D2 D5 D1D4
BNEG
SPL B3
BNEG
ACCESS 3™ HN P-NEG
CA405 (D) +
CA401 (D)
B7 CA402 (C)
CA406 (C) M3
CA407 (B) CA403 (B)
+BV B2 CA404 (A)
CA408 (A)
+BV
FU2
B6
FU1
2 L
D1 2
A2 A1 B6 C2 A6 C1C5C10B2 C5 C10 C2 A4 A13 B4 B8 A12 A5 A11 C1 A7 A14
MCS1, 2, 3, 4 4X IN SERIES
A4 A3 ALM1 R L
ALM2
CHSL
M1-1
M1-2
ACCESS 1 + + K2
ERLS
CHS4
CHS3
BATTERY
ECS
SPS
CHARGER
CA302 (A) TLTS
M2-3
A6 A1A2 A5
FU5
FU6
LGT2
D13
D10
+
LGT1
K6 K2 FU7
+ +
+ L
LGS CB1
8A
3 3
M2-7
K6
D9
DMSL
HGTS118
SB1
HGTS84
HGTS20
DMSR
LMS1
LMS2
GOSR
GCSR
GOSL
GCSL
CHS1
CHS2
HNS
LOS
RAS
HSS
LTS
K1
D8
M2-4
M2-8
L EDS2 EDS4
R PLSL2
A12
A11
A19 A7A18 A17 B5 A23 B4 A8 A6 A27 A21 A22 B11 B12 B18 A20 B2
LED2 A16 A10 A9 B19
+ M2-2 M2-6
B3 PLSL1
B1 K3 K4
A33 MOV1
B10
B17 ACCESS 4 +
ALM4
LHS A31
CA101 (A) EDS1 EDS3
A30 +
RHS
CA102 (B) M4
B16 ALM3 +
B9 A33 K3
A35 +
A34 K4
LED1 A26 A15A3 B15 B21B8 A4 A13A1 A2 A25B14 B13 B7 B6 KYS
4 M2-1 4
DTS
K1 24V
M1-10
M1-7
M1-8
M1-9
M1-3
M1-4
M1-5
M1-6
_ _ _ _
+ S + S + S + S FU8 FU4 FU3
TO
STR CMD +
MOTOR ECRS
1 2 1 2 TXN CMD
A B C
154036 E
Crown 2020 PF28300 Rev. 2/20 DIA-2360-019
287
SCHEMATIC DIAGRAMS
Platform, Access 4
Platform, Access 4
A B C
STR CMD 1 2 ALM1
TXN CMD
LED2
LEFT CONTROL RIGHT CONTROL ACCESS 1 1 2
+BV (KYS)
POD POD
+BV (FU3)
LHS
+ S _ + S _
LED1
CAN H
CAN L
BNEG
BNEG
RHS
ORG
GRN
BLK
VIO
+ S _ + S _
2910
ORG
GRN
2911
1 2 3 4 5 6
BLK
VIO
CA302
1 1
WHT
WHT
RED
BRN
RED
BRN
BLU
BLU
BLK
YEL
BLK
YEL
501
504
2
CA301
LTS
SPL02
KYS 1 2 3 4 5 6 7 8 9 10
HSS
1 3
2924
2923
DMSL
DMSR
1 2 3 4 5 6 7 8 9 10
2950
2949
3 3
2942
CA303
EDS3
EDS1
HGTS20
HGTS84
LGS
HGTS118
HNS
RAS
LOS
1 1
29159
29160
29144
2912
2913
2914
2915
2916
2917
2918
WHT
WHT
2904
2905
2906
2907
2908
2909
2919
2920
2921
2922
BLK
BLK
713
117
621
714
118
622
715
716
119
120
524
001
002
710
618
114
611
711
712
620
115
116
113
CA104 CA107
CA108
CA103
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 1 2 3 4
CA105 CA106
29114
29115
29116
29117
29104
29105
29106
29107
29108
29109
29110
29111
29112
29113
29161
29124
706
111
612
707
112
613
705
702
109
110
29100
29101
29102
29103
2963
2962
2901
702
609
105
106
518
003
004
703
107
610
704
108
611
17 18
22
15 16
2 2
SPL23
TO LGT1 / LGT2
OPTIONS CA109
19 031
503 1
2 032
2
519
2901 3
1 29118
4
SPL15
29119
5
2999
502 SPL16 6
2 29120
2902 SPL21
1
SPL20 CA110
20 033
1 C1 BLK JC608-1
SPL17 034
21 2 C1 WHT JC608-2
SPL18 14 035 3 C1 RED JC608-3
036 4 C1 GRN JC608-4
614
5 C1 ORG JC608-5
305
6 C1 BLU JC608-6
037
7 C1 WHT/BLK JC608-7
038
8 C1 RED/BLK JC608-8
615 C1 GRN/BLK JC608-9
9
306
13 10 C1 ORG/BLK JC608-10
11 C1 BLU/BLK JC608-11
12 C1 BLK/WHT JC608-12
SPL19
CA111
29118
29138
1 C2 BLK JC609-1
3 3
29132
29130
29109
29131
29137
2
29129
C2 WHT JC609-2
914
3 C2 RED JC609-3
29122 4 C2 GRN JC609-4
23
520 5 C2 ORG JC609-5
GOSR
GCSR
23 SPL13 29161
GOSL
GCSL
CHS2
CHS1
6 C2 BLU JC609-6
040
039
29140
29103
29134
9
29137
C2 GRN/BLK JC609-9
29135
29115
29107
29138
29139
29111
29136
29106
29102
29105
29122
5933
037
5931
5934
038
615
617
111
107
306
709
609
10 C2 ORG/BLK JC609-10
29 11 C2 BLU/BLK JC609-11
12 C2 BLK/WHT JC609-12
29126
CA101
522
1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435
1
GCSL (+BV=CLOSED, 0V=OPEN
HGTS20 (+BV=CLOSED, 0V=OPEN
EDS (+BV=CLOSED, 0V=OPEN
LED NEG
LTS-R (+BV=CLOSED, 0V=OPEN
LTS-L (+BV=CLOSED, 0V=OPEN

CAN H
HNS (+BV=CLOSED, 0V=OPEN
RAS (+BV=CLOSED, 0V=OPEN

HGTS118 (+BV=CLOSED, 0V=OPEN
CHS2 (+BV=CLOSED, 0V=OPEN
ALM3 NEG
GOSL (+BV=CLOSED, 0V=OPEN
GCSR (+BV=CLOSED, 0V=OPEN

GCSR (+BV=CLOSED, 0V=OPEN
+BV NEG
K3 NEG
K4 NEG
M1 ECR3 N EG
PLSL NEG
M1 ECR3 POS (12V)
M1 ECR3 CHB
M1 ECR3 CHA
STR/TXN CMD SENSOR 1 NEG (5V)

TXN CMD SENSOR 1 INPUT
CAN L
STR/TXN CMD SENSOR 1 POS (5V)

STR CMD SENSOR 1 INPUT
2
705
WHT
3
BLK
4 29100
TO +/- ACCY CABLE (OPTION)
29112
5
29147
29151
29146
29125
5932
5933
521
305
6
614
7
5931
616 24
SPL14
29123
8
109 CA112
9
105 1 2 3 4 5 6 7 8
10
11 29113 1 2 3 TO MOTORIZED
29117 +
12 LOAD TRAY
13 036
M2 ECR4 CHA ALM3
4 CA102
M2 ECR4 CHB
STR/TXN CMD SENSOR 2 POS (5V)
14 035
708 24
(OPTION)
4
1. KYS (+BV=CLOSED, 0V=OPEN 15
110
5935 SPL24
SPL25
2. BNEG RHS EMITTER 16

3. LED POS 106
LHS EMITTER 17
ACCESS 4 4. HSS (+BV=CLOSED, 0V=OPEN 29146
29143
5. LOS (+BV=CLOSED, 0V=OPEN LMS1 (+BV=CLOSED, 0V=OPEN 18 TO PLSL1/PLSL2

5936
29142
6. M2 ECR4 POS (12V) 29147

915
916
7. M2 ECR4 NEG
LMS2 (+BV=CLOSED, 0V=OPEN 19 (OPTION)
8. STR/TXN CMD SENSOR 2 NEG (5V) 20
9. RHS COLLECTOR 108
10. LHS COLLECTOR STR CMD SENSOR 2 INPUT 21
112
11. DMSR (+BV-CLOSED, 0V=OPEN TXN CMD SENSOR 2 INPUT 22
12. DMSL (+BV-CLOSED, 0V=OPEN 23 CA113 CA114
CA102 1 2 3 4 5 6 1 2 3 4 5 6
A B C
154037 F 3 of 5
DIA-2360-020 Crown 2020 PF28300 Rev. 2/20
288
4
3
2
1
PC116
054
058
Access 2, ECR3
CA118
801
+BV (10V)
1 2 3 4 5 6
A
A
050
PROX DATA 0 INPUT
051 PROX DATA 1 INPUT
CA109
19
25
Crown 2020 PF28300 Rev. 2/20

053 SPL53 052
031 SPLICE17 CAN H CAN H
057 SPL54 056
032 SPLICE18 CAN L CAN L
554 750 +BV (5V)
519 SPLICE13 BNEG
251 550
InfoLink®, Motorised Load Tray
29118 CA111-1 +BV (FU3) DTS BNEG (5V)

29200 150
29119 SPLICE19 +BV (FU3) FROM KYS IMPACT1 X-AXIS INPUT
29201 151
1 2 3 4 5 6
2999 CA103-1 +BV (FU3) TO KYS IMPACT1 Y-AXIS INPUT
061 SPL51 060 RS232 TX

064 SPL52 063
RS232 RX
561 553
1 2 3
BNEG (MODULE)
SPL56 556
DIFFERENTIAL NEG
29200
+BV (KYS)
PC121 CA117
751 SPL57
551 SPL58
1
26
150 557 DIFFERENTIAL NEG
IMPACT
SENSOR
151 152
1 2 3 4
IMPACT2 X-AXIS INPUT
INFOLINK® / ICM
153 IMPACT2 Y-AXIS INPUT

752 558 DIFFERENTIAL NEG
552
PC123
27
152
153 29201
1 2 3 4
+BV (FU3) TO KYS
SPL55 250
+BV (FU3) TO MODULE
29202 29202
ALARM POS
59202 59202
1 2
ALARM NEG
PC120
BLK
1
RH
1 2
WHT
2
559
_
502 SPLICE13 BNEG
LGT1
DIFFERENTIAL NEG
2902
B
B
SPL50
BLK
1
2901 CA103-6 +BV (FU3) LGS
LH
WHT
1 2
2
_
1 2 3 4 5 6 7 8 9 10111213141516171819 2021222324252627282930 3132333435
LGT2
502 SPLICE13 BNEG
CA119
801 RED
CA113
560 BLK
1
WHT
915 SPLICE25 STROBE SYNC
050 GRN
+
RED 051 WHT
1 2 3 4
5935 SPLICE24 ACCESS 4 NEG

READER
RH
BLK
_
29142 SPLICE14 +BV ACCESS 4 COMM
PROXIMITY
PLSL1
1 2 3 4 5 6
252 1_BV
555 2_GND
055 3 CAN H
CA114
WHT 059 4 CAN L
916 SPLICE25 STROBE SYNC
5 VCC
+
RED 062 6_TX
5936 SPLICE24 ACCESS 4 NEG
LH
BLK 7_RX
ADAPTER
_
29143 SPLICE14 +BV ACCESS 4 COMM 065
PLSL2
BLUETOOTH
8_GND
1 2 3 4 5 6
562
1 2 3 4 5 6 7 8
BLK
CA122
REFERENCE RELAY INFORMATION

K3
29153
CA115
(TO CA111)
BLK
28
+/- ACCY CABLE YEL YEL YEL
SB1
WHT
1
K(X) RELAY REFERENCE WHT 509 RED
1 2 3 4 5
V
2957 BLK
M4
1
MOV1
30(1) 29133 RED

RED
+
2
+
2952 29154 29121 BLK
K4
86(2)
K(X)
K4
85(3) SPL27 BLK 29141 RED
1 2 3 4 5 6
K(X)
2953
CA112
87A(4) 510
K3
MOTORIZED LOAD TRAY
2951
LMS2
LMS2
87(5) 29125 SPLICE14 +BV ACCESS 4 COMM SPL26 SPL28
C
C
5906
5933 CA101-33 ACCESS 4 NEG
5905
5932 CA101-34 ACCESS 4 NEG
30
508
29
86
521 CA111-6 BNEG
29152
87
29151 CA111-7 +BV (FU6)
29133
87A
29146 CA102-18 +BV ACCESS 4 INPUT
29141
30
29147 CA102-19 +BV ACCESS 4 INPUT
1 2 3 4 5 6 7 8
85
BOTTOM OF K(X) RELAY
4
3
2
1
DIA-2360-021
SCHEMATIC DIAGRAMS
289
154037 F 4 of 5
InfoLink®, Motorised Load Tray
SCHEMATIC DIAGRAMS
Access 2, Access 3™
Access 2, Access 3™
A B C
CA401 (D)
1
ACCESS 2 / 3 M1 ECR1 CH A 1 025 PC202-3 ECR1 CH A
M1 ECR1 POS (12V) 2 303 PC202-1 +BV (12V) ECR1
M1 TS1 INPUT 3 103 PC201-1 TS1 INPUT
M1 ECR1 CH B 4 026 PC202-4 ECR1 CH B
M1 ECR1 NEG 5 606 PC202-2 BNEG (12V) ECR1
M1 TS1 NEG 6 605 PC201-2 TS1 NEG
1 CA402 (C) 1
KYS (+BV = CLOSED, 0V = OPEN 1 2989 SPLICE 1 +BV (K1)
EDS (+BV = CLOSED, 0V = OPEN 2 2939 SPLICE 12 +BV (K1)
3
4 8
CAN H 5 021 SPLICE 4 CAN H
6
7
8
9 8
CAN L 10 021 SPLICE 5 CAN L
CA403 (B)
2
BRK2 POS 1 RED D7-1 BRK2 POS
+BV SUPPRESSION 2 2966 SPLICE 8
SVL NEG 3 5912 SVL-2 SVL NEG
CHS3 (+BV = CLOSED, 0V = OPEN 4 2985 CHS3-2 +BV (K1) CHS3
3
BRK1 NEG 5 BLK/WHT SPLICE 3 BRK1 NEG
LINE NEG 6 5908 PC601-12 LINE NEG
HN NEG 7 5911 HN-2 HN NEG
SPS (+BV = CLOSED, 0V = OPEN 8 2975 PC605-11 +BV (K1) SPS
CA404 (A)
1
TLTS (+BV = CLOSED, 0V = OPEN 2
3
MCS1, 2, 3, 4 (+BV = CLOSED, 0V = OPEN 4 2983 MCS4-2 +BV (K1) MCS
2 ERLS-R (+BV = CLOSED, 0V = OPEN 5 2972 PC605-8 +BV (K1) ERLS-R 2
6
7 5914 PC604-2 BNEG TLTS
8
9
10
ERLS-L (+BV = CLOSED, 0V = OPEN 11 2973 PC605-9 +BV (K1) ERLS-L
BNEG
ECS (+BV = CLOSED, 0V = OPEN 12 2974 PC605-10 +BV (K1) ECS
CHS4 (+BV = CLOSED, 0V = OPEN 13 2984 CHS4-2 +BV (K1) CHS4
INHIBIT (+BV = CLOSED, 0V = OPEN 14 5910 1 WHT (BATTERY CHARGER)
514 SPLICE 6 BNEG
CA405 (D)
ACCESS 3™ M2 ECR2 CH A 1
4
027 PC205-3 ECR2 CH B
M2 ECR2 POS (12V) 2 304 PC205-1 +BV (12V) ECR2
M2 TS2 INPUT 3 104 PC204-1 TS2 INPUT
M2 ECR2 CH B 4 028 PC205-4 ECR2 CH B
M2 ECR2 NEG 5 608 PC205-2 BNEG (12V) ECR2
M2 TS2 NEG 6 607 PC204-2 TS2 NEG
CA406 (C)
KYS (+BV = CLOSED, 0V = OPEN 1 2987 SPLICE 7 +BV (K1)
EDS (+BV = CLOSED, 0V = OPEN 2 2943 SPLICE 12 +BV (K1) EDS
3
3 4
9
3
CAN H 5 023 SPLICE 4 CAN H
6
7
8
9
9
CAN L 10 024 SPLICE 5 CAN L
CA407 (B)
3 WHT D6-1 BRK1 POS
BRK1 POS 1
+BV SUPPRESSION 2 2986 SPLICE 9
3
4
2
BRK2 NEG 5 BLK/RED SPLICE 1 BRK2 NEG
K2 NEG 6 5907 PC601-10 K2 NEG
7
8
CA408 (A)
ALM2 NEG 1 5913 PC603-2 ALM2 NEG
CHSL NEG 2 5918 PC606-21 CHS NEG
3
4
5
4 CONTROLLER MODE 6 2988 SPLICE 7 +BV (K1) 4
7
8
9
10
11
12
13
14
A B C
154037 F 2 of 5
DIA-2360-022 Crown 2020 PF28300 Rev. 2/20
290
4
3
2
1
1
120 OHM
RESISTOR
Chassis, M1, M2
TOP
M1
M2
ENCODER ENCODER ENCODER ENCODER
ECR4
ECR2
PULSE PULSE PULSE PULSE 021 PC402-5 ACCESS 2/3 CAN H
TERMINATING
/REV. /REV. /REV. /REV. 022 PC402-10 ACCESS 2/3 CAN L
BOTTOM
6
ECR1 TOP
TS1 +t°
TS2 +t°
023 PC406-5 ACCESS 3 CAN H
VCC
VCC
VCC
VCC
NEG
NEG
NEG
NEG
CH A
CH B
CH A
CH B
CH A
CH B
CH A
CH B
A
A
1
2
3
024 PC406-10 ACCESS 3 CAN L
ECR3 BOTTOM
CA607
BLK
BLK
BLK
BLK
BLUE
BLUE
BLUE
BLUE
RED
RED
RED
RED
WHT
WHT
WHT
WHT
LH
Crown 2020 PF28300 Rev. 2/20

RH
BRK2
BRK1
C1 (RIGHT)
019
020
7
10
1
2
1
2
3
4
1
2
3
4
1
2
1
2
3
4
1
2
3
4
SPL4
017 C1 BLK JC110-1
SPL5 018
C-
C-
C+
C1 WHT JC110-2
REFERENCE RELAY INFORMATION
11
014 C1 RED JC110-3
013 C1 GRN JC110-4
CA202
CA201
CA203
CA204
CA205
CA206
C+ 2995
5925
603
2997
2996
5927
2998
5926
C1 ORG JC110-5
5928
301 C1 BLU JC110-6
12
302 C1 ORG/BLK JC110-10
4
028 PC405-4 ACCESS 3 INPUT C1 BLU/BLK JC110-11
C1 BLK/WHT JC110-12
1 2 3 4 5 6 7 8 9 101112
027 PC405-1 ACCESS 3 INPUT
608 PC405-5 BNEG (12V) ACCESS 3 SUPPLY
D5
CA608
C2 (LEFT)
D4
304 PC405-2 BNEG (12V) ACCESS 3 SUPPLY
607 PC405-6 BNEG ACCESS 3 SUPPLY 2971 C2 BLK JC111-1
6
104 PC405-3 ACCESS 3 INPUT 2968
5
C2 WHT JC111-2
1
026 PC401-4 ACCESS 2 / 3 INPUT 913 C2 RED JC111-3
025 PC401-1 ACCESS 2 / 3 INPUT 2990 C2 GRN JC111-4
606 PC401-5 BNEG (12V) ACCESS 2 / 3 SUPPLY 516 C2 ORG JC111-5
303 PC401-2 BNEG (12V) ACCESS 2 / 3 SUPPLY 2970 C2 BLU JC111-6
605 PC401-6 BNEG ACCESS 2 / 3 SUPPLY 517 C2 WHT/BLK JC111-7
31
103 PC401-3 ACCESS 2 / 3 SUPPLY 29150 C2 RED/BLK JC111-8
523 C2 ORG/BLK JC111-10
D6
32
WHT PC407-1 ACCESS 3 POS C2 BLU/BLK JC111-11
3
SPL3
BLK/WHT PC403-5 ACCESS 2 / 3 NEG C2 BLK/WHT JC111-12
1 2 3 4 5 6 7 8 9 101112
CA609
SPL6
514 (CA404) BNEG
D7
RED PC403-1 ACCESS 2 / 3 POS
B
B
2
BLK/RED PC407-5 ACCESS 3 NEG
C3
512
SPL1
CHS3 2987 PC406-1 +BV (K1) ACCESS 3 INPUT
2985 PC403-4 +BV (K1) ACCESS 2 / 3 INPUT 2988 PC408-6 +BV (K1) ACCESS 3 INPUT
2979
SPL7
2984 PC404-13 +BV (K1) ACCESS 2 / 3 INPUT 2978 2989 PC402-1 +BV (K1) ACCESS 2/3 INPUT
2982 2981 2980 CHS4
2983 PC404-4 +BV (K1) ACCESS 2 / 3 INPUT 2939 PC402-2 +BV (K1) ACCESS 2/3 INPUT
MCS4 MCS3 MCS2 MCS1 2977
2986 PC407-2 +BV (K1) ACCESS 3 INPUT
2966 PC403-2 +BV (K1) ACCESS 2/3 INPUT
2943 PC406-2 +BV (K1) ACCESS 3 INPUT
BLK 512 CA606
WHT
5914 PC401-7 BNEG ACCESS 2 / 3 INPUT 913 WHT
TLTS
RED
2967
+
RED
5918 PC408-2 ACCESS 3 NEG
SPL9
BLK
-
ALM4
CHSL
2976 +
1 2 3 CA604
SPL8
2964
1 2 3 4 5 6
1
3
CA611 EDS4
2
BATTERY
1
2970 29157
FROM THE
3
FU3
SPL10
2958 29158
D11
+ SPL
1 2
218 202
5912 PC403-3 ACCESS 2 / 3 NEG EDS2
2921
2968 2927
L
3
DTS
203 206 CA601 2969 2928

SPL12
29167 205 211 211 201

215 29168
FU4
K1
2940 2954 513 506
6
2 5
FU5
SPL29
SPL11
1
3 1 4
2938 2941 2955 5915 5901 5922

FU6
SPL30
29148 29162 29163 29166 2961 2929

29156 2964 2971 2930
1
D13 D9 29149 29150 2931 ERLS

2
CB1 29165 2972 PC404-5 +BV (K1) ACCESS 2/3 INPUT
K6
29164 2944 2958 2932
3
8A
FU7
K1
K6
2936
+
507 515 511 2933 ECS
D10 2974 PC404-12 +BV (K1) ACCESS 2/3 INPUT
1
D8 2937
2
2945 2959 2934
K2
+
1
5919 5902 5907 PC407-6 ACCESS 3 NEG 2935
2946 2960 2903
C
C
+
2947
K2
5903 5908 SPS
D12 PC403-6 ACCESS 3 NEG
D1
1
+
FU8
33
2948 2961
1 2 3 4 5 6 7 8 9 101112 CA605
K5
5904
34
2993 2994
+
1
2965 RED
D2
5917 5916 35
1 2 CA610
GRN
CA603 1 2
D3 5913 PC408-1 ACCESS 1 NEG
33
ALM2
5909 5915 34
919 917
35
920 918
+
2956
K5 1
216 217
5911 PC403-7 ACCESS 2/3 NEG
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8
CA602
4
3
2
1
DIA-2360-023
SCHEMATIC DIAGRAMS
291
Chassis, M1, M2
154037 F 1 of 5
SCHEMATIC DIAGRAMS
Power Cables
Power Cables
A B C
IEC 320
W INLET N
G
L
BACK _ +
-B
1 BATTERY 1 BATTERY 4 1
GRN
BLK
WHT
ACCESS 3™ ANSI AC
_
+
OUTLET
SILVER
+B FU2 +BF
GREEN
BRASS
ITEM 11
ITEM 9
BACK
GRN
BLK
WHT
CHARGER
LED BOARD _ +
WHT (PC404) ACCESS2/3 INPUT

V U
ITEM 10
(GRN)
BATTERY 2 BATTERY 3
(YEL)
(RED)
+ _
ITEM 12
ITEM 8
WHT
RED
GRN
BLK
CA612 WET CELL
PART OF
ITEM 13
1 2 3 4 BATTERIES
2 GRN or BRN
TO 2
WHT or ORG
VEHICLE
BLK
RED
U VW
M2
3
1D1 2D2 BATTERY

M3 CHARGER
ITEM 5
ITEM 6
ITEM 7
RED
BLK
TO
BATTERIES
MAINTENANCE FREE
-P W BATTERIES
ITEM 1
ITEM 4
-B
3 BATTERY 1 BATTERY 4 3
ITEM 10
ITEM 3
LINE
ITEM 2
+B FU1 +BF
_ _
+ +
ITEM 11
ACCESS 2 / 3
ITEM 9
ITEM MF BATTERY WET BATTERY

1 084568-046
2 084568-074 _ _
U + +
V
ITEM 12
3 084568-071
ITEM 8
4 084568-073
5 084568-072
6 084568-075
7 084568-076
4 8
9
084568-055
084568-054
084568-047
084568-050 TO 4
PART OF
VEHICLE
ITEM 13
10 084568-057 084568-049 BATTERY 2 BATTERY 3

11 084568-054 084568-050
12 084568-056 084568-048
13 150776
U VW
M1
3
A B C
154037 F 5 of 5
DIA-2360-024 Crown 2020 PF28300 Rev. 2/20
292
SCHEMATIC DIAGRAMS
Wire Harnesses
Wire Harnesses
Power Unit Wire Harness
Wire Harness Components Connected By:

Part Number
150776 Motor wiring harness: UM, VM, WM, US, VS, WS

150777 Chassis harness: PC201, PC202, PC203, PC204, PC205, PC206, PC401, PC402, PC403,
PC404, PC405, PC406, PC407, PC408, PC601, PC602, PC603, PC604, PC605, PC606,
PC607, PC608, PC609, PC611, ALM2, B-NEG, BRK1, BRK2, CAN resistor (P/N 062846),
CHS, CHS3, CHS4, Left Dynamic, Right Dynamic, ECR1, ECR2, ECR3, ECR4, HN1, INHIBIT,
MCS1, MCS2, MCS3, MCS4, Service panel, TLTS, TS1, TS2, Diode (P/N 066073), SVL
160314 Contactor panel harness: JC601, JC602, Diode ASM P/N 148192, P/N 154265, P/N 157630,
FU3, FU4, FU5, FU6, FU7, FU8, K1, K2, K5, K6, Line coil, Line tips
152528 Dynamic harness: 12-conductor cable
154429 Service panel harness: JC605, JC611, PC610, DTS-1, DTS-2, DTS-3, DTS-4, DTS-5, ECS,
ECS Comm, EDS2-1, EDS2-3, EDS4-1, EDS4-3, ERLS-L, ERSL-R, ERLS Comm, ALM4
Platform Wire Harness
Wire Harness Components Connected By:

Part Number
148193 LED light harness

148207 +/- Accessory wiring harness
151080 Height switch harness: JC105, HGTS20, HGTS84, HGTS118
151799 Platform harness: JC109, PC101, PC102, PC103, PC104, PC105, PC106, PC107, PC108,
PC109, PC110, PC111, PC112, PC112, PC113, PC114, ALM3, CAN, CHS1, CHS2, DMS, Dy-
namic Left, Dynamic Right, GCSL, GCSR, GOSL, GOSR, HGTS, LGT1, LGT2, PLS1, PLS2,
Power tray, Static left, Static right
151871 Steer pod harness: JC301, HSS, LGS, LTS, KYS
161823 Traction pod harness: PC302, JC303, EDS1, EDS3, HNS, LOS, RAS
154163 InfoLink® harness: JC109, JC119, PC116, PC117, PC118, PC120, PC121, PC122, PC123,
CAN, Module, PROG, PROX, Shock
158662 InfoLink® LC filter harness
160194 Power load tray harness: JC112, PC115, K3, K4
Crown 2020 PF28300 Rev. 2/20 DIA-2360-025
293
SCHEMATIC DIAGRAMS
Wire Colour-Codes and Schematic Symbols
Wire Colour-Codes and Wire Colour-Codes

Schematic Symbols See the applicable wire colours in the Wire Colour-
Code table. The function of the circuit determines the
This section includes information on wire colour-codes wire colour. Each wire has a three or four-digit number.
and schematic symbols that are standard on Crown The first one or two digits identify the colour of the lead.
electrical diagrams. The last two digits identify the lead from one to 99. It is
possible that some vendor component leads do not
have these same numbers or colours. A wire pictorial
identifies each wire by number. See the SCHEMATIC
DIAGRAMS / Electrical Diagrams section for wire pic-
torials and electrical diagrams.
Wire Colour-Code
Number Colour Function
0xx Black Digital signal (1)

1xx Brown Analogue signal (1)
2xx Red Primary positive that has not gone through a switch (2)
3xx Orange 12 V Non-battery positive (3)
4xx Yellow Non-battery positive (3)
5xx Green Primary negative that has not gone through a switch (2)
6xx Blue Isolated negative (4)
7xx Violet 5 V Non-battery positive (3)
8xx Grey Non-battery positive (3)
9xx White Miscellaneous
29xx Red/White Primary positive that has gone through a switch (2)
59xx Green/White Primary negative that has gone through a switch (2)
(1) Signal - A conductor that gives a variable input or output potential.
(2) Primary - A conductor that gives battery positive potential or battery negative potential.
(3) Non-battery positive - A conductor that gives a non-battery positive potential from the output of a regulated DC-
to-DC converter.
(4) Isolated negative - A conductor that gives a negative potential that is electrically isolated from battery negative.
DIA-2360-026 Crown 2020 PF28300 Rev. 2/20
294
SCHEMATIC DIAGRAMS
Power Cables
The designators and dash numbers in the Power Ca-
bles Abbreviations table identify the power cables. An
example of such a power cable is PC#1/0 – 10. The Fig. 3 (8117-01)
part number for this cable is 084572-010. or
Power Cables Abbreviations
Abbreviation Part Numbers Fig. 4 (8118-01)

PC#1 084571 Number of Terminals
• All terminals are shown even if not connected.
PC#2 084570
Momentary Contact Switch or Maintained Contact
PC#4 084569
Switch
PC#6 084568 • Momentary contact is a shaded triangle.
PC#8 124474
PC#10 090963
PC#1/0 084572 Fig. 5 (8119-01)
PC#2/0 084573 or
PC#3/0 086749
PC#4/0 137636
Fig. 6 (8120-01)
Switches • Maintained contact is an open circle (an open circle
also shows the common terminal).
The switch symbols show:
• The switch type
• The number of terminals
• If the switch is a momentary contact switch or main- Fig. 7 (8115-01)
tained contact switch or
• How the switch is connected
• How the switch operates
• Function
Fig. 8 (8117-01)
Switch Type
• With common
Fig. 1 (8115-01)
or
Fig. 2 (8116-01)
• Without common
Crown 2020 PF28300 Rev. 2/20 DIA-2360-027
295
SCHEMATIC DIAGRAMS
How the Switch is Connected nal, although they can have a common. Symbols for
See the Examples (All Momentary) table. To know how these switches include the symbols on the actual
the switch is connected, look carefully at the contact switch.
symbols. An open circle shows a maintained contact, Example:
thus it is the normally closed terminal. A shaded trian-
gle shows a momentary contact, thus it is the normally
open terminal.
Switches that have more than one maintained contact
do not have a normally open or normally closed termi- Fig. 9 (8121-01)
Examples (All Momentary)
Description With Common (Transfer) Without Common (Double Break)
Connected normally
open, held open
Fig. 10 (8119-01) Fig. 11 (8120-01)
Connected normally
open, held closed
Fig. 12 (8122)
Fig. 13 (8123)
Connected normally
closed, held open
Fig. 14 (8115-01) Fig. 15 (8117-01)
Connected normally
closed, held closed
Fig. 16 (8124) Fig. 17 (8125)
How the Switch Operates

If it is necessary to include how the switch mechani-
cally operates, there is a note on the electrical diagram.
Function
A component designator shows the switch function (for
example: FS = forward switch). See the COMPONEN-
TRY/Componentry section for more information on the
applicable component designators for your vehicle.
Note:
• On an electrical diagram, the condition of a circuit
includes a note (for example: the vehicle is fully low-
ered with no operator on the vehicle).
• Positive action switches have this symbol:
Fig. 18 (8126-02)
DIA-2360-028 Crown 2020 PF28300 Rev. 2/20
296
SCHEMATIC DIAGRAMS
Switch Symbols (Switches that operate mechanically)
No. of Momentary Fully Maintained

Actuation Description
Terminals w/common w/o common w/common w/o common
Fig. 19 (8100-01)
Crown 2020 PF28300 Rev. 2/20 DIA-2360-029
297
SCHEMATIC DIAGRAMS
Switch Symbols (Switches that operate mechanically)

Continued
No. of Momentary Fully Maintained

Actuation Description Terminals w/common w/o common w/common w/o common
Fig. 20 (8101-02)
DIA-2360-030 Crown 2020 PF28300 Rev. 2/20
298
SCHEMATIC DIAGRAMS
Speciality Switches
Pressure Switch
Fig. 21 (8127)
Reed Switch
Fig. 22 (8128)
Temperature Switch
Fig. 23 (8129)
Brake Fluid Switch
Fig. 24 (8130)
Three Position Key Switch
Start
Off
Fig. 25 (8131-01)
Crown 2020 PF28300 Rev. 2/20 DIA-2360-031
299
SCHEMATIC DIAGRAMS
Other Electrical Symbols
Signal Flow Terminal

Heater
One Way Strip
Signal Flow
Simultaneous T-Connection Thermistor
Signal Flow
Double Mov/
Alternate
Junction Transzorb
Chassis
Ground Mast Cable
Capacitor
Common Power Non-polarised
Return Termination
Capacitor
Female/ Polarised
Test Point Socket
Current
Male Shunt
Cable Pin
Shielded Inductor
Cable Socket & Pin
Twisted Pair
LVDT
Connector
Fixed/Jack
Cable Multi- Ferrite Bead
Twisted Pairs Connector
Moveable/
Plug
Diode
Cable Multi-
Conductor Connector
Assembly
LED
Cable Multi-
Conductor Resistor
Zener Diode
Cable SIP Resistor

Unconnected SCR
Cable
Unconnected Pot
Transistor
Insulated
NPN
Junction
Point Rheostat
Fig. 26 (8132-02)
DIA-2360-032 Crown 2020 PF28300 Rev. 2/20
300
SCHEMATIC DIAGRAMS
Other Electrical Symbols
Transistor DC/DC 1 2 34 5
Dual
PNP Converter
Suppressor
Power Supply 115487
Darlington Battery + – +
NPN Dual
Contactor 082495, 086322, 093757
Suppressor
Normally
Darlington Open
PNP
Contactor 1 3 Filter Block
Normally 112533 5
N-FET With
Closed
Diode Clamp
Coil
P-FET With
Diode Clamp Coil
Suppression
Motor Field, Fuse - Band
Series Shows Positive
Feed
Motor Field,
Shunt Tach Sensor
TT
Series Motor, Hour Meter
M
DC
Lamp
M Shunt Motor,
DC
Horn
Permanent
M Magnet
Encoder
Motor
Suppressor
M Separately 077732
Excited Motor, DC
+ –
Suppressor
M Motor, AC
077728, 085670, 091181
3
Suppressor
Transformer
085484, 086755
Fig. 27 (29910)
Crown 2020 PF28300 Rev. 2/20 DIA-2360-033
301
SCHEMATIC DIAGRAMS
Notes:
DIA-2360-017
302
HYDRAULIC SCHEMATIC
303
Notes:
304
HYDRAULIC SCHEMATIC
Hydraulic Schematic
Hydraulic Schematic
1 Manifold block 5 Pump and pump motor

2 Lift cylinder 6 Filter
3 Vent 7 Reservoir
4 Power unit 8 Aux. outlet port
Fig. 1 (158959 A)
Crown 2016 PF27186 HYD-2360-001
305
HYDRAULIC SCHEMATIC
Hydraulic Schematic
Hydraulic Schematic
Vented reservoir lines above

the fluid level Spring (bias to normal
de-energised position)
Vented reservoir lines below the

fluid level
Filter or strainer Solenoid, single coil or winding
Hydraulic line — could be tubes,

hoses or flow passage in the Component enclosure
manifold, with full flow (manifold block)
Pilot or drain line, limited flow
Lines crossing
Adjustable resistor orifice
throttle
Lines connected
Resistor orifice throttle
Plugged port (test port)
Adjustable relief valve
M Electric motor, unidirectional

single speed
Check valve
Hydraulic pump, fixed

displacement, unidirectional
Fig. 2 (29867)
HYD-2360-002 Crown 2016 PF27186
306
Serie WAV 60
812616-006
20210204 REV. A

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C

Order Number: 812616-001

Crown Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Calibration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Event Code Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

General Maintenance – Limit switches

Crown 2016 PF27593 MA-2360-001

Cleaning of Material Handling Note: Steam cleaning can remove anti-corrosion

Cleaning mechanical components

MA-2360-050 Crown 2016 PF27594

Returning the vehicle to operation after cleaning

6. Turn on the vehicle.

Crown 2016 PF27594 MA-2360-051

MA-2360-100 Crown 2016 PF27592

Crown 2016 PF27592 MA-2360-101

When maintenance is to be performed on the hydraulic

MA-2360-102 Crown 2016 PF27592

Crown 2016 PF27592 MA-2360-103

Moving the vehicle by manually pushing

MA-2360-104 Crown 2016 PF27592

Crown 2016 PF27592 MA-2360-105

MA-2360-106 Crown 2016 PF27592

Crown 2016 PF27592 MA-2360-107

MA-2460-001 Crown 2016 PF27603 Rev. 7/17

1. Lower the platform fully.

Crown 2016 PF27602 MA-2460-025

Loading the vehicle onto a pallet

Fig. 10 Vehicle on a pallet

1. Lower the platform fully.

MA-2460-026 Crown 2016 PF27602

Securing the Vehicle for Trans- 4. Apply the Emergency Disconnect.

Note: If the vehicle is being transported on an open

Fig. 11 Securing the vehicle

Clamping the vehicle

Crown 2016 PF27602 MA-2460-027

Towing the Vehicle

Lowering the platform from the service panel

MA-2460-028 Crown 2016 PF27602

Releasing the brake and pushing the

Fig. 14 Service panel

Releasing the brake

Crown 2016 PF27602 MA-2460-029

Jacking up the Vehicle

Fig. 15 Jacking up the vehicle

Jacking up the vehicle

MA-2460-030 Crown 2016 PF27602

Placing the Vehicle in Storage

Crown 2016 PF27602 MA-2460-031

Restoring the Vehicle to Service

MA-2460-032 Crown 2016 PF27602

Commission pears if the drive motor temperature is below -12°C