sp351110 PDF

SP 3500 SERIES
AC Traction
MAINTENANCE MANUAL
Bestell Nummer: 812574-006

Revision: A • Printed in Germany
This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

– European Headquarter –
Moosacher Str. 52
80809 München
Germany
Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 133
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2008
CROWN Equipment Corporation
TABLE OF CONTENTS
I
Notes:
II
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PAGE
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . 3
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lockout - Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blocking Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . 13
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INTRODUCTION PAGE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operator Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICATION & ADJUSTMENT PAGE

Lubrication and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Component Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Skid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
HYDRAULIC SYSTEM PAGE

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Lift Circuit - One Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . 51
Lift Circuit - Two Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . 52
Lower Circuit - One Speed/Two Speed Lower . . . . . . . . . 53
Manual Lower Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Lift Circuit - One Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . 58
Lifting Fork Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Accumulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Main Lift - One Speed Lift with Lifting Fork . . . . . . . . . . . . 59
Lift Circuit - Two Speed Lift W/Lifting Forks . . . . . . . . . . . . 61
Two Speed Lift with Lifting Fork . . . . . . . . . . . . . . . . . . . . . 62
Lower Circuit - One Speed/Two Speed Lower . . . . . . . . . . 63
One Speed Lower with Lifting Fork . . . . . . . . . . . . . . . . . . 64
Two Speed Lower with Lifting Fork . . . . . . . . . . . . . . . . . . 65
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Lift Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Freezer Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 69
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Pump - Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Composite Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Precharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
DRIVE UNIT PAGE

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Drive Unit Removal and Installation . . . . . . . . . . . . . . . . . . . . 89
ELECTRICAL SYSTEM PAGE

Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Motor Monitoring System (MMS) . . . . . . . . . . . . . . . . . . . . . . . 99
Testing Motor Monitoring System (MMS) . . . . . . . . . . . . . . . 100
Access 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
User Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Steer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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TABLE OF CONTENTS
Model - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . 104

Timer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Trip - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
BDI - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Hours - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . 105
Odometer - Message Mode . . . . . . . . . . . . . . . . . . . . . . 105
Speed - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . 105
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Features Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Performance Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
End Aisle Control (EAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Wire Guidance Calibration Speeds . . . . . . . . . . . . . . . . . . . 160
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Termination Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . 161
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Steering Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Accelerator Potentiometer (POT1) . . . . . . . . . . . . . . . . . . . . 170
Directional Switches (FS & RS) . . . . . . . . . . . . . . . . . . . . . . 171
Directional Switches (FS & RS) . . . . . . . . . . . . . . . . . . . 171
Actuator Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Potentiometer (POT1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Cam, Torsion Spring, Stop . . . . . . . . . . . . . . . . . . . . . . . 172
Twist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
RAS1, RAS2, LOS1, LOS2, HNS, EDS . . . . . . . . . . . . . . . . 176
Button Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Power Disconnect Button Springs . . . . . . . . . . . . . . . . . 178
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Battery Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Event Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Event Code 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Event Code 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Event Code 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Event Code 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Event Code 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Event Code 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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TABLE OF CONTENTS
Event Code 337 .................................... 216

Event Code 338 .................................... 217
Event Code 339 .................................... 218
Event Code 340 .................................... 218
Event Code 341 .................................... 219
Event Code 342 .................................... 219
Event Code 343 .................................... 220
Event Code 344 .................................... 221
Event Code 345 .................................... 221
Event Code 346 .................................... 222
Event Code 348 .................................... 223
Event Code 349 .................................... 224
Event Code 350 .................................... 224
Event Code 351 .................................... 225
Event Code 352 .................................... 226
Event Code 353 .................................... 227
Event Code 354 .................................... 228
Event Code 355 .................................... 229
Event Code 356 .................................... 229
Event Code 357 .................................... 229
Event Code 358 .................................... 230
Event Code 359 .................................... 231
Event Code 360 .................................... 231
Event Code 361 .................................... 232
Event Code 362 .................................... 232
Event Code 363 .................................... 232
Event Code 365 .................................... 232
Event Code 366 .................................... 232
Event Code 367 .................................... 232
Event Code 368 .................................... 233
Event Code 369 .................................... 233
Event Code 370 .................................... 233
Event Code 371 .................................... 233
Event Code 372 .................................... 233
Event Code 373 .................................... 233
Event Code 374 .................................... 233
Event Code 375 .................................... 233
Event Code 378 .................................... 234
Event Code 379 .................................... 234
Event Code 380 .................................... 234
Event Code 381 .................................... 234
Event Code 382 .................................... 234
Event Code 383 .................................... 235
Event Code 384 .................................... 235
Event Code 385 .................................... 235
Event Code 386 .................................... 235
Event Code 387 .................................... 236
Event Code 389 .................................... 236
Event Code 390 .................................... 236
Event Code 392 .................................... 236
Event Code 393 .................................... 236
Event Code 395 .................................... 236
Event Code 401 .................................... 237
Event Code 405 .................................... 238
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TABLE OF CONTENTS
Event Code 411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Event Code 413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event Code 415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event Code 423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Event Code 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Event Code 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Event Code 426 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event Code 427 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event Code 429 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Event Code 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Event Code 432 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Event Code 433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Event Code 435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Event Code 440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Event Code 441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Event Code 442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Event Code 443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Event Code 445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Event Code 446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Event Code 447 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Event Code 448 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event Code 449 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event Code 452 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event Code 453 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Event Code 460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Event Code 462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Event Code 463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event Code 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event Code 466 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Event Code 469 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Event Code 470 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Event Code 473 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Event Code 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Event Code 504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Event Code 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Event Code 506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Event Code 511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 514 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 526 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
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Event Code 531 .................................... 283

Event Code 532 .................................... 284
Event Code 533 .................................... 285
Event Code 534 .................................... 286
Event Code 535 .................................... 286
Event Code 536 .................................... 286
Event Code 537 .................................... 287
Event Code 538 .................................... 287
Event Code 539 .................................... 287
Event Code 540 .................................... 288
Event Code 541 .................................... 290
Event Code 542 .................................... 292
Event Code 544 .................................... 292
Event Code 545 .................................... 292
Event Code 546 .................................... 292
Event Code 548 .................................... 292
Event Code 549 .................................... 293
Event Code 551 .................................... 293
Event Code 552 .................................... 294
Event Code 553 .................................... 294
Event Code 554 .................................... 294
Event Code 555 .................................... 294
Event Code 556 .................................... 294
Event Code 557 .................................... 295
Event Code 558 .................................... 296
Event Code 561 .................................... 296
Event Code 562 .................................... 297
Event Code 563 .................................... 297
Event Code 564 .................................... 297
Event Code 565 .................................... 298
Event Code 566 .................................... 298
Event Code 567 .................................... 299
Event Code 568 .................................... 300
Event Code 569 .................................... 301
Event Code 570 .................................... 302
Event Code 571 .................................... 303
Event Code 572 .................................... 303
Event Code 573 .................................... 304
Event Code 574 .................................... 304
Event Code 576 .................................... 305
Event Code 581 .................................... 305
Event Code 582 .................................... 305
Event Code 585 .................................... 305
Event Code 586 .................................... 305
Event Code 587 .................................... 306
Event Code 588 .................................... 306
Event Code 589 .................................... 307
Event Code 590 .................................... 307
Event Code 591 .................................... 307
Event Code 592 .................................... 307
Event Code 593 .................................... 307
Event Code 594 .................................... 308
Event Code 595 .................................... 308
Event Code 596 .................................... 309
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Event Code 597 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Event Code 601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Event Code 603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Event Code 604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Event Code 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Event Code 611 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Event Code 612 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Event Code 621 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Event Code 628 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Event Code 631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Event Code 632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Event Code 633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Event Code 636 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Event Code 637 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Event Code 638 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Event Code 639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Event Code 652 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Event Code 659 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Event Code 660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Event Code 663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Event Code 664 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Event Code 667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Event Code 668 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Event Code 671 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Event Code 672 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
BRAKE SYSTEM PAGE

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Braking Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Brake Force Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Torque Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Rotor and Brake Pad Replacement . . . . . . . . . . . . . . . . . 327
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
STEERING PAGE
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Steering Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Steering Wheel Direction Indicator . . . . . . . . . . . . . . . . . . . . 334
Steering Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Steering Motor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
LIFTING MECHANISM PAGE

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Shim Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
TL Mast Column Roller Removal . . . . . . . . . . . . . . . . . . . . . 341
TT Mast Column Roller Removal . . . . . . . . . . . . . . . . . . . . . 343
Shim Measurements (Tolerances) . . . . . . . . . . . . . . . . . . . . 345
Mast Testing (Assembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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TABLE OF CONTENTS
Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Top Column Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Bottom Column Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . 353
Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Chain Anchors and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 355
Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Disconnect Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . 355
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Mounting Support And Platform Bore Measurement . . . 364
Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
CYLINDERS PAGE
Mast and Free Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 369
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Accessing Mast Cylinder Rod Packing . . . . . . . . . . . . . . . . 371
Accessing Free Lift Cylinder Rod Packing . . . . . . . . . . . . . . 371
Rod Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 372
Mast Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Free Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . 375
Mast And Free Lift Cylinder Assembly . . . . . . . . . . . . . . . . . 376
Mast And Free Lift Cylinder Installation . . . . . . . . . . . . . . . . 376
PLATFORM PAGE
Platform Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Height Sensor Encoder Replacement (ECR4) . . . . . . . . . . . 379
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
GLOSSARY PAGE
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
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TABLE OF CONTENTS
SCHEMATIC DIAGRAMS PAGE

Introduction to Diagram Usage . . . . . . . . . . . . . . . . . . . . . . . . 397
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Electrical Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Schematic - Power Unit w/Options . . . . . . . . . . . . . . . . . . . . . 400
Schematic - Platform w/Options . . . . . . . . . . . . . . . . . . . . . . . 401
Schematic - Power Unit w/PDS Options . . . . . . . . . . . . . . . . 402
Schematic - Platform w/PDS Options . . . . . . . . . . . . . . . . . . . 403
Platform Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Platform Distribution Panel w/PDS . . . . . . . . . . . . . . . . . . . . . 405
Platform Distribution Panel Forks First Option . . . . . . . . . . . 406
Power Unit Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . 407
Power Unit Distribution Panel w/PDS . . . . . . . . . . . . . . . . . . 408
Platform Modules Access 1 & 4 . . . . . . . . . . . . . . . . . . . . . . . 409
Platform Modules Access 1 & 4 Forks First Option . . . . . . . 410
Platform Modules Access 1 & 4 w/PDS . . . . . . . . . . . . . . . . . 411
Control Pod and Light Switches . . . . . . . . . . . . . . . . . . . . . . . 412
Control Pod and Light Switches Forks First Option . . . . . . . 413
Overhead Guard Lights/Fans . . . . . . . . . . . . . . . . . . . . . . . . . 414
Overhead Guard Lights/Fans Forks First Option . . . . . . . . . 415
Traction Control Module Access 3 . . . . . . . . . . . . . . . . . . . . . 416
Traction Control Module Access 3 w/PDS . . . . . . . . . . . . . . . 417
Steering Control Module Access 5 . . . . . . . . . . . . . . . . . . . . . 418
Steering Control Module Access 5 w/PDS . . . . . . . . . . . . . . . 419
Hydraulics & Optional MMS . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Guidance Control Module Access 6 (Optional) . . . . . . . . . . . 421
PDS/FSB1 Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
PDS/FSB1 & Forks First Option . . . . . . . . . . . . . . . . . . . . . . . 423
Freezer Conditioning (Optional) . . . . . . . . . . . . . . . . . . . . . . . 424
Freezer Conditioning Forks First Optional . . . . . . . . . . . . . . 425
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
HYDRAULIC SCHEMATIC PAGE

Single Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Two Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Single Speed Lift (With Lifting Fork) . . . . . . . . . . . . . . . . . . . 433
Two Speed Lift (With Lifting Fork) . . . . . . . . . . . . . . . . . . . . . 434
Mast Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
SP 3500
XII
SAFETY
1
Notes:
2
SAFETY
General Maintenance Instructions
General Maintenance Instructions 5. Before starting to operate truck—

– Be in operating position.
WARNING – Apply brake.

– Place directional control in neutral.
TO PREVENT SERIOUS RISK OF INJURY TO
YOURSELF AND OTHERS OBSERVE THE FOL- – Before operating truck, check functions of lift
LOWING SAFETY INSTRUCTIONS systems, directional control, speed control,
steering, warning devices, brakes and any at-
Power industrial trucks may become hazardous if ade- tachments if any used.
quate maintenance is neglected. Therefore, adequate
maintenance facilities, trained personnel and proce- 6. Avoid fire hazards and have fire protection equip-
dures should be provided. ment present. Do not use an open flame to check
level, or for leakage of electrolyte and fluids or oil.
Maintenance and inspection shall be performed in con- Do not use open pans of fuel or flammable clean-
formance with the following practices: ing fluids for cleaning parts.
1. A scheduled planned maintenance, lubrication, 7. Keep shop well ventilated, clean and dry.
and inspection system should be followed.
8. Brakes, steering mechanisms, control mecha-
2. Only qualified and authorized personnel shall be nisms, lift overload devices, guards, and safety de-
permitted to maintain, repair, adjust and inspect vices shall be inspected regularly and maintained
truck. in a safe operating condition.
3. Before leaving the truck— 9. Capacity, operation and maintenance instruction
– Stop truck. plates or decals shall be maintained in legible con-
dition.
– Fully lower the load engaging means.
10. All parts of lift mechanisms shall be inspected to
– Place directional controls in neutral. maintain them in safe operating condition.
– Apply the parking brake. 11. All hydraulic systems shall be regularly inspected
– Turn off power (power disconnect). and maintained in conformance with good practice.
Cylinders, valves, and other similar parts shall be
– Remove key. checked to assure that “drift” has not developed to
– Block the wheels if truck is on an incline. the extent that it would create a hazard.
4. Before working on truck— 12. Batteries, motors, controllers, limit switches, pro-
tective devices, electrical conductors, and connec-
– Raise drive wheel free of floor or disconnect tions shall be maintained in conformance with
power sources. good practice. Special attention shall be paid to the
– Use chocks or other positive positioning de- condition of electrical insulation.
vices.
13. Trucks shall be kept in a clean condition to mini-
– Block load engaging means, inter masts, or mize fire hazards and facilitate detection of loose
chassis before working under them. or defective parts.
– Operation to check performance of truck or at- 14. Modifications and additions which affect capacity
tachments shall be conducted in an authorized and safe truck operation shall not be performed by
safe clearance area. the customer or user without manufacturers prior
written approval. Capacity, operation and mainte-
nance plates or decals shall be changed accord-
ingly.
15. Care shall be taken to assure that all replacement
parts are interchangeable with the original parts
and of equal quality to that provided in the original
equipment.
Crown 1980 PF6285-1 Rev. 10/06 SP 3500 MA-04.5-001

03 Rev. 10/06
3
SAFETY
16. Be sure that any equipment added to the truck (ter-

minal, fan, clipboard, etc.) is positioned so that it
does not block your vision or interfere with safe and
efficient operation of the truck.
For further information pertaining to operating and
maintenance procedures, refer to F.E.M. safety code -
Power Industrial Truck (section 4).
For copies send to:
F.E.M.
10 Avenue Hoche
75382 Paris Cedex 08 France
MA-04.5-002 SP 3500 Crown 1980 PF6285-2 Rev. 10/06
03 Rev. 10/06
4
SAFETY
Control of Hazardous Energy
Control of Hazardous Energy • Do not allow dirt, cleaning solution or other foreign
material to enter cells. Impurities in the electrolyte
have a neutralizing effect reducing available
Lockout/Tagout charge.
In the interest of safety and to ensure compliance with • If battery repair is planned, follow the battery man-
OSHA Regulations, (Standards - 29 CFR), control of ufacturer's instructions concerning repair practices
hazardous energy (lockout/tagout) - 1910.147, Crown and procedures.
has developed guidelines for proper energy control
when performing service and maintenance on the
truck. Before performing any service or maintenance, Battery Care
review the appropriate sections in this service manual
for additional procedures to be followed.
CAUTION
In addition, Crown recommends that all mechanics
wear appropriate protective items, such as safety Only qualified and experienced personnel should per-
glasses, work gloves, and steel-toed shoes, whenever form maintenance and repair on batteries.
performing service or maintenance work on Crown
equipment.
• Make certain the charger being used matches the
voltage and amperage of the truck battery. This
voltage is listed on the truck serial plate.
Battery
• Before disconnecting or connecting batteries to a
charger, make sure the charger is "OFF". If an at-
Safety Rules tempt is made while the charger is "ON", serious
injury to you, the battery and charger could result.
• Wear protective clothing, such as, rubber apron,
gloves, boots and full-face shield when performing • Never use a match or lighter. Battery fumes are ex-
any maintenance on batteries. Do not allow elec- plosive.
trolyte to come in contact with eyes, skin, clothing
or floor. If electrolyte comes in contact with eyes, • Make certain battery used meets weight, size and
flush immediately and thoroughly with clean water. voltage requirements of truck (refer to serial plate).
Obtain medical attention immediately. Should elec- NEVER operate truck with an undersized battery.
trolyte be spilled on skin, rinse promptly with clean
water and wash with soap. A baking soda solution Charging
(one pound to one gallon of water) will neutralize
acid spilled on clothing, floor or any other surface.
Apply solution until bubbling stops and rinse with CAUTION
clean water.
Never smoke or bring flame near the battery. Gas
• Keep vent plugs firmly in place at all times except formed during charging is highly explosive and can
when adding water or taking hydrometer readings. cause serious injury.
• Do not bring any type of flame, spark, etc., near the Consult the charger manufacturer's manual covering
battery. Gas formed while the battery is charging, your charger for hints on operation and maintenance.
is highly explosive. This gas remains in the cells
long after charging has stopped.
• Do not lay metallic or conductive objects on bat-

tery. Arcing will result.
Crown 2008 PF17175-1 SP 3500 MA-7535-100
5
SAFETY
Battery Removal
CAUTION
When removing the battery, move truck to area in-
tended for battery care. Floor must be level. Turn key
switch or toggle switch to "OFF" position and remove
key. Disconnect battery and lockout or tagout truck as
described in Lockout - Tagout in this section. Never
move battery partially from truck without roller stand in
place. Lower load engaging means completely. If bat-
tery is removed with load engaging means raised, use
lifting device attached to mast to provide tip over pro-
tection. Do not allow any metallic object to come in con-
tact with the top of the battery cells. This may cause a
short circuit when removing, transporting the battery. Figure 8251
Use an insulator (such as plywood) to cover the top of
the battery before and during removal. Lockout - Tagout
Always turn key switch to "OFF", remove key and apply
Battery Installation tag to steering wheel or twist grip with cable tie warning
others truck is being serviced.
CAUTION
When installing the battery, move truck to area in-
switch or toggle switch to "OFF" position and remove
key. Lockout or tagout truck as described in Lockout -
Tagout in this section. If battery was removed with load
engaging means raised, use lifting device attached to
mast to provide tip over protection. Make sure lifting
device and sling are sufficiently rated to withstand the
weight being lifted. Never work under or around a truck
that is not properly secured. Do not allow any metallic
object to come in contact with the top of the battery Figure 18496
cells. This may cause a short circuit when transporting
When maintenance is to be performed and the battery
or installing the battery. Use an insulator (such as ply-
will be left in the truck, disconnect battery, remove the
wood) to cover the top of the battery before and during
main power fuses and install a commercially available
installation.
lockout device on the battery connector.
When maintenance is performed and the battery is re-
CAUTION moved from the truck, remove main power fuses, install
a lockout device on the truck's battery connector if pos-
Make certain battery used meets weight, size and volt-
sible, or if possible install a tag with a cable tie on the
age requirements of truck (refer to serial plate).
truck's battery connector so it cannot be removed eas-
NEVER operate truck with an undersized battery.
ily warning that the truck is not available for operation.
MA-7535-101 SP 3500 Crown 2008 PF17175-2
6
SAFETY
Brake
The brakes can be released through the use of the
Drive/Tow switch (DTS1) during a maintenance situa-
tion. When using this method to release the brakes, the
truck will not have brakes available for stopping. The
truck will not have traction control and the power steer-
ing system will not work.
WARNING
Extreme care must be taken when using the Drive/Tow
switch to release the brakes. The truck will be free-
wheeling and the brake pedal in the operator compart-
ment will have no effect on braking. Brakes will only be
applied when DTS1 is moved from the Tow to the Drive
position.
• Lockout or tagout truck as described in Lockout -

Tagout in this section.
• Chock wheels or make sure truck is secured by

some means to keep it from rolling away.
• When towing the truck make sure all operators are

Distribution Panel
informed of the trucks lack of braking.
• Insert PC407, to JC413 on harness.
• Move switch DTS1 from the Drive position to the

Tow position. Figure 16317
• Move truck to area intended for maintenance.
• Move DTS1 from the Tow to the Drive position. Dis-

connect battery.
• Disconnect brake from JC413 and connect to orig-

inal connection, CA407.
Crown 2008 PF17175-3 SP 3500 MA-7535-102
7
SAFETY
Capacitance
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance which
may permit contact with the bus bars and associated
power cables, discharge the capacitors.
• Move truck to a secure non-traffic maintenance

area with a level floor.

• Place a minimum 100 ohm, 2 watt resistor between

the positive and negative terminals of the controller
for 15 or more seconds.
(a) Battery Positive

(b) Battery Negative
Figure 16318-01
MA-7535-103 SP 3500 Crown 2008 PF17175-4
8
SAFETY
Hydraulic
WARNING
AVOID HIGH PRESSURE FLUIDS – Escaping fluid
under pressure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pres-
sure. Keep hands and body away from pin holes which
eject fluids under high pressure. Use a piece of card-
board or paper to search for leaks. Do not use your
hand.
Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency
despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage
may occur. Medical attention should be sought imme- Manual Lower Valve
diately by a specialist who has had experience with this
type of injury. Figure 15658
When maintenance is to be performed on the hydraulic
system, make certain the hydraulic system is not under
pressure by:

• No load on forks.
• Completely lower load engaging means (mast) or,

if required for maintenance, block mast sections at
the appropriate height as described in Mast of this
section.

• Open power unit doors and locate the lift manifold.
• Open the manual lower valve to remove hydraulic

pressure.
Crown 2008 PF17175-5 SP 3500 MA-7535-104
9
SAFETY
Accumulator Lifting and Blocking

The accumulator (hydraulic system shock absorber)
contains a charge of inert gas such as dry nitrogen. Do
not tamper with the gas valve on the accumulator in an WARNING
attempt to reduce the amount of this charge. Use accu- Make sure lifting device and sling are sufficiently rated
mulator charging equipment and procedures as de- to withstand the weight being lifted. Never work under
scribed under Accumulator in Hydraulic Maintenance. or around a truck that is not properly secured. Refer to
truck data plate for truck weight information.


NOTES:
• Hydraulic Jack Capacity: 3620 kg (8000 lb)

• Crown Part Number: 122599
• Collapsed Height Minimum: 60 mm (2.25 in)
• Raised Height Maximum: 400 mm (16.0 in)
• Jack Stand Capacity: 4500 kg (10000 lb)

• Commercially Available.
WARNING
Accumulator
Truck stability decreases dramatically if load wheels
Figure 15726 are raised more than 13 mm (0.5 in). Attach sling and
overhead lifting device to all cross members of the
mast to prevent truck from tipping over when raising
the side of the truck. Make sure lifting device and sling
are sufficiently rated to withstand the weight being
lifted. Never work under or around a truck that is not
properly secured. Refer to truck data plate for truck
weight information.
(a) Accumulator
(b) Gas Valve
(c) Hydraulic Line Connection
Figure 16830-01
MA-7535-105 SP 3500 Crown 2008 PF17175-6
10
SAFETY
SIDE STEER
WHEEL
(a) Load Wheels

(b) Hardwood
Block
Figure 16831-01
(a) Raise platform 70 - 150 mm (3 - 6 in) from floor

(b) Wheel chock both load wheels
(c) Set jack stand height as required - not to exceed
400 mm (16 in). Locate jack stands and jack on
truck skirt.
Figure 16832-01
Crown 2008 PF17175-7 SP 3500 MA-7535-106
11
SAFETY
Mast
Blocking Masts
Use 100 x 100 mm (4.0 x 4.0 in) or bigger hardwood
blocks of the appropriate length for supporting the mast
channels. Block both mast rails of each stage to main-
tain truck stability.
Remove any carriage mounted accessories (i.e., roll
loader, etc.) before blocking masts. These accessories
add significant weight to the mast.

• Chock wheels of truck (refer to Lifting and Blocking

in this section).
• Connect battery.
• Raise forks and position blocks under first stage (a) Clamps
mast of appropriate length. Do not block the first (b) Set Under Platform
stage mast when work at the main frame base is to (c) Set under First Stage
be performed. Set blocks under the platform only,
as described in the following steps. Figure 16833-01
• Using clamps, secure blocks to mast channel.
• Using the manual lowering valve, lower platform

and position appropriate length blocks under plat-
form frame in mast channels.
• Using clamps, secure blocks to mast channel or

first stage block.
• Continue to lower platform until platform frame

rests on blocks.

MA-7535-107 SP 3500 Crown 2008 PF17175-8
12
SAFETY
Cleaning of Material Handling Equipment
Cleaning of Material Handling operation or immediate failure could be the resultant of

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

Degreaser & Cleaner 363105-001 20 oz. Can
363105-012 (12) 20 oz. Cans
All Purpose Cleaner 363114-001 20 oz. Can
363114-012 (12) 20 oz. Cans
Glass Cleaner 363101-001 20 oz. Can
363101-012 (12) 20 oz. Cans
Waterless Hand Cleaner 363111-001 15 oz. Tube
363111-012 (12) 15 oz. Tubes
Pumiced & Smooth Hand Cleaner 363112-001 1 Gallon Jug
363112-004 (4) 1 Gallon Jugs
Wall Mounted Deluxe Soap Dispenser 363122 Used with 363112-001
Tough On Grease 063009-005 1 Gallon Jug
Crown 2000 PF11969-1 Rev. 10/06 SP 3500 MA-1140-050

02 Rev. 10/06
13
Notes:
14
INTRODUCTION
15
Notes:
16
INTRODUCTION
Introduction
Introduction Service Training

This manual is intended for the service technician who Complete Service Training is available to the lift truck
is seeking information about maintenance and service technician covering all Crown Lift Trucks, module sys-
replacement parts. It contains a section on trouble tems, wire guidance, hydraulic and electrical systems.
shooting which will enable a qualified technician to lo- To obtain more information concerning service training,
cate and solve problems which may occur. contact your Crown Dealer or under "Training" on
www.crown.com.
Operator Instructions
Replacement Parts
This manual does not contain operation instructions.
Operator Instructions in tag or booklet form are sent When ordering replacement parts from this manual, al-
with each truck. Additional copies can be ordered if re- ways specify, along with the part number, the model
quired. These booklets are for you and your personnel and serial number of the truck. This information will fur-
to insure years of safe, trouble-free operation of your ther enable us to give correct, fast and efficient service.
Crown Lift Truck. For SP 3500 Series operator instruc-
For current part number of operator manuals, service
tions, refer to Crown publication, "Operator Manual
manuals, operator training programs, truck capacities
SP 3500 Series".
and technical specifications, contact your dealer or at
www.crown.com.
Operator Training This manual is arranged according to major sections
which covers maintenance and replacement parts. The
Crown has available a complete series of operator
sectional descriptions are as follows:
training programs, available through your local Crown
dealer. A complete listing of these and other available
programs can be found under "Training" on
www.crown.com
MAINTENANCE REPLACEMENT PARTS
SECTION DESCRIPTION SECTION DESCRIPTION

M1 Lubrication and Adjustment 1 Power Unit Parts
M2 Hydraulic 2 Hydraulic Parts
M3 Drive Unit 3 Drive Unit Parts
M4 Electrical 4 Electrical Parts
M5 Brake 5 Brake Parts
M6 Steering 6 Steering Parts
M7 Lifting Mechanism 7 Lifting Mechanism Parts
M8 Cylinders 8 Cylinder Parts
M9 Platform 9 Platform Parts
M10 Glossary 10 Labels and Decals
Crown 2007 PF17125-1 SP 3500 ITD-7535-001
17
INTRODUCTION
Introduction
The data plate for the SP 3500 Series truck is located

on the lower right corner, mast side, of the platform and
includes a model number and truck data number. From
these two numbers, you can identify the truck model,
series, series up dates, determine performance, ca-
pacity and specific truck data. The following pages ex-
plain the model & truck data numbering system.
Truck Data Plate
Figure 18273
Model Number Example

Series Update
Significant change(s) to the product
* Capacity
that would not merit a new series
1.0 = 1000 kg (1100 lb) (Lifting Fork Trucks)
number (generation).
1.25 = 1250 kg (1375 lb)
Image Generator
SP - Stockpicker SP3511-1.25
Performance 1.0/1.25
Series
11/12 Single speed raise & two speed lower
Major technical and design changes
making product a new and improved 21/22 Two speed raise & lower
generation. 21/22H Two speed raise & lower, High Lift Only
Example of the model number shown above *Actual rated capacity may vary, depending on special
(SP 3511-1.25) is a SP 3500 Series truck. It is equipment or modifications. Consult capacity plate lo-
equipped with single speed raise & two speed lower, cated on the overhead guard. Refer to Figure 18274.
AC traction motor and 1250 kg (1375 lb) capacity.
ITD-7535-002 SP 3500 Crown 2007 PF17125-2
18
INTRODUCTION
Introduction
Truck Serial Number Plate
Figure 18274
The truck data number provides you and your Crown

dealer with a wealth of information to insure the selec-
tion of proper parts for your Crown truck. You may sim-
ply provide this number to your Crown dealer, or use
the following breakdown if selecting your own part
numbers or service information from this manual.
An example of a truck data number shown is a stand-
ard truck with telescopic triple stage mast, 4955 mm
(195 in) lift height, straddle width of 1067 mm (42 in),
no rail guidance, with freezer condition, non-marking
drive tire, platform width of 1067 mm (42 in), with fork
orverride switch, zone select switch, work light, dome
light, fan and spot light. Refer to Figure 18273.
Crown 2007 PF17125-3 SP 3500 ITD-7535-003
19
INTRODUCTION
Introduction
Truck Data Number Example
Drive Tires
Wire Guidance CG = Center Groove Switch Panel
- = No Wire Guidance DS = Diagonal Siped 1 = Standard
W = Wire Guidance PP = Poly, Black 30l 2 = Lift/Lower Limit Override
40 = Poly, Cream 40 3 = Lift/Lower Limit Override, Zone
RS = Razor Siped Select
NM = Poly, Non Marking 4 = Work Light, Dome Light, Fan
Straddle Width ** = Special 5 = Lift/Lower Limit Override, Work
42 = 1067 mm (42 in) Light, Dome Light, Fan
1067 mm (42 in) thru 6 = Lift/Lower Limit Override, Zone
1830 mm (72 in) in 25 mm Select, Work Light, Dome Light, Fan
(1.0 in) increments 7 = Work Light, Dome Light, Fan,
Spotlight
Mast Type 8 = Lift/Lower Limit Override, Work
TT = Telescopic Triple Stage Light, Dome Light, Fan, Spotlight
TL = Telescopic Limited Free Lift 9 = Lift/Lower Limit Override, Zone
Select, Work Light, Dome Light, Fan,
Spotlight
- TT 195 42 ----- - F PP 42 9 C
Application
Standard/Custom/Special
- = Standard
- = Standard
1 = EAC
C = Custom
S = Special
Platform Width
Lift Height 42 = 1065 mm (42 in)
1.0 TL Mast 1.25 TL Mast 48 = 1220 mm (48 in)
4216 mm (166 in) 3455 mm (136 in)
54 = 1370 mm (54 in)
60 = 1525 mm (60 in)
4521 mm (178 in) 3760 mm (148 in)
64 = 1625 mm (64 in)
5131 mm (202 in) 4370 mm (172 in)
5690 mm (224 in) 4930 mm (194 in) Cold Conditioning
6198 mm (244 in) 5435 mm (214 in) - = No Cold Conditioning/Wire Mesh Windshield
1.0 TT Mast 1.25 TT Mast C = Corrosion Conditioning/Wire Mesh Windshield
5715 mm (225 in) 4953 mm (195 in) F = Freezer Conditioning/Wire Mesh Windshield
6096 mm (240 in) 5334 mm (210 in)
6858 mm (270 in) 6096 mm (240 in) Aisle Guide Wheel Width
7772 mm (306 in) 7010 mm (276 in)
Display Aisle Guide Wheel Width i.e.
48.75 = 48.75 in
8230 mm (324 in) 7467 mm (294 in)
----- = No Rail Guidance
8687 mm (342 in) 7925 mm (312 in) ***** = Special Aisle Guide
9144 mm (360 in) 8382 mm (330 in)
9601 mm (378 in) 8840 mm (348 in)
9296 mm (366 in)
ITD-7535-004 SP 3500 Crown 2007 PF17125-4
20
LUBRICATION & ADJUSTMENT
21
Notes:
22
Lubrication and Adjustment
Lubrication and Adjustment Before performing maintenance to any unit, it should

be taken to an area set aside for maintenance or a sec-
To obtain maximum life of any industrial equipment, a tion where there is adequate space to perform required
well planned maintenance program (PM), performed work. This is a must to insure the safety of others and
by qualified technical personnel should be followed. In to insure that proper maintenance is performed to the
conjunction with, and an integral part of, any planned unit.
maintenance program should be daily operator input.
If desired, padded packs of this checklist (OF-3772)
Operator involvement can greatly reduce truck down
are available through your Crown dealer.
time, assist in determining planned maintenance (PM)
schedules and ultimately save money. For these rea-
sons, Crown recommends a checklist similar to the Op-
erators Daily Checklist shown below.
Figure 14990
Crown 1987 PF7886-1 Rev. 6/08 SP 3500 M1.0-04.0-001

17 Rev. 6/08
23
The following is a list of lubricants and maintenance

products recommended when doing Planned Mainte-
nance on Crown Lift Trucks.
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity

363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB(1) Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
C Oil (SAE 40)
363500-001 1 Quart
CC Engine Oil (10W30)
363500-012 (12) 1 Quart
363504-101 1 Gallon
D Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD(1) Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon
DDD Hydraulic Oil - DTE24 063001-021 1 Gallon
063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
063002-039 1 lb
I Grease (Lift Pump Coupling)
127801S 1 oz
063004-002 12 oz
J Brake Fluid - Dot 5
063004-003 1 Gallon
(1) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
M1.0-04.0-002 SP 3500 Crown 1987 PF7886-2 Rev. 6/08
17 Rev. 6/08
24

063002-034 14.5 oz Cartridge
K Grease (Wheel Bearing)
063002-045 (40) 14.5 oz Cartridges
L Metal Assembly Spray 063002-021 11 oz Spray
M Silicone Grease (Clear) 063002-020 5.3 oz Tube
363102-001 14 oz Can
Brake & Parts Cleaner
363102-012 (12) 14 oz Cans
363103-001 14 oz Can
N Low VOC Brake & Parts Cleaner
363103-012 (12) 14 oz Cans
363116-001 19 oz Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 19 oz Cans
363104-001 20 oz Can
O Penetrating Lubricant
363104-012 (12) 20 oz Cans
363108-001 11 oz Can
P Premium Formula Multi-Purpose Grease
363108-012 (12) 11 oz Cans
363110-001 11 oz Can
Q White Lithium Grease
363110-012 (12) 11 oz Cans
363109-001 15 oz Can
R Choke & Carburetor Cleaner
363109-012 (12) 16 oz Cans
363106-001 10 oz Can
Contact Cleaner - Non-Flammable
363106-012 (12) 10 oz Cans
S
363128-001 11 oz Can
Contact Cleaner
363128-012 (12) 11 oz Cans
T Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc
363124-001 18 oz Can
U Battery Cleaner
363124-012 (12) 18 oz Cans
363125-001 15 oz Can
V Battery Protector
363125-012 (12) 15 oz Cans
363127-001 12 oz Can
W Food Grade Machine Lubricant
363127-012 (12) 12 oz Cans
363126-001 11 oz Can
X Food Grade Silicone Spray
363126-012 (12) 11 oz Cans
363509-101 1 Gallon
Coolant
363509-106 (6) 1 Gallon
Y
363511-101 1 Gallon
Extended Life Coolant
363511-106 (6) 1 Gallon
Crown 1987 PF7886-3 Rev. 6/08 SP 3500 M1.0-04.0-003

17 Rev. 6/08
25
Alternate Lubricants & Fluids Chart
Manufacturer
Type of Lubricant Product Name
/ Distributor
A Gear Lube 80W-90 (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
Mobilgrease XHP 222 Special Mobil
Union Unoba EP No 2 Union 76 Co.
B Grease (Multi-Purpose) Retinax A(1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease (Low Temp) (2) Alvania RA(1) Shell
Helveum O(1) Burmah Castrol
BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
C Oil (SAE 40)
D Hydraulic Oil Crown Crown
DD Hydraulic Oil (Low Temp) (2) Crown Crown
DDD Hydraulic Oil - DTE24 (3) Mobil DTE 24 Mobil

E Channel Grease Factran #2 Standard Oil Co.
F Gear, Channel & Shaft Grease Molykote BR-2 Plus Dow Corning
Chain & Cable Lube Crown Crown
G
Premium Chain & Cable Lube Crown Crown
H Final Finish - Rubber & Vinyl Dressing Crown Crown
I Grease (Lift Pump Coupling) Nyogel 774F-MS NYE Lubricants
J Brake Fluid - Dot 5 Q2-1141 Silicon Brake Fluid Dow Corning
K Grease (Wheel Bearing) Unirex EP-2 Exxon
Lubriplate No. 1242(1) Fiske Bros. Refining Co.
L Metal Assembly Spray Dow Corning Dow Corning
M Silicon Grease (Clear) Dow Corning 111 Compound Dow Corning
Brake & Parts Cleaner Crown Crown
N Low VOC Brake & Parts Cleaner Crown Crown
Non-Flammable Brake & Parts Cleaner Crown Crown
(1) Denotes allowable substitutes, contact factory if unavailable.
(3) Premium antiwear hydraulic oil used in blending with low temp oil.
M1.0-04.0-004 SP 3500 Crown 1987 PF7886-4 Rev. 6/08
17 Rev. 6/08
26
Manufacturer
/ Distributor
O Penetrating Lubricant Crown Crown
P Premium Formula Multi-Purpose Grease Crown Crown
Q White Lithium Grease Crown Crown
R Choke & Carburetor Cleaner Crown Crown
S Contact Cleaner Crown Crown
Electrical Connector Oxidation &
T Nye Grease NYE Lubricants
Corrosion Inhibitor
U Battery Cleaner Crown Crown
V Battery Protector Crown Crown
W Food Grade Machinery Lubricant Crown Crown
X Food Grade Silicone Spray Crown Crown
Y Extended Life Coolant
Crown 1987 PF7886-5 Rev. 6/08 SP 3500 M1.0-04.0-005

17 Rev. 6/08
27
Notes:
28
Lubrication and Adjustment fications may be used. (Refer to Lubrication Identifica-

tion Chart in Lubrication and Adjustment).
WARNING On trucks equipped to operate in below freezing tem-
peratures, low temperature hydraulic oil must be used.
Wear appropriate items, such as safety glasses and
steel-toe shoes whenever performing maintenance
work. Do not place fingers, hands or arms through Component Accessibility
mast or position them at pinch points.
For regular maintenance, access to various truck com-
In this section you may be required to lift and block the
ponents is accomplished by removing covers, panels
truck and mast or raise and lower different components
and/or doors. The following is a general explanation of
for removal and installation. Make sure lifting device
what cover, panel, etc. must be removed to allow for
and sling are sufficiently rated to withstand the weight
the most efficient access when performing service and/
being lifted. Never work under or around a truck that is
or maintenance to components. Refer to figures in this
not properly secured. Refer to truck Data Plate for truck
section as an aid in locating parts that require attention.
weight information.
More details are given in following sections on hydrau-
It will be necessary to disconnect and remove the bat-
lics, electrical, brakes, etc.
tery from the truck, disconnect tilt cylinders from the
mast, disconnect electrical connections and hydraulic Top cover can be opened to allow access to battery
lines. "Control of Hazardous Energy" section provides connector, battery cell caps, check battery condition,
information for performing the above procedures along strobe light, and additional mechanical and electrical
with some additional information on other procedures components.
dealing with truck maintenance. This section should be
Battery side covers can be removed to service and/or
read and reviewed prior to mast removal, installation
remove battery.
and maintenance as outlined in this section.
Power unit doors can be opened to allow access to the
following: drive unit, traction panel, lift/power panel,
General drive motor, electric brake and related components,
Before performing maintenance to the truck, move steer motor/encoder and related components, lift
truck to an area set aside for maintenance or where pump(s) and motor(s), hydraulic reservoir, filter,
there is adequate space to perform required work. This strainer and related components.
is a must to ensure safety of others and to ensure Located under platform are horn, pallet grab, fork pins
proper maintenance is performed. and associated parts.
Console on platform, when removed, will allow access
WARNING to side-gate switches, steering command encoder, dis-
play panel, platform distribution panel, vehicle control
Be sure battery connectors are disconnected and all module and associated platform electrical wiring.
wheels are chocked before proceeding.
Located on front side of platform are chain slack
To obtain maximum life of any industrial equipment, a switches, pallet grab linkage and limit switch(es).
well planned maintenance program should be fol-
Control module must be removed to gain access to di-
lowed. The following information is intended to provide
rectional and lift switches, various control switches and
guidelines for proper lubrication intervals; this is ac-
linkages.
cording to hours of truck operation and/or a specific
number of days or months. This section should be used Refer to figures and charts in this section as a guide for
as an aid in maintaining safe and efficient truck opera- inspection and adjustment that may be necessary. This
tion. Some operating conditions will require more fre- information used with a Planned Maintenance Inspec-
quent checks and lubrication than listed. Applications tion Report for Stock pickers available from your Crown
with much dust or moisture will require modification of dealer will be very helpful to a good maintenance pro-
the schedule to fit that particular application. gram.
Only high grade lubricants and fluids should be used.
Sources of these lubricants may be from almost any of
the oil companies; any lubricant with equivalent speci-
Crown 2007 PF17167-1 SP 3500 M1.0-7535-001
29
Figure 18472
M1.0-7535-002 SP 3500 Crown 2007 PF17167-2
30
Chart 1 - Lubrication Chart
Lube 60 days 90 days 6 months 12 months

Index Component Quantity
Type 250 hr 500 hr 1000 hr 2000 hr
L-1 Brake Pedal Guides C (1) (2)
L-2 Platform Gates C (1) (2)
L-3 Battery Cover Hinge C (1) (3)
L-4 Power Unit Door Hinges C (1) (2)
L-5 Battery Rollers B (1) (3)
L-6 Battery Restraint Threads B (1) (2)
L-7 Aisle Guide Wheels B (1) (3)
L-8 Load Wheel Axles B (1) (3)
(1) As Required
(2) Check
(3) Lubricate
See Lubrication Identification Chart in Lubrication and Adjustment for Lube Type explanation and
capacity.
See Figure 18472 for Lubrication locations.
Chart 2 - Inspection and Adjustment Chart
60 days 90 days 6 months 12 months

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-1 Brake Pedal Switch (1)
I-2 Brake Pedal Mechanism (1)
I-3 Platform Gates and Switches (1)
I-4 Load Wheels (1)
I-5 Aisle Guide Wheels and Switches (1)
I-6 Skids (1)
I-7 Aisle Guide Skids (1)
(1) Inspect, Clean and/or Adjust. See Figure 18472 for component locations.
Refer to appropriate section of service manual for additional information concerning inspection and/or
adjustment.
Crown 2007 PF17167-3 SP 3500 M1.0-7535-003
31
Figure 18473
M1.0-7535-004 SP 3500 Crown 2007 PF17167-4
32

Type 250 hr 500 hr 1000 hr 2000 hr
Mast, Channels, Column
L-9 E (1) (2)
Rollers
L-19 Platform Gates H (1) (2)
(1) As Required
(2) Check
capacity.

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-8 Battery Connector (1)
I-9 Battery (1)
I-10 Strobe Light/Flashing Light (1)
I-11 Lift Cylinders and Restraints (1)
I-12 Column Rollers - Mast (1)
I-13 Column Rollers - Platform (1)
I-14 Operator Harness (1)
I-15 Forks (1)
I-16 Motor Brushes - Lift (1)
I-17 Motor Brushes - Power Steering (1)
I-18 Hydraulic Lines, Fittings, Hoses (1)
I-19 Power Unit to Mast Bolts (1)
adjustment.
Crown 2007 PF17167-5 SP 3500 M1.0-7535-005
33
TT
Mast
Shown
Figure 18474
M1.0-7535-006 SP 3500 Crown 2007 PF17167-6
34

Type 250 hr 500 hr 1000 hr 2000 hr
L-10 Lift Chain G (1) (2)
L-11 Pallet Grab Linkage C (1) (2)
(1) As Required
(2) Check
capacity.

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-20 Lift Chains (1)
I-21 Chain Anchors and Retainers (1)
I-22 Chain Slack Linkage (1)
I-23 Brake Friction Plates and Operation (1)
I-24 Pallet Grab Linkage and Operation (1)
I-25 Horn (1)
I-26 Height Sensor Contacts (1)
I-27 Steering Encoder (1)
I-28 Access 4 (VCM) (1)
adjustment.
Crown 2007 PF17167-7 SP 3500 M1.0-7535-007
35
Freezer/Corrosion
Distribution Panel
(Optional)
Figure 18475
M1.0-7535-008 SP 3500 Crown 2007 PF17167-8
36

Type 250 hr 500 hr 1000 hr 2000 hr
L-12 Steering Gearbox Oil Level DDD (1) 1 liter (1 qt) (2) (2)
L-13 Steering Gears F (3) (4)
L-14 Hydraulic Filter (4) (2) (2)
Hydraulic Reservoir - Single

L-15 D 13.2 liter (14 qt) (4) (2)
Pump
Hydraulic Reservoir - Dual Pump D 17.5 liter (18.5 qt) (4) (2)
L-16 Hydraulic Strainer (2)
L-17 Drive Unit Thrust Bearing B (3) (5)
L-18 Drive Unit Fluid Level A 0.7 liter (0.75 qt) (4) (2)
(1) Use “DDD” (see Lubrication and Adjustment) hydraulic oil in steering gearbox for both normal and low
temperature applications.
(2) Change; for L-12 and L-14, change first time only as noted, thereafter check at 250 hr/60 day intervals
and change at longer interval as noted.
(3) As Required
(4) Check
(5) Lubricate
capacity.

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-29 Contactor Tips (1)
I-30 Steering Gears and Sprockets (1)
I-31 Chain Slack Switch (1)
I-32 Stop Blocks (1)
I-33 Drive Tire (1)
I-34 All Electrical Termination Points (1)
adjustment.
Crown 2007 PF17167-9 SP 3500 M1.0-7535-009
37
(a) Multiple option cables shown

(b) Specific options require
additional cables, only two
cables on standard truck
Figure 18476
M1.0-7535-010 SP 3500 Crown 2007 PF17167-10
38

Type 250 hr 500 hr 1000 hr 2000 hr
Control Cables and Pulleys
L-20 H (1) (2)
(Plastic)
(1) As Required
(2) Check
capacity.

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-35 Travel and Lift Controls (1)
I-36 Power Disconnect (1)
I-37 Panel Indicator Lights (1)
I-38 Panel Switches (1)
I-39 Cable Tension Devices (1)
I-40 Control Cables and Guides (1)
I-41 Mast Cushion Mechanisms (1)
I-42 Tow Switch (1)
I-43 Overhead Console Lights (1)
I-44 Overhead Console Fan (1)
adjustment.
Crown 2007 PF17167-11 SP 3500 M1.0-7535-011
39
Notes:
40
Skid Inspection
Skid Inspection
On trucks equipped without aisle guide wheels, skids
are located in the lower left and right corner of the
power unit skirt.
(1) Floor
(1) Power Unit Skirt
(2) Skid
(2) Skid
(4) 25.4 mm (1.0 in) Maximum Allowable Distance
Figure 17019
On trucks equipped with aisle guide wheels; skids are Figure 17021
mounted on the bottom of the front (power unit end)
aisle guide wheel supports. If measurement exceeds 25.4 mm (1.0 in), replace
skids.
(1) Skid
(3) Aisle Guide Wheels
Figure 17020
CAUTION
These skids are used to maintain truck stability and
should be periodically inspected.
Check to be sure skid mounting bolts are secure.
Torque to 162.5 Nm ± 13.5 Nm (120 ft lb ± 10 ft lb).
Measure the distance from the bottom of skid to level
floor. The maximum allowable distance from skid to
level floor is 25.4 mm (1.0 in).
Crown 1994 PF10332-1 Rev. 7/07 SP 3500 M1.5-7330-001

02 Rev. 7/07
41
Notes:
42
Metric Torque Values

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

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

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

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all of its bolted
assemblies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener
is replaced that is unmarked, replace the fastener with a class 8.8.
Figure 15048
Crown 1989 PF8514-1 Rev. 10/06 SP 3500 M1.9-06.6-001

01 Rev. 10/06
43
Metric Torque Chart
Class 8.8 Class 10.9

Bolt Dry Torque Requirement Dry Torque Requirement
Diameter
kgm Nm ft lb kgm Nm ft lb
M6 1.2 ±.4 12 ±4 9 ±3 1.8±.5 17.5 ±5.5 13 ±4
M8 2.5 ±.7 24.5±7 18 ±5 3.5 ±.7 34 ±7 25 ±5
M10 4.4 ±.7 43.5 ±7 32 ±5 6.6 ±1.3 65 ±13.5 48 ±10
M12 10.4 ±1.4 101.5 ±13.5 75 ±10 15.5 ±2.0 152 ±20.5 112 ±15
M14 15.2 ±2.0 149 ±20.5 110 ±15 22.5 ±3.0 221 ±27 163 ±20
M16 20.7 ±2.8 203.5 ±27 150 ±20 31.1 ±4.1 305 ±41 225 ±30
M20 36.6 ±408 359 ±47.5 265 ±35 55.2 ±6.9 542 ±68 400 ±50
M22 58.1 ±8.3 569 ±81 420 ±60 88.3 ±11.0 868 ±108 640 ±80
M24 88.5 ±11.1 868 ±109 640 ±80 132.5 ±15.9 1300 ±156 960 ±115
M27 110.6 ±13.8 1085 ±136 800 ±100
M30 138 ±16.6 1356 ±163 1000 ±120
M36 166 ±20.7 1630 ±203 1200 ±150
M39 207 ±27.7 2034 ±271 1500 ±200
Mounting Bolt Torque requirements
involving hydraulic valves.
M8 1.8 ±.3 17.5 ±2.5 13 ±2
M10 3.3 ±.3 3205 ±2.5 24 ±2
NOTE: Torque values called out in the maintenance section of this manual will take precedence
over torque values found on this page.
M1.9-06.6-002 SP 3500 Crown 1989 PF8514-2 Rev. 10/06
01 Rev. 10/06
44
Torque Values
Torque Values
All Crown Trucks are manufactured with Grade 5 or
on your lift truck.
Grade

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

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

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted
assemblies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is
replaced that is unmarked, replace the fastener with a Grade 5.
Figure 14916
Crown 1979 PF5067-1 Rev. 9/06 SP 3500 M1.9-14.0-001

04 Rev. 9/06
45
Torque Values
Torque Chart
Bolt Grade 5 Grade 8

Diameter Dry Torque Requirement Dry Torque Requirement
in ft Ib kgm Nm ft lb kgm Nm
1/4 9±3 1.2 ± .4 12 ± 4 13 ± 4 1.8 ± .5 17.5 ± 5.5
5/16 18 ± 5 2.5 ± .7 24.5 ± 7 25 ± 5 3.5 ± .7 34 ± 7
3/8 32 ± 5 4.4 ± .7 43.5 ± 7 48 ± 10 6.6 ± 1.3 65 ± 13.5
7/16 50 ± 10 6.9 ± 1.4 67.5 ± 13.5 75 ± 10 10.4 ± 1.4 102 ± 13.5
1/2 75 ± 10 10.4 ± 1.4 101.5 ± 13.5 112 ± 15 15.5 ± 2.0 152 ± 20.5
9/16 110 ± 15 15.2 ± 2.0 149 ± 20.5 163 ± 20 22.5 ± 3.0 221 ± 27
5/8 150 ± 20 20.7 ± 2.8 203.5 ± 27 225 ± 30 31.1 ± 4.1 305 ± 41
3/4 265 ± 35 36.6 ± 4.8 359 ± 47.5 400 ± 50 55.2 ± 6.9 542 ± 68
7/8 420 ± 60 58.1 ± 8.3 569 ± 81 640 ± 80 88.3 ± 11.0 868 ± 108
1 640 ± 80 88.5 ± 11.1 868 ± 109 960 ± 115 132.5 ± 15.9 1300 ± 156
1 1/8 800 ± 100 110.6 ± 13.8 1085 ± 136
1 1/4 1000 ± 120 138 ± 16.6 1356 ± 163
1 3/8 1200 ± 150 166 ± 20.7 1630 ± 203
1 1/2 1500 ± 200 207 ± 27.7 2034 ± 271
Mounting bolt torque requirements in-
volving hydraulic valves.
5/16 13 ± 2 1.8 ± .3 17.5 ± 2.5

3/8 24 ± 2 3.3 ± .3 32.5 ± 2.5
7/16 39 ± 2 5.4 ± .3 53 ± 2.5
NOTE:Torque values called out in the maintenance section of this manual will take prece-
dence over torque values found on this page.
M1.9-14.0-002 SP 3500 Crown 1979 PF5067-2 Rev. 9/06
04 Rev. 9/06
46
HYDRAULIC SYSTEM
47
Notes:
48
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic System
The hydraulic system in your truck is powered by gear
type pumps. These pumps, P1 & P2, supply oil flow for
lift and accessory functions.
Maximum pressure is limited by an adjustable relief
valve, RV1 (refer to Lift/Lower Manifold & Control
Valve). The setting for RV1 is noted on hydraulic sche-
matics. Refer to Componentry for pump, valve and
manifold information.
Figure 18196 shows hydraulic component location in
power unit.
Crown 2007 PF17165-1 SP 3500 M2.0-7535-001
49
HYDRAULIC SYSTEM
Hydraulic System
One Speed Lift Two Speed Lift
(a) Test Point (e) Reservoir

(b) Lift/Lower Manifold (f) Strainer
(c) Sight Gauge (g) Accumulator
(d) Filter
Figure 18196
M2.0-7535-002 SP 3500 Crown 2007 PF17165-2
50
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic Circuits Relief Valve Operation

During lift function, relief valve RV1 monitors hydraulic
These pages contain a brief description of hydraulic cir-
pressure. If oil pressure exceeds relief pressure set-
cuits for SP trucks which are typical of current standard
ting, relief valve is forced open, allowing pressurized oil
units. Your unit may vary. Refer to Hydraulic Schematic
to bypass lift circuit. From relief valve, oil exits from
for appropriate schematic.
manifold block through port T1. From port T1, oil
passes through return line filter then back to reservoir.
Lift Circuit - One Speed Lift
When lift is selected, oil is drawn from hydraulic reser- Accumulator Operation
voir to hydraulic pump P1. P1 supplies pressurized oil Accumulator is used as a shock absorber for lift/lower
to lift/lower manifold block. Oil enters manifold block hydraulic system. If platform is stopped suddenly,
through port P1 and goes directly to check valve CV2. change in oil flow exerts pressure on hydraulic system.
Oil passes through manifold block until it exits port C1. Accumulator absorbs this oil pressure change by using
Pressurized oil enters lift cylinders and begins to ex- gas pressurized bladder located within accumulator.
tend mast. Bladder acts as a pillow to pressurized oil, cushioning
applied pressure within hydraulic circuit. The typical
symptom of a bad or de-pressurized accumulator is
abrupt starting and stopping of platform during lift or
lower.
(a) Accumulator 3.45 MPa (500 psi) Pre-charge (f) Filter

(b) Lift/Lower Manifold (g) Mast Cylinder
(c) Pump and Motor (h) Free Lift Cylinder
(d) Reservoir (i) Velocity Fuse
(e) Strainer (j) TT Mast
(k) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
Figure 18197
Crown 2007 PF17165-3 SP 3500 M2.0-7535-003
51
HYDRAULIC SYSTEM
Hydraulic System
Lift Circuit - Two Speed Lift Relief Valve Operation

Low Speed Lift pressure. Oil pressure exceeding relief pressure set-
When lift button is depressed to first detent, oil is drawn ting will force RV1 open, allowing pressurized oil to by-
from hydraulic reservoir to hydraulic pump P1. Hydrau- pass lift circuit. Oil exits manifold block through port T1.
lic pump supplies pressurized oil to lift/lower manifold From port T1, oil passes through return line filter then
block. Oil enters manifold block through port P1 and back to reservoir.
goes directly to check valve CV1. Oil passes through
manifold block until it exits port C1. Pressurized oil en- Accumulator Operation
ters lift cylinders and begins to extend mast. Accumulator is used as a shock absorber for lift/lower
hydraulic system. If platform is stopped suddenly,
High Speed Lift change in oil flow exerts pressure on hydraulic system.
When lift button is completely depressed, pump P2 Accumulator absorbs this oil pressure change by using
turns on simultaneously with pump P1. Hydraulic pump gas pressurized bladder located within accumulator.
P2 supplies pressurized oil to lift/lower manifold block. Bladder acts as a pillow to pressurized oil, cushioning
Oil enters manifold block through port P2 and goes di- applied pressure within hydraulic circuit. The typical
rectly to check valve CV3. This oil passes through symptom of a bad or de-pressurized accumulator is
manifold block where it joins oil supplied from pump P1 abrupt starting and stopping of platform during lift or
out to lift cylinders. lower.

(k) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
Figure 18198
M2.0-7535-004 SP 3500 Crown 2007 PF17165-4
52
HYDRAULIC SYSTEM
Hydraulic System
Lower Circuit - One Speed/Two Speed Lower

Lower When lower button is depressed, oil exits lift cylinders
When lower is selected, oil begins to exit lift cylinder. and enters lift/lower manifold block through port C1. Oil
Oil leaving cylinder is monitored by internal velocity passes through open envelope (envelope without a
fuse in each cylinder. check valve) of proportional solenoid valve PVL, which
is in energized position. Oil is directed from PVL to
Velocity fuses are designed to prevent sudden release pressure compensator valve PCL. PCL limits maxi-
of hydraulic oil from cylinder under a condition such as mum oil rate. Once oil exits PCL, it is directed out of
a line rupture. If a cylinder line ruptures, oil exiting cyl- manifold through port T1. From port T1, oil enters re-
inder would create pressure on velocity fuse, forcing turn line filter then back to reservoir.
fuse to close. This will block oil from exiting cylinder.
A partially opened proportional valve performs slow
speed lowering. High speed lowering is accomplished
by completely opening proportional valve.
One Speed Lower

(k) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
Figure 18199
Crown 2007 PF17165-5 SP 3500 M2.0-7535-005
53
HYDRAULIC SYSTEM
Hydraulic System
Two Speed Lower

(k) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
Figure 18200
M2.0-7535-006 SP 3500 Crown 2007 PF17165-6
54
HYDRAULIC SYSTEM
Hydraulic System
Manual Lower Circuits is directed to manual lowering valve's open envelope

(envelope without check valve). Oil exits manifold
Manual lowering feature is used to lower mast during through port T1. From port T1, oil enters return line fil-
truck down situations. Manual lowering valve MVL is ter then back to reservoir.
located on lift/lower manifold block. When MVL is actu-
ated, oil trapped in cylinder is released. Oil enters lift/ Manual Lower - One Speed Lift/Lower
lower manifold through port C1. From port C1, oil flow

(k) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
Figure 18201
Crown 2007 PF17165-7 SP 3500 M2.0-7535-007
55
HYDRAULIC SYSTEM
Hydraulic System
Manual Lower - Two Speed Lift/Lower

(k) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
Figure 18202
Hydraulic System
The hydraulic system in your truck is powered by gear
type pumps. These pumps, P1 & P2, supply oil flow for
lift and accessory functions.
valve, RV1 (refer to Lift/Lower Manifold & Control
Valve). The setting for RV1 is noted on hydraulic sche-
matics. Refer to Componentry for pump, valve and
manifold information.
Figure 18483 shows hydraulic component location in
power unit.
M2.0-7535-008 SP 3500 Crown 2007 PF17165-8
56
HYDRAULIC SYSTEM
Hydraulic System
One Speed Lift with Lifting Fork Two Speed Lift with Lifting Fork
(a) Lift/Lower Manifold (d) Reservoir

(b) Sight Gauge (fe Strainer
(c) Filter (f) Accumulator
Figure 18483
Crown 2007 PF17165-9 SP 3500 M2.0-7535-009
57
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic Circuits
These pages contain a brief description of hydraulic cir-
cuits for SP trucks which are typical of current standard
units. Your unit may vary. Refer to Hydraulic Schematic
for appropriate schematic.
Lift Circuit - One Speed Lift

When lift is selected, oil is drawn from hydraulic reser-
voir to hydraulic pump P1. P1 supplies pressurized oil
to lift/lower manifold block. Oil enters manifold block
through port P1 and goes directly to check valve CV2.
Oil passes through manifold block until it exits port C1.
Pressurized oil enters lift cylinders and begins to ex-
tend mast.
Lifting Fork Lift Circuit

Depressing both lifting fork raise buttons starts lift
pump and energizes solenoid valve SV1. Energizing
SV1 opens a path for oil flow to lifting fork cylinder and
PVLF blocks path for oil flow to reservoir. Lift pump
draws oil from reservoir through a filter. Pressurized oil
then flows through energized solenoid valve SV1.
Pressurized oil exits port F to flow control valve, unre-
stricted, into lifting fork cylinder.
Relief Valve Operation

pressure. If oil pressure exceeds relief pressure set-
ting, relief valve is forced open, allowing pressurized oil
to bypass lift circuit. From relief valve, oil exits from
manifold block through port T1. From port T1, oil
passes through return line filter then back to reservoir.
Accumulator Operation
Accumulator is used as a shock absorber for lift/lower
hydraulic system. If platform is stopped suddenly, the
change in oil flow exerts pressure on hydraulic system.
Accumulator absorbs this oil pressure change by using
a gas pressurized bladder located within accumulator.
Bladder acts as a pillow to pressurized oil, cushioning
lower.
M2.0-7535-010 SP 3500 Crown 2007 PF17165-10
58
HYDRAULIC SYSTEM
Hydraulic System
Main Lift - One Speed Lift with Lifting Fork
(a) Accumulator 3.45 MPa (500 psi) Pre-charge (h) Free Lift Cylinder
(b) Lift/Lower Manifold (i) Velocity Fuse
(c) Pump and Motor (j) TT Mast
(d) Reservoir (k) Lifting Fork Cylinder
(e) Strainer (l) Flow Control Valve
(f) Filter (m) RV1 Setting:
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
(g) Mast Cylinder (n) RV2 Setting:
TL 14.48 to 14.65 MPa (2100 to 2125 psi)
TT 14.48 to 14.65 MPa (2100 to 2125 psi)
Figure 18484
Crown 2007 PF17165-11 SP 3500 M2.0-7535-011
59
HYDRAULIC SYSTEM
Hydraulic System
One Speed Lift with Lifting Fork
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
TL 14.48 to 14.65 MPa (2100 to 2125 psi)
TT 14.48 to 14.65 MPa (2100 to 2125 psi)
Figure 18485
M2.0-7535-012 SP 3500 Crown 2007 PF17165-12
60
HYDRAULIC SYSTEM
Hydraulic System
Lift Circuit - Two Speed Lift W/Lifting Forks
Low Speed Lift

When lift button is depressed to first detent, oil is drawn
from hydraulic reservoir to hydraulic pump P1. Hydrau-
lic pump supplies pressurized oil to lift/lower manifold
block. Oil enters manifold block through port P1 and
goes directly to check valve CV1 and CV3. Oil passes
through manifold block until it exits port C1. Pressu-
rized oil enters lift cylinders and begins to extend mast.
High Speed Lift

When lift button is completely depressed, pump P2
turns on simultaneously with pump P1. Hydraulic pump
P2 supplies pressurized oil to lift/lower manifold block.
Oil enters manifold block through port P2 and goes di-
rectly to check valve CV3 and CV1. This oil passes
through manifold block where it joins oil supplied from
pump P1 out to lift cylinders.
Relief Valve Operation

pressure. Oil pressure exceeding relief pressure set-
ting will force RV1 open, allowing pressurized oil to by-
pass lift circuit. Oil exits manifold block through port T1.
From port T1, oil passes through return line filter then
back to reservoir.
Accumulator Operation
Accumulator is used as a shock absorber for lift/lower
hydraulic system. If platform is stopped suddenly, the
change in oil flow exerts pressure on hydraulic system.
Accumulator absorbs this oil pressure change by using
gas pressurized bladder located within accumulator.
Bladder acts as a pillow to pressurized oil, cushioning
lower.
Crown 2007 PF17165-13 SP 3500 M2.0-7535-013
61
HYDRAULIC SYSTEM
Hydraulic System
Two Speed Lift with Lifting Fork
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
TL 14.48 to 14.65 MPa (2100 to 2125 psi)
TT 14.48 to 14.65 MPa (2100 to 2125 psi)
Figure 18486
M2.0-7535-014 SP 3500 Crown 2007 PF17165-14
62
HYDRAULIC SYSTEM
Hydraulic System
Lower Circuit - One Speed/Two Speed

Lower
When lower is selected, oil begins to exit lift cylinder.
Oil leaving cylinder is monitored by internal velocity
fuse in each cylinder.
Velocity fuses are designed to prevent sudden release
of hydraulic oil from cylinder under a condition such as
a line rupture. If a cylinder line ruptures, oil exiting cyl-
inder would create pressure on velocity fuse, forcing
fuse to close. This will block oil from exiting cylinder.
Lower
When lower button is depressed, oil exits lift cylinders
and enters lift/lower manifold block through port C1. Oil
passes through open envelope (envelope without a
check valve) of proportional solenoid valve PVL which
is in the energized position. Oil is directed from PVL to
pressure compensator valve PCL. PCL limits maxi-
mum oil rate. Once oil exits PCL, it is directed out of
manifold through port T1. From port T1, oil enters re-
turn line filter then back to reservoir.
A partially opened proportional valve performs slow
speed lowering. High speed lowering is accomplished
by completely opening proportional valve.
Crown 2007 PF17165-15 SP 3500 M2.0-7535-015
63
HYDRAULIC SYSTEM
Hydraulic System
One Speed Lower with Lifting Fork
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
TL 14.48 to 14.65 MPa (2100 to 2125 psi)
TT 14.48 to 14.65 MPa (2100 to 2125 psi)
Figure 18487
M2.0-7535-016 SP 3500 Crown 2007 PF17165-16
64
HYDRAULIC SYSTEM
Hydraulic System
Two Speed Lower with Lifting Fork
TL 19.20 to 19.37 MPa (2785 to 2810 psi)
TT 19.20 to 19.37 MPa (2785 to 2810 psi)
TL 14.48 to 14.65 MPa (2100 to 2125 psi)
TT 14.48 to 14.65 MPa (2100 to 2125 psi)
Figure 18488
Crown 2007 PF17165-17 SP 3500 M2.0-7535-017
65
HYDRAULIC SYSTEM
Hydraulic System
Reservoir 1. Blow air through all hoses and lines to remove

loose particles before installing. Any rubber hose
With all cylinders in retracted position and after all air with wire braid inner construction, and any steel
has been bled from hydraulic system, fill reservoir so oil tube lines which have been collapsed or kinked are
level is at high mark on reservoir sight gauge (Figure permanently damaged and must be replaced even
17175). Total capacity of hydraulic system at this level if damage is not externally visible.
should be approximately 13 litres (3.5 gallons) for
2. Flexible hose must be replaced if it collapses in
trucks with one speed lift, and 17 litres (4.5 gallons) for
normal operating position.
trucks with two speed lift.
3. All hoses and lines are to be clear of any surface or
edge which will cause damaging wear and cuts, or
on which they can become caught.
4. All connections are to be leak free.
5. Beaded elbows in suction ports of all pumps must
Reservoir Sight Gauge be positioned such that the suction hose retains its
full volume flow and does not collapse.
Filter
Figure 17175 NOTE

Do not tighten filter with use of a wrench. A wrench
Hydraulic Lines and Fittings should only be used for removal of filter.
The spin on filter cartridge has been tightened by
Crown. When replacing filter, apply a film of oil
WARNING
063001-001 to seal and hand tighten until seal contacts
AVOID HIGH PRESSURE FLUIDS - Escaping fluid un- filter head.
der pressure can penetrate the skin causing serious in-
jury. Relieve pressure before disconnecting hydraulic NOTE
sure. Keep hands and body away from pin holes which Do not use hydraulic brake fluid.
eject fluids under high pressure. Use a piece of card- Use only a good grade of hydraulic oil such as Mobil
board or paper to search for leaks. Do not use your DTE 24 (Crown No. 063001-001) or equal. On trucks
hand. equipped to operate in below freezing temperatures,
Any fluid injected into the skin under high pressure Mobil Aero HFA or equal is recommended (Crown No.
should be considered as a serious medical emergency 063001-006) in a 50/50 blend with standard hydraulic
despite an initial normal appearance of the skin. There oil.
may occur. Medical attention should be sought imme-
type of injury.
M2.0-7535-018 SP 3500 Crown 2007 PF17165-18
66
HYDRAULIC SYSTEM
Hydraulic System
Drift Test For truck applications operating continually in temper-

atures at or above 4° C (40° F), use 100% standard hy-
draulic oil (063001-001).
CAUTION For truck applications primarily operating in a cooler
environment with intermittent freezer entry, use a 50/50
Never stand or work under a suspended load.
blend, 50% low temperature (063001-006) and 50%
All drift tests should be conducted with a capacity load standard hydraulic oil (063001-021).
(refer to serial plate for rated capacity of your truck).
For truck applications primarily operating in a freezer
Material used for test load must be evenly stacked
environment, use an 80/20 blend, 80% low tempera-
within limits of a four foot square pallet and must be
ture (063001-006) and 20% standard hydraulic oil
secured to fork carriage with forks spread to their max-
(063001-021).
imum width.
Proper mixture of freezer hydraulic oil will ensure the
best and most efficient operation of your Crown equip-
Lift Drift Test ment.
NOTE
Lift measurement is to be taken from tip of fork to floor.
Elevate test load above staging height. After five min-
utes, measure distance forks have drifted. Drifting in
excess of 15 mm (0.5 in) over a five minute period is
considered unacceptable.
Occasionally, a slight creep of fork assembly may oc-
cur due to internal leakage in piston pack, but it can
also be caused by leakage in check or manifold valves.
To seat these valves properly when this occurs, lift and
lower forks to flush out any foreign material from valve
seat.
(a) 50/50 Mix of Low Temperature
A thorough check for leaks in system should be con- (063001-006 [50%] and Stan-
ducted if abnormal oil losses occur. Hydraulic system is dard Hydraulic Oil
(063001-021 [50%])
designed to eliminate mechanical damage even if fit-
tings become loose. (b) Standard Hydraulic Oil
(063001-001 [100%]
(c) 80/20 Mix of Low Temperature
Freezer Preparation (063001-006 [80%] and
Standard Hydraulic Oil
(063001-021 [20%])
NOTE
Trucks equipped with velocity fuses may experience
Figure 18203
staging issues if an insufficient mix of low temperature
oil has been used.
Crown trucks may require a mixture of low temperature
hydraulic oil, Crown P/N 063001-006 (gallons),
blended with standard hydraulic oil, Crown P/N
063001-021 (gallons) when used in a freezer or cooler.
100% low temperature oil is too thin for most cold stor-
age operations and therefore could shorten life of cyl-
inder packings and pumps if used in higher ambient
temperatures.
Crown 2007 PF17165-19 SP 3500 M2.0-7535-019
67
Notes:
68
HYDRAULIC SYSTEM
Hydraulic Schematic Symbols
VENTED RESERVOIR
with lines above fluid level ELECTRIC MOTOR
unidirectional single speed
VENTED RESERVOIR
with lines below fluid level
ELECTRIC MOTOR
unidirectional variable speed
FILTER or STRAINER
HYDRAULIC LINE HYDRAULIC PUMP

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

HYDRAULIC MOTOR
limited flow
bi-directional
LINES CROSSING
GAUGE
LINES CONNECTED pressure
QUICK DISCONNECT
(disconnected) GAUGE
temperature
PLUGGED PORT
(test port)
ACCUMULATOR
gas charged diaphragm type
FLOW METER
Figure 3559-03
Crown 1979 PF5066-1 Rev. 9/06 SP 3500 M2.1-00.0-001

04 Rev 9/06
69
HYDRAULIC SYSTEM
PRESSURE SWITCH
ACTUATOR MANUAL
CYLINDER SPRING
double acting unequal area (bias to normal
de-energized position)
CYLINDER
double acting equal area
(steer) (double end) SOLENOID
single coil or winding
CYLINDER
single acting spring returned
(rod end vented)
HYDRAULIC PILOT
OPERATED
CYLINDER
single acting ram type
SOLENOID
pilot operated
CYLINDER
single acting with cushion
SOLENOID DUAL
COMPONENT ENCLOSURE
manifold block SOLENOID PROPORTIONAL
ACTUATOR MANUAL LEVER

VALVE PILOT CHECK
(pilot to open)
Figure 3560-03
M2.1-00.0-002 SP 3500 Crown 1979 PF5066-2 Rev. 9/06
04 Rev 9/06
70
HYDRAULIC SYSTEM
ORIFICE THROTTLE
VALVE SHUTTLE
fixed
ORIFICE THROTTLE
adjustable
VALVE
SINGLE COUNTERBALANCE
FLOW CONTROL in manifold
PRESSURE COMPENSATED
fixed
FLOW CONTROL
fixed with reverse flow bypass FLOW DIVIDER/COMBINER
FUSE VELOCITY
BYPASS FLOW CONTROL
regulated flow
pressure compensated
VALVE RELIEF
VALVE MANUAL SHUTOFF
fixed setting
TORQUE GENERATOR
VALVE RELIEF
adjustable
STEER UNIT
hydrostatic
VALVE CHECK
Figure 3561-03
Crown 1979 PF5066-3 Rev. 9/06 SP 3500 M2.1-00.0-003

04 Rev 9/06
71
HYDRAULIC SYSTEM
VALVE
VALVE
2 way 2 position
3 way 2 position
spring bias, solenoid control
VALVE
3 way 2 position
VALVE
4 way 3 position
dual spring centered,
VALVE manual lever control
4 way 2 position
VALVE
4 way 3 position
NOTE: The type of valve

depends on the number of
spools found in the
VALVE component enclosure
2 way infinite positions (Triple spool valve
shown)
VALVE
4 way infinite positions
Figure 3562-03
M2.1-00.0-004 SP 3500 Crown 1979 PF5066-4 Rev. 9/06
04 Rev 9/06
72
HYDRAULIC SYSTEM
Pump Maintenance
Pump Maintenance
Figure 9221-01
Pump - Gear Oil Seal Removal

Overhaul the pump only in a clean, dust-free location, The oil seal (index 11) is best removed by applying
using clean tools and equipment. Dirt or grit will dam- pressure simultaneously to the pump inlet and outlet
age the highly polished machined surfaces and will re- ports. This has the effect of pressurizing the seal cavity
sult in leakage or premature failure of the pump. and forcing out the oil seal while ensuring that the pres-
sure on each side of the lobe seals (item 3 & 4) is
Before beginning the disassembly, scribe match marks
equalized so that these seals are not displaced. If the
on the body assembly, the end cover and mounting
oil seal is distorted and leaking badly, it may not be pos-
flange to insure that the pump will be reassembled
sible to build up sufficient pressure to remove it in this
properly. This pump can be assembled for either clock-
way. In this case, disassemble the pump as far as step
wise or counter-clockwise rotation as viewed from the
5 of the "DISASSEMBLY PROCEDURE" and clamp
end of the splined drive gear assembly. Arrows are
the mounting flange securely in a soft-jawed vice. The
molded in to the body assembly and the word "ROTA-
seal can then be removed with the use of a seal remov-
TION" appears on the mounting flange to aid in deter-
ing tool. Be careful not to damage the mounting flange
mining the pumps rotation. Note which direction the ar-
seal bore or the drive shafts sealing surface.
row is pointing next to the word "ROTATION" prior to
disassembly.
Crown 1982 PF5372-1 Rev. 9/06 SP 3500 M2.1-10.0-001

01 Rev. 9/06
73
HYDRAULIC SYSTEM
Pump Maintenance
Oil Seal Replacement 7. Hold the pump body vertically with the mounting
flange end downward and with one hand under-
1. Make sure the seal housing in the pump mounting neath to prevent the bushings (index 5) from falling
flange is clean and free from burrs. out. Tap the side of the body with a rawhide mallet
to dislodge the lower bushings, and slide them
2. Pack the space between the lips of the seal with a
carefully out of the body. Keep the bushings as a
high melting point, mineral based grease.
pair and place them on or near the mounting
3. Seat the oil seal. flange.
– If the mounting flange has been removed: 8. Invert the body and lift out the drive (index 9) and
Start the oil seal squarely into the housing, with the idler (index 8) gears.
the garter spring facing inward and press home
9. Remove the remaining pair of bushings as de-
to the full depth of the recess.
scribed in step 7 and place on or near the end
– If the pump is assembled: cover.
Slide an "Assembly Sleeve" (available from
Crown [#93170]) over the shaft splines until it
comes in contact with the shaft shoulder. Parts Inspection
Lightly grease the sleeve. Slide the oil seal,
Wash all metal parts thoroughly with a good cleaning
with the garter spring facing inwards, over the
fluid. Inspect, in the order disassembled, for wear and
sleeve and start it squarely into the housing.
damage.
4. Press the seal into the full depth of the recess.
5. Remove the Assembly Sleeve. Body
To obtain high efficiency the design allows for the tips
Pump Disassembly of the gear teeth to wipe the walls of the body bores
when the pump is running. Pressure will force the
1. Remove the bolts which hold the pump to the lift gears against the inlet side of the bores a wear pattern
motor. will be visible in this area. If excessive wear of the
bushing inserts or gear journals occurs this wear pat-
2. Lightly mark or scribe the end cover (index 2), the
tern will deepen to form a step in the bore. Examine the
body (index 7) and the mounting flange (index 10)
body bores and if a pronounced step is felt the body
to ensure re-assembly in the correct relationship.
should be rejected. It is not advisable to fit worn bush-
Also note the direction of rotation of the pump.
ings into a new body. Check to make sure the two hol-
3. Loosen the bolts and lockwashers (index 1) and low dowels are not loose.
pull out the bolts.
4. Remove the end cover (index 2) and carefully lift Composite Bushings
out the two backing washers (index 3), the lobe Examine the bearing inserts for signs of wear and
seals (index 4) and the body "O" ring seals (index check the bushing faces adjacent to the gears for scor-
6). The body seal is a moulded rubber seal on early ing or pitting. Make sure the holes and slots in the
pumps but changed to an "O" ring on newer units bushings are not plugged. Light scored on the bush-
(Specify when ordering). ings faces can be polished out on a lapping plate.
5. Fit an "Assembly Sleeve" tool (available from
Crown [#93170]) over the splines on the drive shaft NOTE
before withdrawing the mounting flange. Lightly tap
the mounting flange clear of the two hollow dowels If new bushings are to be used in an old body, check
in the pump body and slide it squarely off of the for any burrs at the edge of the wear track. If present,
shaft. this burr must be polished out or it may hold the bush-
ing faces away from the gears and increase the internal
6. Carefully lift out the body "O" ring seal (index 6), leakage.
the two backing washers (index 3) and the lobe
seal (index 4).
M2.1-10.0-002 SP 3500 Crown 1982 PF5372-2 Rev. 9/06
01 Rev. 9/06
74
HYDRAULIC SYSTEM
Pump Maintenance
Gears
Examine the gears for discoloration, caused by over-
heating. Check the shafts for scoring. Make sure the
contact marks on the teeth are evenly distributed
across each tooth surface and that none of the teeth
are chipped.
NOTE
Bushings and/or gears are matched for widths within
0.005 mm (0.0002 in) and can only be sold and re-
placed as a matched pair.
End Cover
Examine the cover to insure flatness and inspect for
scoring and pitting.
Mounting Flange
Check for damage and check the condition of the oil
seal. If the seal needs replacement refer to the "Oil
Seal Replacement" section.
Lobe
Seal
Backing Washers
Figure 9222-01
Crown 1982 PF5372-3 Rev. 9/06 SP 3500 M2.1-10.0-003

01 Rev. 9/06
75
HYDRAULIC SYSTEM
Pump Maintenance
Clockwise Rotation
Cover End Mounting Flange End
Flat
Bushing Lobes Bushing Lobes
Assemble Drive Gear in this Bore Assemble Drive Gear in this Bore
Flat Bushing Flat

Lobes
Counter-Clockwise Rotation
Figure 9223-01
Pump Reassembly 3. Pack the space between the lips of the oil seal (in-
dex 11) with a high melting point, mineral based
Make sure that all pump components are perfectly grease.
clean and lubricated with the hydraulic oil to be used in
4. Pick up the body and hold it with the hollow dowels
the pump, prior to assembly.
up and with the fingers of one hand inside the
1. Prepare the bushings (index 5) for mounting flange bores of the body, ready to support the bushings.
end of the body for assembly as follows:
5. Pick up the mounting flange bushing complete with
(Refer to Figure 9222-01)
lobe seal and backing washers, and slide them into
Place the bushings on the workbench with their
the body bores with the lobes facing outwards and
lobes up and the flats in contact. Lubricate the lobe
away from the flat at the intersection of the body
seal (index 4) with a mineral based grease and fit
bores. The bushings must be inserted squarely
it around the bushing lobes. Fit a backing washer
into the bores and must be kept square to each
(index 3) inside each lobe seal. When fitted cor-
other. Do not use force when installing the bush-
rectly, the backing washer must be level and flush
ings. If the bushings should cock in the bores, re-
with the top surface of the bushing lobes.
move them and examine for scored body walls.
2. Prepare the bushings for the cover end of the body Light scoring can be stoned out with a fine grit hand
for installation into the pump in the same manner. stone.
M2.1-10.0-004 SP 3500 Crown 1982 PF5372-4 Rev. 9/06
01 Rev. 9/06
76
HYDRAULIC SYSTEM
Pump Maintenance
6. Lubricate the body seals "O" ring (index 6) with a Start Up Procedure
mineral based grease and seat it in the body.
A pump that has been re-assembled with new gears,
7. Refer to Figure 9223-01to find the position of the
bushings or body must be carefully broke-in before it is
drive gear bore for the direction of rotation you re-
subjected to full load working conditions.
quire. Lay the pump body on its side and slide the
drive gear (index 9) through the drive gear bore (as When test rig facilities are not available the following
called out in Figure 9223-01) so that the shaft pro- procedure must be carried out:
trudes out of the hollow dowel end of the body.
1. Install the pump on the application.
8. Slide the "Assembly Sleeve" (#93170) over the
2. Where the pump speed is variable set the speed to
end of the splined shaft. Hold the drive gear journal
1500 rev/min; otherwise run the pump at its normal
with one hand and slide the mounting flange (index
operating speed.
10) squarely over the shaft and onto the two hollow
dowels, flush against the body. The "Assembly 3. Run the pump at this speed for a period of 10 min-
Sleeve" provides a lead-in for the oil seal. Remove utes at minimum pressure, that is, with the hydrau-
the "Sleeve" and clamp the mounting flange in a lic system unloaded.
soft jawed vice with the pump body above the
4. If the pump operating pressure can be directly con-
flange. If the sleeve is stuck on the splines it can be
trolled, ensure that the pressure is progressively
removed by tightening a 1/4"-28 bolt into the end of
increased up to full working requirements over the
the "Assembly Sleeve".
first hour of operation. In circumstances where the
9. Check that the bushings are flush against the pressure cannot be directly controlled the same ef-
mounting flange face and that the lobe seals (index fect can be obtained by progressively increasing
4) and backing washers (index 3) have not become the work load on the machine, over the same pe-
dislodged. Check to see that the arrow on the riod of time.
body, adjacent to the word "ROTATION" is point-
5. During this period make frequent checks of the
ing in the correct pump rotation.
pump casing temperature, or the oil temperature, if
10. Mesh the idler gear (index 8) with the drive gear. If a temperature gauge is included in the system.
the original gears are being replaced on a new The temperature should not exceed that experi-
shaft, make sure that the marked side of the teeth enced under normal working conditions. If the tem-
are in contact so the bedded-in position of the teeth perature does rise excessively then it is possible
is maintained. that the pump has been assembled incorrectly and
it must be dismantled to check this. If no fault is
11. Pick up the bushings for the end cover side of the
found then further period of running-in at low pres-
pump, complete with lobe seals and backing wash-
sure, as in step 3, must be carried out.
ers and slide them over the gear journals with the
lobes facing outward and away from the flats in the
bores. Again, the bushings must be installed
squarely and without force.
12. Lubricate the body seal "O" ring (index 6) and seat
it in the body.
13. Place the end cover in position, aligning the scribe
marks made earlier.
14. Insert the bolts and lockwashers into the body and
hand tighten into the tapped holes in the mounting
flange. Apply a torque load of 4.7 to 5 kgm (34 to
36 ft lbs) to each bolt head.
15. Pour a small amount of hydraulic oil into the ports
and check the pump for freeness and direction of
rotation.
Crown 1982 PF5372-5 Rev. 9/06 SP 3500 M2.1-10.0-005

01 Rev. 9/06
77
Notes:
78
HYDRAULIC SYSTEM
Accumulator
Accumulator Precharging
The accumulator is a device in which compressed gas 1. Lower platform completely.
and oil is stored for the purpose of absorbing shock.
2. Turn key switch off, disconnect battery and chock
When the oil pressure in the line rises, incoming oil
wheels.
compresses the gas. As the surge of oil pressure
passes, the gas expands to its original size, forcing out 3. Open the power unit doors and locate the lift man-
oil. This reduces vibrations and shock in the system ifold. Open the manual valve (MV1) to remove oil
and reduces shock when contacting stops during lift pressure from oil side of the accumulator.
and lower.
Lift/Lower Manifold Block
Manual Lower Valve (MV1)
Figure 15727
Accumulator
4. Disconnect the hose from the accumulator, located
Figure 15726 below the oil reservoir, loosen mounting clamp and
remove accumulator. Refer to Figure 15726.
Use an inert gas, such as Nitrogen for precharging or
topping off of accumulators. Size "T" bottle dry nitro-
NOTE
gen, 8.5m3 (300 cu ft), 17.9 MPa (2600 psi) is recom-
mended. Since this procedure disconnects oil line, care should
be taken to catch as much oil as possible.
WARNING 5. Remove dust cap from accumulator gas valve.

6. Use thread sealing and lubricating compound on
Never use oxygen as a charging agent for accumula-
pipe threads of gage.
tors. Use only dry nitrogen as a charging agent for ac-
cumulators. 7. Attach one end of charging hose to the nitrogen
If the gas pressure in the nitrogen bottle is higher than bottle and the other end to the accumulator charg-
the maximum operating pressure of the accumulator, a ing tool. Refer to Figure 15728. Procedure is simi-
gas pressure reducing valve must be used. lar when using only charging hose with or without
other accessories.
Crown has available a 103623-004 Accumulator
Charging Tool, designed for charging and testing blad- 8. Back gas chuck stem all the way out before attach-
der and/or diaphragm type nitrogen charged accumu- ing assembly to accumulator gas valve.
lators.
The accumulator must be removed from the truck prior
to testing or charging.
Crown 2007 PF15655-1 SP 3500 M2.6-7335-001
79
HYDRAULIC SYSTEM
Accumulator
12. If desired precharge pressure is exceeded, make

sure nitrogen bottle valve is closed, then open
Bleeder Valve bleeder valve slightly, but only momentarily, to re-
duce pressure.
13. Once desired accumulator charge has been
achieved, remove Accumulator charging tool.
Bottle Valve
14. With the use of sealing spray or soapy water,
check accumulator for leaks.
Gage 15. Replace dust cap on accumulator and install on
truck.
Accumulator 16. Reconnect battery.
17. To bleed air from the accumulator, the empty forks
should be raised to sufficiently pressurize the lift
cylinders.
NOTE
Nitrogen
Since this procedure disconnects oil line, care should
be taken to catch as much oil as possible.
18. Slowly loosen the hose connection at the accumu-
lator until an air-oil mixture is released.
Figure 15728
WARNING
9. Use wrench to tighten gas chuck swivel nut onto
accumulator gas valve. Close bleeder valve. AVOID HIGH PRESSURE FLUIDS-Escaping fluid un-
10. Use gas chuck stem to loosen gas valve in accu- jury. Relieve pressure before disconnecting hydraulic
mulator. lines. Tighten all connections before applying pres-
11. Slowly open nitrogen bottle valve to fill accumula- sure. Keep hands and body away from pin holes which
tor. Once the pointer on the gage starts to deflect eject fluids under high pressure. Use a piece of card-
unscrew the gas chuck stem one full turn. The board or paper to search for leaks. Do not use your
charge should be over a 2 to 4 minute period to hand.
assure a proper charge and to prevent damage to Any fluid injected into the skin under high pressure
accumulator. Shut off when gage indicates proper should be considered as a serious medical emergency
charge. Use the gas chuck stem to tighten gas despite an initial normal appearance of the skin. There
valve in accumulator to 11 Nm (8 ft lb). The pre- is a delayed onset of pain, and serious tissue damage
charge pressure setting is 3445 kPa (500 psi). may occur. Medical attention should be sought imme-
diately by a specialist who has experience with this
type of injury.
CAUTION 19. Continue until a solid stream of oil is achieved.
Do not loop or twist hose as it will stiffen when gas 20. Tighten connector.
pressure is released from nitrogen bottle.
21. Remove wheel chocks and return truck to service.
Never loosen swivel nut attached to gas valve in accu-
mulator without first backing gas chuck stem out all the
way.
Do not reduce accumulator precharge by depressing
valve core (high pressure may rupture rubber valve
seat).
M2.6-7335-002 SP 3500 Crown 2007 PF15655-2
80
HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting proceed in solving the problem grows with experience.

The following chart contains symptom, probable cause
The following Troubleshooting Chart contains general and remedy. The information is general in nature and a
information necessary to effectively solve the more remedy may simply refer you to a maintenance section
common hydraulic problems. Know the system to the that has more complete troubleshooting. Use the
best of your ability. Understand the components and chart(s) carefully and completely. Do not make the sys-
their function within the system. Develop a systematic tem more complicated than necessary. Do not overlook
pattern to locate and solve the various hydraulic prob- the simplest reason(s) for a hydraulic problem.
lems that occur. The ability to identify problems and
Hydraulic Troubleshooting Chart
Symptom Probable Cause Remedy

Hydraulic oil foaming Introduction of air into pump Check reservoir oil level.
Check for proper oil viscosity.
Check plumbing.
Water in oil Check reservoir.
Hydraulic oil overheating (1) Oil too thin (1) Change to proper viscosity oil.
Oil contaminated Change filters and fill with clean oil.

Introduction of air into pump Check plumbing.
Oil level low Fill reservoir to proper level.
Platform/lifting forks will not Mast assembly binding Inspect mast for damage or misalignment.
raise
Lift motor or pump not operating Refer to pump troubleshooting.
Manual lowering valve open Refer to valve assembly troubleshooting.
Relief valve setting incorrect Reset relief valve.
Carriage damaged/misaligned (2) Inspect carriage for malfunction. (2)

Platform/lifting forks will not Velocity fuse actuated Check for severe oil leak.
lower
Check for more than capacity load.
Flow control valve reset.
Raise slightly to reset velocity fuse.
Chain slack switch actuated Platform/Forks resting on obstruction.
Raise slightly to eliminate chain slack.
Solenoid valve malfunction Refer to valve assembly troubleshooting.
Binding in mast assembly Inspect mast & platform for damage, misalign-
ment, etc.
Carriage binding (2) Inspect carriage for damage or misalignment. (2)

(1) Be sure the truck has been performing its normal duty cycle at this time. Trucks equipped to operate in
freezer require a thinner weight oil.
(2) 1.0 Lifting Fork Trucks Only.
Crown 2006 PF15258-1 Rev. 11/07 SP 3500 M2.9-7534-001

01 Rev. 11/07
81
HYDRAULIC SYSTEM
Hydraulic Troubleshooting Chart (Continued)

Lowers too slow Debris in flow control valve Cycle through lift/lower to free possible debris.
Line restriction Check plumbing.
Accumulator malfunction Check accumulator operation.
ment, etc.

Lowers too fast Debris in flow control valve Cycle through lift/lower to free possible debris.
External oil leak Check plumbing for leak(s).
Accumulator malfunction Refer to accumulator maintenance.
No hi-speed raise HSRCS switch malfunction Check HSRCS switch operation.
RAS switch malfunction in control Refer to componentry.
module
No hi-speed lower HSLCS switch malfunction Check HSLCS switch operation.
LOS switch malfunction in control Refer to componentry.
module
Solenoid valve malfunction Refer to valve assembly troubleshooting.
No cushion during raise or Accumulator malfunction Charge accumulator properly. Refer to accumu-
lower lator service.
Damaged cushion springs or Inspect for damage.
bumpers
Will not lift capacity load Relief valve not adjusted properly Adjust relief valve. Refer to valve assembly.
Mast binding Inspect mast for damage, misalignment, etc.
Hydraulic component(s) malfunc- Refer to hydraulic pump & cylinders.
tion

Platform drifts down Debris in lift/lower valve Cycle through lift/lower to free possible debris.
(in excess of drift test)
Lift cylinder packings leaking Refer to cylinder information.
Accumulator loses charge Accumulator valve leaking, Repair. Refer to accumulator maintenance.
cracked, deformed, etc.
Abnormal hydraulic oil us- External leak Check plumbing, cylinder, other hydraulic com-
age ponents.
(2) 1.0 Lifiting Fork Trucks Only.
M2.9-7534-002 SP 3500 Crown 2006 PF15258-2 Rev. 11/07
01 Rev. 11/07
82
HYDRAULIC SYSTEM

Lift pump & motor over- Relief valve setting too high Reset relief valve. Refer to hydraulic mainte-
heating (1) nance.
Exceeding capacity load Check load weight.
Worn or damaged pump & motor Inspect pump & motor. Repair or replace.
Fluid level low Inspect fluid level. Fill system to proper level.
Refer to accumulator service.
Failure of platform to raise Lift chains not adjusted properly Adjust chains.
and lower smoothly
Mast and/or platform binding Inspect mast & platform for damage, wear, etc.
Hydraulic component malfunction Inspect pump, motor, valve, cylinder, etc. for
damage, leaks, wear, etc.
Accumulator malfunction Refer to accumulator service.
Air trapped in cylinder Bleed.

(1) Be sure the truck has been performing its normal duty cycle at this time.
(2) 1.0 Lifting Fork Trucks Only.
Crown 2006 PF15258-3 Rev. 11/07 SP 3500 M2.9-7534-003

01 Rev. 11/07
83
Notes:
84
DRIVE UNIT
85
Notes:
86
DRIVE UNIT
Drive Unit
Drive Unit
Drive Tire Replacement

When replacing drive tire, make sure composition and
size are such that maneuverability and braking require-
ments are maintained. Drive tire is a "press-on" type;
press old tire off hub and press new tire on.
1. Disconnect battery and chock wheels.
2. Raise and block power unit so drive tire is off floor.
Loosen and remove eight lug bolts and remove
wheel and hub from drive unit.
3. Remove old drive tire and replace with new drive
tire. Outside of hub must be pressed flush with out-
side edge of tire.
4. Inspect hub and remove any paint that may be
present on tapered lug seats or on inner hub face
that contacts truck axle. See Figure 16865.
5. Finger tighten lug bolts, then tighten to 135 -
150 Nm (100 - 110 ft lb) making sure that they are
tightened in the sequence shown in Figure 16865.
(1) Inner Hub Face

(2) Hub
(3) Tapered Lug Seats
(4) If Present, Remove Paint on Tapered
Lug Seats and on Inner Hub Face that
Contacts Truck Axle
(5) Tighten Lug Nuts in Sequence Shown
Figure 16865
6. Remove blocks, lower power unit, connect battery

and remove wheel chocks.
Crown 2007 PF15810-1 SP 3500 M3.0-7335-001
87
DRIVE UNIT
Drive Unit
Drive Unit Lubrication Oil Pump Disassembly

The drive unit has a capacity of approximately 1000 ml
(Refer to Figures 16867 and 17179)
(1.5 pints) of 90W gear lube, Crown no. 063003-003
(or 063001-023, ATF for trucks operating in freezer ap- 1. Disconnect battery and chock wheels.
plications below 0°C [32°F]). Remove drain plug to
completely drain unit. To fill, remove fill plug. Add gear
oil until present at oil level check plug. Refer to Figure
17178.
(1) Oil Pump Housing (8) Spring

(2) O-Ring (9) Piston
(3) O-Ring (10) Bearing Cup
(4) Ball (11) Bearing Cone
(5) Spring (12) Axle
(6) Special Plug (13) Cam
(1) Fill and Oil Level Check Plug
(7) Ball (14) Drive Unit Housing
(2) Drain Plug
Figure 16867
Figure 17178 2. Remove drain plug (2); drain oil from drive unit. Re-
fer to Figure 17178.
M3.0-7335-002 SP 3500 Crown 2007 PF15810-2
88
DRIVE UNIT
Drive Unit
Oil Pump Assembly

(Refer to Figures 16867 and 17179)
Inspect all component parts and drive unit casting for
dirt and burrs before assembly.
1. Place ball (4) and spring (5) into oil pump housing
(1).
2. Place ball (7), spring (8) and special pipe plug into
piston (9). Lubricate piston with oil to aid in smooth
action and install piston into oil pump housing in-
stalled in drive unit housing.
3. Install o-rings (2) and (3) onto pump body.
4. Oil pump body and port thoroughly and screw
pump assembly into casting until seated.
5. Apply hydraulic sealer (061004-005) to drain plug
and replace drain plug. Fill drive unit with 1000 ml
(1.5 pints) of 90W gear lube, Crown no.
063002-003 (or 063001-023, ATF for trucks oper-
ating in freezer applications below 0°C [32°F]).
Drive Unit Removal and Installation

(Refer to Figure 17180)
2. Open power unit doors.
(1) Tubing is Installed Through Cored Hole in Casting
NOTE
Figure 17179 Make note of all electrical connections removed.
3. Remove oil pump housing (1) from drive unit and 3. Disconnect all electrical wiring to drive motor and
move to a clean work area for further disassembly. electric brake. Remove four bolts that secure drive
4. Check o-rings (2) and (3) for damage and replace motor and electric brake to drive unit and remove
if necessary. completely.
5. Remove piston (9), spring (8) and ball (7) from oil
pump housing.
6. Remove special pipe plug (6), spring (5) and ball
(4) from oil pump housing.
7. Thoroughly clean housing and all parts.
Crown 2007 PF15810-3 SP 3500 M3.0-7335-003
89
DRIVE UNIT
Drive Unit
9. Reverse steps 1 through 7 to install drive unit. Align

marks on drive unit and drive unit mounting
bracket. This ensures steered wheel is in straight
ahead position.
(1.5 pints) of 90W gear lube, Crown no.
063002-003 (or 063001-023, ATF for trucks oper-
ating in freezer applications below 0°C [32°F]).
(a) Steering Motor and Gearbox Assembly

(b) Electric Brake
(c) Drive Motor
(d) Drive Unit Mounting Bolts and Dowel Pins
(e) Alignment Marks on Drive Unit and Drive
Unit Mounting Bracket
(f) Steering Encoder (ECR2)
Figure 18208
4. Remove drain plug in bottom of drive unit and allow

gear oil to drain.
5. Raise and block power unit. Remove drive tire. Re-
fer to Drive Tire Replacement when assembling
drive tire.
6. Remove four bolts and two dowel pins that fasten
drive unit to power unit. When reattaching drive
unit with these bolts, apply a small amount of
thread locking adhesive (061004-009) and tighten
to 340 - 370 Nm (250 - 275 ft lb).
7. Stabilize drive unit and raise and block power unit
until drive unit will clear power unit.
8. Move drive unit to a clean work area for further dis-
assembly.
M3.0-7335-004 SP 3500 Crown 2007 PF15810-4
90
ELECTRICAL SYSTEM
91
Notes:
92
ELECTRICAL SYSTEM
Encoders
Encoders
Encoders are used to verify direction, speed, position
and height on Crown lift trucks.
The encoders are located in various locations depend-
ing on application. Refer to Figure 18205-02. There is
no adjustment required of encoders. If encoder does
not work properly, check connections and current for
proper voltage.
Crown 2007 PF15811-1 Rev. 12/07 SP 3500 M4.0-7335-001

02 Rev. 12/07
93
ELECTRICAL SYSTEM
Encoders
(a) Steering Encoder

(b) Lift Height Encoder
(c) Traction Encoder
(d) Steering Feedback Encoder
(e) ECR3 Mounted Inside Motor
Figure 18205-02
M4.0-7335-002 SP 3500 Crown 2007 PF15811-2 Rev. 12/07
02 Rev. 12/07
94
ELECTRICAL SYSTEM
Wiring
Wiring Color
Wire colors will be limited to those in the chart. The
color of the wire will be chosen based on the function
Wiring Color Codes of the circuit in which it is used.
The following information is an explanation of wiring
color codes used. Number
Each wire is assigned a three or four digit number. The
first one or two digits will identify the color of the wire
and the last two digits are the sequential numbering of
the wires from 01 to 99.
Wire Numbering
Abbreviation Color Number Circuit Function

BLK Black 0** Digital Signal
BRN Brown 1** Analog Signal
RED Red 2** Battery Positive
ORG Orange 3** +12 volts (DC - DC converter)
YEL Yellow 4** Third DC - DC converter
GRE Green 5** Battery Negative
BLU Blue 6** Isolated Negative
VIO Violet 7** +5 volts (DC - DC converter)
GRAY Gray 8** Fourth DC - DC converter
WHT White 9** Miscellaneous
R/W Red Stripe on White 29** Battery Positive after a switch
G/W Green Stripe on White 59** Battery Negative after a switch or resistor
** - Sequential number from 01 to 99
Crown 1993 PF9710-1 Rev. 8/06 SP 3500 M4.1-1430-001

02 Rev. 8/06
95
ELECTRICAL SYSTEM
Wiring
Power Cables
Power cables are designated using the initials PC
which stands for power cable, #- is the AWG size of the
cable and the dash number. This designation also rep-
resents the part number to be ordered. e.g. PC#1/0-10
is a power cable that is size 1/0 AWG and is part num-
ber 084572-010. Refer to the following chart for the
base part number of all cable sizes used.
Power Cables
Abbreviation Part No.

PC#1 084571
PC#2 084570
PC#4 084569
PC#6 084568
PC#10 090963
PC#1/0 084572
PC#2/0 084573
PC#3/0 086749
M4.1-1430-002 SP 3500 Crown 1993 PF9710-2 Rev. 8/06
02 Rev. 8/06
96
ELECTRICAL SYSTEM
Wiring
Maintained Contact Switches Momentary Contact Switches

Operator Actuated Operator Actuated
Normally Open Normally Open
Normally Closed
Held Open
Center Off
Normally Closed
Double Throw
Held Closed
Multiple Pole 2 Circuit

Break Before Make
Center Off
Multiple Pole
Make Before Break
Double Throw
Start
Key Momentary Contact Switches

ACC
Switch Mechanically Actuated
IGN
Normally Open
Off
Normally Open
Maintained Contact Switches Held Closed
Mechanically Actuated
Normally Closed
Normally Open Held Closed
Held Closed Normally Closed
Held Open
Normally Closed
Open On Rise Close On Rise
Double Throw
2 Circuit
Figure 3804-01
Crown 1993 PF9710-3 Rev. 8/06 SP 3500 M4.1-1430-003

02 Rev. 8/06
97
Notes:
98
ELECTRICAL SYSTEM
Motor Monitoring System (MMS)

Seven inputs of the truck management system are
used to monitor the traction motor and both pump mo-
tors. Each motor contains one temperature sensor and
two brushwear sensors. The information is communi-
cated to the traction controller. The information is then
communicated to the display. The display will light the
appropriate LED and tell the operator which motor the
overtemperature or the brush-wear event is occurring. Figure 18234
A Motor Monitoring System (MMS) event will not inhibit
any truck functions. The traction controller will only
check the status when passing through neutral.
(a) Distribution Panel Freezer/Corrosion

(Not Shown) (Optional)
(b) Access 6 Guidance Control Module
(GCM) (Optional)
(c) Access 5 Steering Control Module (SCM)
(d) Access 3 Traction Control Module (TCM)
(e) Traction Motor
(f) Lift Pump Motor
(g) Lift Pump Motor
(h) Distribution Panel (Power Unit)
Figure 18235-01
Crown 2007 PF17137-1 Rev. 12/07 SP 3500 M4.2-7335-200

01 Rev. 12/07
99
ELECTRICAL SYSTEM
Testing Motor Monitoring System Temperature Sensors: To test a pump motor thermal
sensor. Remove the wire harness connections from the
(MMS) motor thermal sensor, short the harness wire ends to-
General Description: Each SP3500 pump motor has 2 gether and command lift. The thermal fault shall be in-
active low brushwear outputs that connect to the distri- dicated on the display as "Lift 1" or "Lift 2" and logged
bution panel and 1 active high temperature sensor out- in the fault history. Test the traction motor thermal sen-
put that connects to Access3 (TCM) (MMS circuit). The sor by unplugging CA411 and commanding traction to
2 temperature sensors connect to CA401-10 and log to sensor fault event. Refer to Charts 1 and 2 for
CA401-13 and the 4 brushwear indicators are summed location and fault codes.
to a single signal that connects to CA401-7. The AC Brushwear Sensors: To test the pump motor brush-
traction motor active high temperature sensor con- wear sensors. Remove the harness connection to a
nects to Access3 CA401-16. Motor faults are for- brushwear sensor, jumper the wire end to - BV at the
warded to the display and can be accessed to deter- distribution panel TP3 and command lift. The brush
mine which motor is experiencing the temperature or fault shall be indicated on the display as "Lift 1" or "Lift
brush fault. MMS faults do not inhibit any truck func- 2" and logged in fault history. Refer to Charts 1 and 2
tions. for location and fault codes.
Chart 1 - Sensor Information
Sensor Location T.M.M. Terminal

Temperature M1 Traction Motor M1 CA401-16
Temperature M3 Pump Motor M3 CA401-10
Temperature M4 Pump Motor M4 CA401-13
Brushwear M3A Pump Motor M3 CA201-15
Brushwear M3B Pump Motor M3 CA201-16
Brushwear M4A Pump Motor M4 CA201-13
Brushwear M4B Pump Motor M4 CA201-14
Chart 2 - Fault Information
Character Dis-
Active Sensor Icon Fault History
play
M1 Thermal Traction (M1) Over temperature 328
M1 Thermal Traction (M1) Sensor fault 329
M3 Thermal Lift 2 (M4) Over temperature 396
M4 Thermal Lift 1 (M3) Over temperature 397
M3 Brush A Lift 1 (M3) Brushwear 398
M3 Brush B Lift 1 (M3) Brushwear 398
M4 Brush A Lift 2 (M4) Brushwear 398
M4 Brush B Lift 2 (M4) Brushwear 398
M4.2-7335-201 SP 3500 Crown 2007 PF17137-2 Rev. 12/07
01 Rev. 12/07
100
ELECTRICAL SYSTEM
(a) M1 Thermal Switch Open Upon Event

(b) M3/M4 Thermal Switches Close Upon Event
(c) M3/M4 Brushwear Switches Short to Motor Negative or Positive Upon Event
Figure 12523-03
Crown 2007 PF17137-3 Rev. 12/07 SP 3500 M4.2-7335-202

01 Rev. 12/07
101
Notes:
102
ELECTRICAL SYSTEM
Access 123
Access 123
(a) Display Screen

(b) Navigation Keys (Up Arrow, Down Arrow, Left Arrow, Right Arrow) Used to Scroll
through Menus
(c) Enter or Return Key Used to Navigate in and out of Menus and to Accept Inputs
(d) Wire Guidance Display (Optional)
(e) Performance Level Indicators
(f) Battery Discharge Indicator
Figure 17869-01
Typical navigation button usage: up and down arrows The following messages will be displayed in order of
will scroll through menu choices, right arrow will enter priority (if enabled), regardless of user selection:
a menu and left arrow allows will exit the current menu.
1. PM Due
The enter/return button is used to select a function or
choice. 2. User Code
3. SRO/Advise Message
User Level 4. User selected message
The following pages describe user controlled display If any message is more than eight characters it will be
options. The user may choose from the following op- scrolled across the display from right to left.
tions (provided a higher priority message is not active):
The display will continue to display the last selected
• Message (for example BDI = 70%) message even if the truck is turned OFF and back ON.
To change the message displayed, enter the Message
• Hour Mode and select one of the other choices.
• Events
• Service
• Performance
Crown 2007 PF15813-1 Rev. 6/08 SP 3500 M4.3-7335-001

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103
ELECTRICAL SYSTEM
Access 123
Message Mode Press the enter/return button. The display will exit the
Message Mode and show (SP3500).
To enter the Message Mode, key up truck. With a Mes-
sage (for example BDI = 70%) present on the display, Timer - Message Mode
press the right arrow to enter this menu. Press the up/
down arrows to scroll through menu choices: This menu allows the operator to display a stopwatch.
To select this message, key up the truck. Press the
1. Steer
right arrow, use up/down arrows to display Timer.
2. Model Press the right arrow to enter the Timer menu. Use the
up/down arrows to scroll through choices:
3. Timer
4. Trip • Stop
5. BDI • Start
6. Hours • Reset
7. Odometer
Timer - Start
8. Speed
Press the enter/return button. The display will exit the
NOTE Message Mode and display;
Stopwatch (00:00:00), which will be incrementing.
Message Mode is controlled by the Features menu
(F26). F26 allows one of the message choices (in
Timer - Stop
which case you would not be able to scroll through any
choices) or ALL. Use the up/down arrows to display Stopwatch. Press
the right arrow to enter the Message Mode. Use the up/
Steer - Message Mode down arrows to display Timer. Press the right arrow to
enter the Timer menu. Use the up/down arrows to dis-
This menu allows the operator to display the approxi- play Stop, press the enter/return button. The display
mate steer tire position on the eight character display will exit the Message Mode and show the Stopwatch
at all travel speeds. If the truck is operating in other stopped, with whatever amount time accumulated (ex-
message modes, the approximate steer tire position ample, 01:01:32).
will be displayed on the eight character display when-
ever the operator is depressing the brake pedal and will Timer - Reset
remain until the truck is traveling at a slow speed. Once
the truck begins travel, the steer indicator will go away Use the up/down arrows to display the Stopwatch.
to allow the displaying of the other messages. If the Press the right arrow to enter the Message Mode. Use
operator would prefer to have the steer indicator the up/down arrows to display Timer. Press the right
present at all travel speeds, then the operator would arrow to enter Timer menu. Use the up/down arrows to
select Steer as the message mode. To select this mes- display Reset. Press the enter/return button. The dis-
sage, key up the truck. Press the right arrow button to play will exit the Message Mode. The Stopwatch will be
enter the Message Mode. Use the up/down arrows to zeroed, and not counting (00:00:00).
scroll to Steer. Press the enter/return button. The dis-
play will exit the Message Mode and show (Steer ^). Trip - Message Mode
This menu allows the operator to display the distance
Model - Message Mode traveled in either direction since the last reset, in feet.
This menu allows the operator to display the generic To select this message, key up the truck. Press the
truck model. It is intended to be used in locations where right arrow to enter the Message Mode. Use the up/
the operator has no need for the other message mode down arrows to scroll to Trip. Press the enter/return
choices. To select this message, key up the truck. button and the display will exit the Message Mode. The
Press the right arrow button to enter the Message display will show ft=00000 or m=00000.
Mode. Use the up/down arrows to scroll to Model.
M4.3-7335-002 SP 3500 Crown 2007 PF15813-2
104
ELECTRICAL SYSTEM
Access 123
Trip - Reset Hour

Press the right arrow to enter Message Mode. Use the
This menu allows the user to view one of twelve differ-
up/down arrows to display Trip. Press the right arrow to
ent hour meter readings.
display Reset. Press the enter/return button. The dis-
play will exit Message Mode and display distance trav- • H1 (key on, truck being used)
eled reset (ft=00000) or (m=00000).
• H2 (key on, truck being used plus delay)
BDI - Message Mode
• H3 (odometer)
This menu allows the operator to display the battery
percent of remaining charge. To select this message, • H4 (lift motor on time)
key up the truck. Press the right arrow to enter the Mes-
sage Mode. Use the up/down arrows to scroll to BDI. • H5 (platform on time)
Press the enter/return button. The display will exit the
Message Mode and show (BDI = XX%).
• H6 (traction motor on time)
• H7 (steer motor on time)

Hours - Message Mode
• H8 (Access 1 on time)
This menu allows the operator to display accumulated
runtime hours. To select this message, key up the • H9 (Access 3 on time)
truck. Press the right arrow. Use the up/down arrows,
scroll to Hours. Press the enter/return button. The dis- • H10 (Access 4 on time)
play will exit the Message Mode and show (H1=XX).
• H11 (Access 5 on time)
Odometer - Message Mode • H12 (Access 6 on time)
Press the right arrow. Use the up/down arrows to scroll
To enter this menu, key up the truck. Press the down
to Odometer. Press the enter/return button. The dis-
arrow to display Hour. Press the right arrow, H1 will be
play will exit the Message Mode and show the distance
displayed. Use the up/down arrows to view different
the truck has traveled, in miles (mi=XX) or kilometers
hour meter readings. To stop the message from scroll-
(km=XX).
ing press the right arrow at the desired hour meter. To
exit Hour menu press the left arrow until Hour is dis-
Speed - Message Mode played.
This menu allows the operator to display the travel
speed. Press the right arrow button to enter the Mes- Events
sage Mode. Use the up/down arrows to scroll to Speed.
Press the enter/return button. The display will exit the This menu allows the user to view stored event codes
Message Mode and show the travel speed in miles per (up to 15). To enter this menu, key up the truck. Press
hour (X.X Mph) or kilometer per hour (X.X Kph). the down arrow until Events is displayed. Press the
right arrow, Last will briefly be displayed. The last event
code stored will then be displayed (EV=XXX). Use the
up/down arrows to scroll through stored event codes
(Last to Last-15). Press the left arrow button to return
to the main menu at Events.
NOTE
Event codes can not be cleared from the User level
menu.
Crown 2007 PF15813-3 SP 3500 M4.3-7335-003
105
ELECTRICAL SYSTEM
Access 123
Service
This menu enters maintenance levels 2 and 3. A pass-
word is required to enter maintenance levels. Contact
your local Crown dealer to obtain this password.
To enter this menu, key up the truck. Press the down
arrow until Service is displayed. Press the right arrow,
Level 2 will be displayed. Press the right arrow. Level 2
will be displayed. Press the down arrow to go to Level
3, if desired. From either level, press the right arrow,
four blank boxes will be displayed. Use the up/down
arrows to enter the first digit of the password. Press the
right arrow to move to the next digit, continue until the
final digit is entered. Press the enter/return button to
accept the password.
NOTE
Once maintenance Levels 2 or 3 are entered the truck
must be turned OFF then back ON to exit the Service
menu.
Performance
This menu allows the operator to choose one of three
performance modes to operate the truck in only if User
Performance is enabled in the Features menu (F20).
• P1 (maximum achievable performance level)
• P2 (reduced performance from maximum, similar

to previous model)
• P3 (used where operational conditions require low-

est truck performance)
To enter Performance menu, key up the truck. Use the
up/down arrows to scroll to Performance. Press the
right arrow P1, P2 or P3 will be displayed. Use the up/
down arrows to display a different performance level.
Once the desired level is displayed, press the enter/
return button to select. Press the left arrow button to
return to the main menu at Performance.
M4.3-7335-004 SP 3500 Crown 2007 PF15813-4
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ELECTRICAL SYSTEM
Access 123
Operator Menus
continued from page -007
Range
continues
...
Message Mode
Priority
1 PM Due
(if enabled)
2 User Code
(if enabled)
3 SRO/Advise
Message
4 User Selected
Message Message Mode Menus
Allows the user to select what
is displayed in message mode
if no higher priority items are
active. Also allows the user to
control the trip meter and
timer. Only the appropriate
menus will be made visible
based on the “Default Mes-
sage” feature item. Message
continued on next page is displayed until item from
menu is chosen.
Figure 17902
Crown 2007 PF15813-5 SP 3500 M4.3-7335-005
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ELECTRICAL SYSTEM
Access 123
Hour Menus
continued from previous page
continued on next page
Figure 17903-01
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01 Rev. 12/07
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ELECTRICAL SYSTEM
Access 123
Event & Utilities Menus

continued on page -005
Performance menu only

visible when selected in
the service menu
Figure 17904-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Figure 17905-01
M4.3-7335-008 SP 3500 Crown 2007 PF15813-8 Rev. 12/07
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus

Access Navigation Note:
When navigating through
Analyzer menus, A3 continued on page -015
menu is not available in
Level 3 and A4 menu is
not available in Level 2.
Figure 17906-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 1 Inputs
0=Open
1=Closed
continued from
page -008 Not displayed on North American Models.
Only if F14 is enabled.
Access 3 Inputs
continued from
page -008
Only displayed on selected models.
A2.2.4, A2.2.5 and A2.2.6 only

displayed when F24 is enabled.
Figure 17907-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 4 Inputs
continued from
page -008
0=Open
1=Closed
A2.3.4 and A2.2.5 only displayed on selected models.
Only displayed if TT Mast is enabled in F6.
Figure 17908-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 4 Inputs Continued
0=Open
continued from previous page 1=Closed
A2.3.14, A2.3.15 and A2.3.16 only

A2.3.17 and A2.3.18 only displayed

when F17 is enabled.
A2.3.19 only displayed on selected models.
Figure 17909-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 5 Inputs
0=Open
1=Closed
Only displayed if BRES
is set to Yes in F18.
Access 6 Inputs
Must toggle GUS switch after
continued from page -008 key on to work properly.
A2.5.1 and A2.5.2 only

A2.5.3, A2.3.4, A2.5.5 and A2.5.6 only

Figure 17910-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 1 Outputs
Access 3 Outputs
Only displayed on selected models.
Figure 17911-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 1 Outputs

Only displayed when F19 is enabled.
A3.3.2/A3.3.3 only displayed on selected models.
Only displayed when F17 is enabled.

0=Open
1=Closed
Access 5 Outputs
Figure 17912-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus
Access 5 Outputs
Access 1 Test Outputs
Only displayed on
selected models
Figure 17913-01
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ELECTRICAL SYSTEM
Access 123
Analyzer Menus

Only displayed if
F19 is enabled.
A4.3.2 and A4.3.3

only displayed on
selected models.
Only displayed if F17 is enabled.
Figure 17914-01
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ELECTRICAL SYSTEM
Access 123
Features Menus
Figure 17915-01
M4.3-7335-018 SP 3500 Crown 2007 PF15813-18 Rev. 12/07
01 Rev. 12/07
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ELECTRICAL SYSTEM
Access 123
Features Menus

North America Australia
N. America Australia
Refer to truck data plate
for setting information N. America Australia
N. America Australia
Europe
Europe
Europe
Europe
Figure 17916-02
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ELECTRICAL SYSTEM
Access 123
Features Menus
F15.2 only displayed if

“Sense & Slow” or “Sense
& Stop” are selected.
Figure 17917-01
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ELECTRICAL SYSTEM
Access 123
Features Menus
F19.2 only
available when
Off is not selected
from F19.1.
Figure 17918-01
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ELECTRICAL SYSTEM
Access 123
Features Menus
Only displayed if
F14 is disabled.
Figure 17919-01
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ELECTRICAL SYSTEM
Access 123
Features Menus
Figure 17920-01
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01 Rev. 12/07
125
ELECTRICAL SYSTEM
Access 123
Features Menus
Figure 17921-01
M4.3-7335-024 SP 3500 Crown 2007 PF15813-24 Rev. 12/07
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ELECTRICAL SYSTEM
Access 123
Performance Menus

Figure 17922-01
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ELECTRICAL SYSTEM
Access 123
Performance Menus
continued from Max Allowable

previous page Speed
dependant on
truck model.
continued from
previous page
continued from
previous page
continued from
previous page
continued from
previous page
continued from
previous page
Figure 17923-01
M4.3-7335-026 SP 3500 Crown 2007 PF15813-26 Rev. 12/07
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128
ELECTRICAL SYSTEM
Access 123
Performance Menus
Figure 17924-01
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ELECTRICAL SYSTEM
Access 123
Performance Menus
F16 must be
selected before
you can see
EAC Setup
Only available if Slowdown with Auto Resume Mode.
Only available if Slowdown with Auto Stop Mode.
Not available if Slowdown

with Auto Resume Mode
Only available if Slowdown

with Auto Resume Mode
continued on
next page
Figure 17925-01
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ELECTRICAL SYSTEM
Access 123
Performance Menus
F17 must be
enabled before
you can see
PDS Setup
F14.3 is only available

on the following trucks:
European 3512-1.0
European 3522-1.0
Figure 17926-01
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ELECTRICAL SYSTEM
Access 123
Calibration Menus
Save? Y/N User

must Save after
completing Han-
dle Calibration.
Calibration Note:
Perform C1 calibration Momentary
after replacing POT1, Message
FS, RS or Access.
Save? Y/N
Platform must be above
HGTRS position (approx-
imately 15 in) and must
not be in staging area of
mast. Press and hold Step Pressing right arrow will
lower button. Follow Dis- automatically display PVL current
play instructions. from menu
to menu
This message occurs
when you have reached
the forks bottom or the
continued on page -034 staging area and need
to raise to continue.
Momentary Message
continued on page -052 Calibration Note:

Perform C2 calibration after replacing or
adjusting PVL, HGTRS or an Access
Figure 17927-01
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ELECTRICAL SYSTEM
Access 123
Calibration Menus
Save? Y, N
or Clear All
User must Save

after completing
Raise/Lower
Cutout
Calibration Note:
Perform C3 calibra-
tion after replacing C3.1.4 is only
Access. displayed if
F25 is enabled.
# = The number of
allowed cutouts to
be configured.
C3.2.4 is only
displayed if
continued on next page F25 is enabled.
Figure 17928-01
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ELECTRICAL SYSTEM
Access 123
Calibration Menus
Calibration Note: Perform C4 calibration after replacing or adjusting ECR2.
The steered wheel alignment marks must be lined up indicating that the
continued from previous page wheel is a straight ahead.
Display goes to counts Rotate encoder towards 0 counts
if index already seen. until constant beep sounds.
User must Save

calibration after Recommended checks for saturated coils(s):
completing PEAK 1) Verify that field strength meets Crown’s rec-
ommendations.
Coil, Wheel Angle,
2) Verify that sensor bars are mounted 82 to
Truck Angle and 86 mm (3.25 to 3.38 in) from floor.
offset Null A saturated coil does not invalidate sensor coil
Calibration. calibration. If a sensor bar is re-positioned or
field strength is adjusted, re-do sensor coil cali-
bration.
Acquire wire and drive a minimum of 60 ft.
Drive at least
18.3 m (60 ft)
Directional change (travel
distance is additive)
Travel distance completed

in both directions.
Acquire wire and drive a minimum of 60 ft
Drive at least18.3 m (60 ft)

Directional change (travel
distance is additive)

Travel distance completed
in both directions.
Figure 17929-01
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ELECTRICAL SYSTEM
Access 123
Calibration Menus
Acquire wire and drive a minimum of 30 ft Offset Null calibration:

Travel must be continuous in each direction.
If direction change occurs, then % complete
Drive at least 9.1 m (30 ft) resets to 0%.
Travel distance
completed
in both directions
Calibration Note:
Perform C5 calibration after replacing or
adjusting GS1, GS2 or Access 6.
continued from previous page When entering x-offset calibration, x-offset

value is set to zero in both directions.
User must save

after completing Travel on wire at
x-offset calibration. least 12.2 m (40 ft)
Note: Travel distance must be

continuous in each direction. If
direction change occurs, then %
complete resets to 0%.
Figure 17930-01
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ELECTRICAL SYSTEM
Access 123
Hour Menus

Level 2: View Only
Level 3: Increase Only
Level 2: View Only/Level 3: Increase Only
Level 2: View Only

Level 3: Increase Only Kph if F2 is
selected in Metric
Level 2: View Only/Level 3: Increase/Decrease
Level 2: View Only/Level 3: View Only
continued on
page -036 continued on next page
Figure 17931-01
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ELECTRICAL SYSTEM
Access 123
Hour Menus
Figure 17932-01
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ELECTRICAL SYSTEM
Access 123
Event Menus
Range
continues
...
continued on
next page
Figure 17933-01
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ELECTRICAL SYSTEM
Access 123
Utilities Menus
continued on
page -008
To de-activate Tow Mode -

key down truck and
repower.
Figure 18035-01
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ELECTRICAL SYSTEM
Access 123
Features F11 Max Load Weight = ___; This feature prompts you
to enter the maximum capacity load, which is indicated
The feature menu is shown on the following pages. The on the truck's Capacity Data Plate. If more than one
first level of the menu shows the different areas of capacity is listed, then enter the heaviest weight listed
setup for the truck. on the Capacity Data Plate. Factory setting is 3000 lb.
Range dependant on truck model.
Features Access F14 Wire Guidance = ___; This feature adjusts wire
guidance setting. Factory setting is disabled.
After powering up the truck, navigate to the SERVICE
menu by pressing the down arrow button. At the SER- F15 Manual Wire Sense = ___; This feature adjusts
VICE menu, press the right arrow to enter LEVEL 2. manual wire sense setting. Factory setting is disabled.
Press the right arrow again to enter the Access pass- F16 End Aisle Control = ___; This feature adjusts end
word. Use the up/down arrow buttons to change num- aisle control to no EAC, north sensing or south sens-
ber, press right arrow to move to the next number. ing. Factory setting is No EAC.
Once all numbers in the Access code have been en-
tered press the enter/return button. Using the down ar- F17 PDS = ___; This feature adjusts PDS setting. Fac-
row, navigate to the FEATURES menu and then press tory setting is Disable.
the right arrow. The message displayed will be F1 Lan- F18 Battery Retainer Switch = ___; This feature ad-
guage =. justs battery retainer alarm setting. Factory setting is
If changes have been made in the sub menus, pressing No.
the left arrow at the first level menu will prompt "Save? F19 Travel Alarm = ___; This feature sets the alarm
N" in the settings. Use the up and down arrows to se- when traveling. Factory setting is Off.
lect Save? Y then press enter/return to save settings.
F20 User Performance = ___; This feature deter-
F1 Language = ___; This feature displays the desired mines whether the operator has the ability to select dif-
language for Access 1 display messages. Factory set- ferent truck performance levels. If enabled and F21 is
ting is English. Press down to scroll through 11 total disabled, any user can select any performance level
choices. (P1, P2, P3). If disabled, the operator can not change
F2 Unit of Measure = ___; This feature determines the truck performance modes. Press the right arrow, use
units of measure displayed (English or Metric). Factory the up and down arrows to change. Press enter/return.
setting is English. Press down arrow to continue. Press the down arrow to continue. Factory setting is
Disabled.
F3 Region = ___; This feature displays desired region.
Range includes North America, Europe and Australia. F21 User Codes = ____ Use this feature to enter up to
Factory setting is North America. 25 user codes (4 digits each) which can be applied to
various performance levels. To modify, press the right
F5 Truck Model = ___; This feature is must be se- arrow. Use the up and down arrows to enable or dis-
lected at setup. able. Press the right arrow to continue. Factory setting
F6 Mast Type = ___; This feature displays two mast is Disabled.
types: TT or TL. Factory setting is TT. Note: If F21 is enabled, operators can not change per-
F7 Collapsed Height = ___; This feature displays formance levels regardless of F20 setting. Truck will be
truck collapsed height. Factory setting is 107 in. limited to the performance level assigned to the User
Code.
F8 Lift Height = ___; This feature prompts you to enter
the truck lift height as shown on the truck data plate. F24 Motor Monitor System (MMS) = ___; This feature
Factory setting is 240 in. adjusts MMS setting. Factory setting is Disabled.
F10 Truck Weight = ___; This feature prompts you to F25 Zone Switch = ___; This feature adjusts zone
enter the truck weight as equipped with maximum bat- switch setting. Factory setting is No.
tery, which is indicated on the truck's Capacity Data
Plate. Factory setting is 8500 lb.
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ELECTRICAL SYSTEM
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F26 Message Mode = ___; This feature changes infor-

mation displayed during operation. Press the right ar-
row, use the up and down arrows to change.
Select from: BDI (battery percent of charge), Hours
(hour meter reading), Odometer (total distance truck
has traveled in miles), Trip (total distance truck has
traveled since last reset), Timer (stopwatch) or All (al-
lows operator to determine message using display but-
tons). Press enter/return. Menu will return to F26.
Press the down arrow to continue. Factory setting is
None.
F27 Truck Operation = ___; This feature adjusts set-
ting. Set to enabled or disabled. Only available if F14
setting is disabled. Factory setting depends on F14 set-
ting.
F28 Hour Meter Mode = ___; This feature determines
the hour meter that will be displayed during operation.
To change the displayed hour meter, press the right ar-
row, use the up and down arrows to change between
H1 and H2 (see hour meter description to determine
monitored system item). Press the enter/return button.
Menu will return to F28, press the down arrow to con-
tinue. Factory setting is Access 1.
F29 Reset Switch (HGTRS) Height = ___; This fea-
ture resets the height encoders. Factory setting is
15 in.
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ELECTRICAL SYSTEM
Access 123
Performance P1.2.1.1 Speed Curve = ___; This setting adjusts the

speed of the truck when the platform is elevated (ap-
The performance menu is shown on the following plies to free range mode only). Adjusting to a setting of
pages. The features menu determines adjustable 1 provides the slowest travel speed while a setting of 9
ranges for several performance items. Verification of provides the fastest travel speed. Factory setting is 9.0
proper features settings is recommended prior to set- in P1 mode. This setting does not affect the travel
ting up performance. speed of the truck when the platform is completely low-
ered.
P1, P2 and P3: Three performance levels may be se-
lected from when in the operator mode. These settings P1.2.1.2 Max FF = ___; Sets maximum speed in forks
affect forward and reverse travel speed and accelera- first direction (1.0 to 7.0 MPH dependant on truck
tion rate. Refer to F19 in the features menu to enable/ model).
disable. The factory settings for the P1 performance
P1.2.1.3 Max PUF = ___; Sets maximum speed in
level are set to achieve the maximum performance.
power unit first direction (1.0 to 7.5 MPH dependant on
The P3 performance level is the lowest setting of the
truck model).
three performance levels. Travel speeds displayed do
not account for the boosted speed when equipped with P1.2.2 Guided = ___; Applies to guided or rail guided
the Capacity Data Monitor (CDM) option. Also, trucks mode.
equipped with the CDM option have faster fork empty
P1.2.2.1 Speed Curve = ___; This setting adjusts the
lowering speed than what is displayed in the submenu.
Settings for each performance level can be higher, plies to guided or rail guided mode only). Adjusting to a
lower or the same as the setting under any other per- setting of 1 provides the slowest travel speed while a
formance level, for example - traction speeds forward setting of 9 provides the fastest travel speed. This set-
and reverse can be the same for all performance levels ting does not affect the travel speed of the truck when
and the acceleration rate can be different for all perfor- the platform is completely lowered. Factory setting is
mance levels. 9.0 in P1 mode.
P1.2.2.2 Max FF = ___; Sets maximum speed in forks
Performance Access first direction (1.0 to 7.0 MPH dependant on truck
Power up the truck, navigate to the SERVICE menu by model).
pressing the down arrow button. At the SERVICE P1.2.2.3 Max PUF = ___; Sets maximum speed in
menu, press the right arrow to enter LEVEL 2. Press power unit first direction (1.0 to 7.5 MPH dependant on
the right arrow again to enter the Access password. truck model).
Use the up/down arrow buttons to change number,
press right arrow to move to the next number. Once all P2 Setup P2 - Enter the parameters for the P2 level in
numbers in the Access code have been entered press this sub menu. Press the right arrow to view/modify the
the enter/return button. Using the down arrow navigate current P2 settings.
to the PERFORMANCE menu, and then press the right P2.1 Travel Acceleration = ___; This setting…. Ad-
arrow. This message displayed will be P1 Setup. justing to a setting of 1 provides the least aggressive
P1 Setup P1 - Enter the parameters for the P1 level in acceleration. Adjusting to a setting of 9 provides the
this sub menu. Press the right arrow to view/modify the most aggressive acceleration.
current P1 settings. P2.2 Travel Speeds = ___; This setting displays vari-
P1.1 Travel Acceleration = ___; Adjusting to a setting ous truck speeds.
of 1 provides the least aggressive acceleration while a P2.2.1 Free Range = ___; Applies to free range mode.
setting of 9 provides the most aggressive acceleration.
Factory setting is 9.0 in P1 mode. P2.2.1.1 Speed Curve = ___; This setting adjusts the
P1.2 Travel Speeds = ___; This setting displays vari- plies to free range mode only). Adjusting to a setting of
ous truck speeds. 1 provides the slowest travel speed while a setting of 9
P1.2.1 Free Range = ___; Affects truck performance provides the fastest travel speed. This setting does not
with forks raised above free lift. affect the travel speed of the truck when the platform is
completely lowered. Factory setting is 7.0.
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ELECTRICAL SYSTEM
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P2.2.1.2 Max FF = ___; Sets maximum speed in forks P3.2.2.1 Speed Curve = ___; This setting adjusts the
first direction (1.0 to 7.0 MPH dependant on truck speed of the truck when the platform is elevated (ap-
model). plies to guided or rail guided mode only). Adjusting to a
setting of 1 provides the slowest travel speed while a
setting of 9 provides the fastest travel speed. This set-
ting does not affect the travel speed of the truck when
truck model).
the platform is completely lowered. Factory setting is
P2.2.2 Guided = ___; Applies to guided or rail guided 5.0.
mode.
P2.2.2.1 Speed Curve = ___; This setting adjusts the first direction (1.0 to 7.0 MPH dependant on truck
speed of the truck when the platform is elevated (ap- model).
plies to guided or rail guided mode only). Adjusting to a
setting of 1 provides the slowest travel speed while a
setting of 9 provides the fastest travel speed. This set-
truck model).
ting does not affect the travel speed of the truck when
the platform is completely lowered. Factory setting is P4 Plug = ___; Adjusts the plugging force. Setting al-
7.0. lows the adjustment of plugging distance. Adjusting to
a setting of 1 provides the least aggressive decelera-
tion. Adjusting to a setting of 9 provides the most ag-
first direction (1.0 to 7.0 MPH dependant on truck
gressive deceleration. The longest plugging distance
model).
will occur with the accelerator pedal near the neutral
P2.2.2.3 Max PUF = ___; Sets maximum speed in position and P4 setting of 1. The shortest plugging dis-
power unit first direction (1.0 to 7.5 MPH dependant on tance is achieved when the accelerator pedal is fully
truck model). depressed and P4 setting of 9. Factory setting is 9.0.
P3 Setup P3 - Enter the parameters for the P3 level in Press the right arrow to modify. Range is 1 to 9. Factory
this sub menu. Press the right arrow to view/modify the setting is 9. Press the enter/return button to accept.
current P3 settings. The menu will return to P5, press the down arrow to
continue.
P3.1 Travel Acceleration = ___; This setting…. Ad-
justing to a setting of 1 provides the least aggressive P5 Coast = ___; Controls the amount of regenerative
acceleration. Adjusting to a setting of 9 provides the braking current applied to the drive motor when the op-
most aggressive acceleration. erator returns the accelerator pedal to neutral while the
truck is moving. The higher the setting, the lower the
P3.2 Travel Speeds = ___; This setting displays vari-
amount of regenerative braking current applied to the
ous truck speeds.
drive motor, resulting in the longest coasting distance.
P3.2.1 Free Range = ___; Applies to free range mode. The lower the setting, the higher the amount of regen-
erative braking current applied to the drive motor, the
P3.2.1.1 Speed Curve = ___; This setting adjusts the
shorter the coasting distance. Press the right arrow to
adjust. Use the up/down arrows to select desired
plies to free range mode only). Adjusting to a setting of
amount of regenerative braking applied. Adjusting to a
1 provides the slowest travel speed while a setting of 9
setting of 1 provides the least coast distance while ad-
provides the fastest travel speed. This setting does not
justing to a setting of 9 provides the most coast dis-
affect the travel speed of the truck when the platform is
tance. Factory setting is 9. Press the Enter button to
completely lowered. Factory setting is 5.0.
save. Display returns to P5 Coast =, press the down
P3.2.1.2 Max FF = ___; Sets maximum speed in forks arrow.
first direction (1.0 to 7.0 MPH dependant on truck
P6 Braking = ___; Settings regarding truck stoppage.
model).
P6.1 FF Braking = ___; This setting affects the braking
effort of the drive motor brake when traveling in the
forks first (FF) direction. Adjusting to a setting of 1 pro-
truck model).
vides the least aggressive braking while adjusting to a
P3.2.2 Guided = ___; Applies to guided or rail guided setting of 9 provides the most aggressive braking. Fac-
mode. tory setting is 7.
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ELECTRICAL SYSTEM
Access 123
P6.2 PUF Braking = ___; This setting affects the brak- P12.1 Mode = ___; This setting determines the EAC
ing effort of the drive motor brake when traveling in the operating mode of trucks equipped with EAC. Choices
power unit first (PUF) direction. Adjusting to a setting of are slowdown, slowdown with auto resume, slowdown
1 provides the least aggressive braking while adjusting with auto stop, stop using motor and stop using brake.
to a setting of 9 provides the most aggressive braking. Factory setting is slowdown mode.
Factory setting is 7.
P12.2 FF Direction = ___; This setting adjusts forks
P7 Free Range Speeds; Affects truck performance first (FF) direction.
with forks raised above free lift. Press the right arrow to
P12.2.1 Slowdown Speed = ___; This setting adjusts
modify.
the truck speed when traveling forks first in slowdown
P7.1 1 MPH Height = ___; Enter lift height where travel mode (adjustment range from 1.0 to 6.0 MPH). Factory
is cutback to 1 MPH when the truck is in free ranging setting is 2.0 MPH.
mode. Factory setting is 600 in.
P12.2.2 Decel Rate = ___; This setting adjusts the
P7.2 0 MPH Height = ___; Enter lift height where travel maximum speed to slowdown speed in the forks first
is cutback to 0 MPH when the truck is in free ranging direction. Adjusting to a setting of 1 provides the least
mode. Factory setting is 600 in. aggressive deceleration. Adjusting to a setting of 9 pro-
vides the most aggressive deceleration. Factory set-
P8 Guided Speeds = ___;
ting is 3.0 MPH.
P8.1 1 MPH Height = ___; Enter lift height where travel
P12.2.3 Resume Distance = ___; This setting adjusts
is cutback to 1 MPH when the truck is in guiding or rail
the forks first distance that the truck must travel beyond
guiding mode. Factory setting is 600 in.
the EAC magnets (into the slowdown zone) before
P8.2 0 MPH Height = ___; Enter lift height where travel traction speed is released from the slowdown speed
is cutback to 0 MPH when the truck is in guiding or rail (adjustment range from 10 to 60 ft). This setting is used
guiding mode. Factory setting is 600 in. on trucks set to slowdown with auto resume (see
P12.1). Factory setting is 45 ft.
P8.3 Acquire Speed = ___; Sets the travel speed
when trucks with wire guidance are acquiring the wire. P12.2.4 Stop Distance = ___; This setting adjusts the
Factory setting is 2.5 MPH. forks first distance that the truck must travel beyond the
EAC magnets (into the slowdown zone) before the
P9 BDI = ___; This setting adjusts the electronic sys-
truck stops (adjustment range from 0 to 40 ft). Factory
tem that monitors the battery's state of charge. Chang-
setting is 20 ft. This setting is used on trucks set to
ing this setting will affect the battery lift lockout level,
slowdown with auto stop (see P12.1).
which disables the lift circuit when the battery is dis-
charged 80%. Decreasing the P9 setting will allow the P12.3 PUF Direction = ___; This setting adjusts power
battery to go into deeper discharge before lift lockout unit first (PUF) direction.
occurs. Increasing the P9 setting will increase the volts
per cell monitor level disabling the lift function earlier in
the truck speed when traveling power unit first in slow-
the discharge cycle. Adjusting to a setting of 1 takes
down mode (adjustment range from 1.0 to 6.0 MPH).
the battery to the deepest discharge. Adjusting to a set-
Factory setting is 2.0 MPH.
ting of 9 decreases the level of discharge. Factory set-
ting is 5. Press the enter/return button to accept. The P12.3.2 Decel Rate = ___; This setting adjusts the
menu will return to P9, press the down arrow to con- maximum speed to slowdown speed in the power unit
tinue. first direction. Adjusting to a setting of 1 provides the
least aggressive deceleration. Adjusting to a setting of
Note: Adjusting the P9 setting to a level that permits
9 provides the most aggressive deceleration. Factory
the battery to discharge too deep, may affect truck per-
setting is 5.
formance and reduce battery life.
P12.3.3 Resume Distance = ___; This setting adjusts
P12 EAC Setup = ___; This setting adjusts End Aisle
the power unit first distance that the truck must travel
Control settings.
beyond the EAC magnets (into the slowdown zone) be-
fore traction speed is released from the slowdown
speed (adjustment range from 10 to 60 ft). This setting
is used on trucks set to slowdown with auto resume
(see P12.1). Factory setting is 45 ft.
M4.3-7335-042 SP 3500 Crown 2007 PF15813-42
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ELECTRICAL SYSTEM
Access 123
P12.3.4 Stop Distance = ___; This setting adjusts the P14 Low Speed Lower = ___; Adjusts various lower-
power unit first distance that the truck must travel being speeds.
yond the EAC magnets (into the slowdown zone) be-
P14.1 Low Speed Lower 1 = ___; This setting adjusts
fore the truck stops (adjustment range from 0 to 40 ft).
the low speed lowering above 15 in of lift. Adjusting to
Factory setting is 20 ft. This setting is used on trucks
a setting of 1 provides the slowest lowering speed. Ad-
set to slowdown with auto stop (see P12.1).
justing to a setting of 9 provides the fastest lowering
P12.4 Slowdown Direction = ___; This setting tells speed.
the truck if it should slowdown when traveling out of the
P14.2 Low Speed Lower 2 = ___; This setting adjusts
aisle only or in both directions. Choices are "Out of
the platform sit down rate (fork fully lower to the
Aisle Only" or "Into and Out of Aisle". This setting does
ground). Adjusting to a setting of 1 provides the slow-
not apply to trucks set to Slowdown with Auto Resume
est/softest lowering speed. Adjusting to a setting of 9
(see P12.1). Factory setting is Out of Aisle Only.
provides the fastest/hardest lowering speed.
P12.5 Magnet Spread = ___; This setting tells the
P14.3 Aux Lower Speed = ___; Adjusting to a setting
truck the distance between the inside magnets at a
of 1 decreases aux lowering speed. Adjusting to a set-
cross aisle (adjustment range from 20 to 150 ft). This
ting of 9 decreases aux lowering speed. This setting
setting is used on trucks set to Slowdown with Auto Re-
adjusts the lowering speed of the lifting forks on se-
sume (see P12.1).
lected models.
P13 PDS Setup = ___; Adjusts PDS settings.
P15 Soft Shift = ___; This setting adjusts the deceler-
P13.1 FF Direction = ___; This setting adjusts forks ation rate of the platform lowering after the lower switch
first (FF) direction. has been released. Adjusting to a setting of 1 provides
the slowest/softest stop. Adjusting to a setting of 9 pro-
P13.1.1 Max Speed = ___; Sets maximum speed in
vides the fastest/hardest stop.
forks first direction when PDS is active (1.0 to 6.5
MPH). Factory setting is 6.0 MPH. P99 Load factory defaults - Loads factory settings for
all Performance menu levels. Press the right arrow to
select this feature. Use up arrow to select "Y" to accept
the forks first truck speed when in PDS slowdown
factory settings. Display returns to P99, press the left
mode (adjustment range from 1.0 to 6.0 MPH). Factory
arrow to exit to main menu.
setting is 1.5 MPH.
P13.1.3 Decel Rate = ___; This setting adjusts the de-
celeration from maximum speed to slowdown speed in
the forks first direction. Adjusting to a setting of 1 pro-
vides the least aggressive deceleration. Adjusting to a
setting of 9 provides the most aggressive deceleration.
Factory setting is 9.0 MPH.
P13.2 PUF Direction = ___; This setting adjusts power
unit first (PUF) direction.
P13.2.1 Max Speed = ___; Sets maximum speed in
power unit first direction when PDS is active (1.0 to 7.5
MPH). Factory setting is 6.0 MPH.
the power unit first truck speed when in PDS slowdown
mode (adjustment range from 1.0 to 6.0 MPH). Factory
setting is 1.5 MPH.
P13.2.3 Decel Rate = ___; This setting adjusts the de-
celeration from maximum speed to slowdown speed in
the power unit first direction. Adjusting to a setting of 1
provides the least aggressive deceleration. Adjusting
to a setting of 9 provides the most aggressive deceler-
ation.
Crown 2007 PF15813-43 SP 3500 M4.3-7335-043
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ELECTRICAL SYSTEM
Access 123
Chart 1 -
Chart 1 - FACTORY SETTING CHART
FACTORY SETTING CHART
P12.1 Slowdown Mode
Menu Factory Setting P12.2.1 3.2 kph (2.0 mph)
P12.2.2 3
P1.1 14.0 kph (9.0 mph)
P12.2.3 13.7 m (45 ft)
P1.2.1.1 14.0 kph (9.0 mph)
P12.2.4 6.1 m (20 ft)
P1.2.1.2 See Chart 2
P12.3.1 3.2 kph (2.0 mph)
P12.3.2 5
P1.2.2.1 14.0 kph (9.0 mph)
P12.3.3 13.7 m (45 ft)
P12.3.4 6.1 m (20 ft)
P12.4 Out of Aisle Only
P2.1 11.3 kph (7.0 mph)
P12.5 24.4 m (80 ft)
P2.2.1.1 11.3 kph (7.0 mph)
P13.1.1 9.7 kph (6.0 mph)
P13.1.2 2.4 kph (1.5 mph)
P13.1.3 9
P2.2.2.1 11.3 kph (7.0 mph)
P13.2.1 9.7 kph (6.0 mph)
P13.2.2 2.4 kph (1.5 mph)
P13.2.3 9
P3.1 8.0 kph (5.0 mph)
P14.1 5
P3.2.1.1 8.0 kph (5.0 mph)
P14.2 1
P14.3 5
P15 5
P3.2.2.1 8.0 kph (5.0 mph)
P4 9
P5 9
P6.1 7
P6.2 7
P7.1 15240 mm (600 in)
P7.2 15240 mm (600 in)
P8.1 15240 mm (600 in)
P8.2 15240 mm (600 in)
P8.3 4.0 kph (2.5 mph)
P9 5
M4.3-7335-044 SP 3500 Crown 2007 PF15813-44
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ELECTRICAL SYSTEM
Access 123
Chart 2 - P1 PERFORMANCE CHART
P1 Default and Maximum

Region Model Free Range Guided
FF PUF FF PUF
9.7 kph 10.5 kph 9.7 kph 10.5 kph
SP3505
(6.0 mph) (6.5 mph) (6.0 mph) (6.5 mph)
10.5 kph 12.1 kph 10.5 kph 12.1 kph
SP3510
North (6.5 mph) (7.5 mph) (6.5 mph) (7.5 mph)
America 10.5 kph 12.1 kph 10.5 kph 12.1 kph
SP3520
(6.5 mph) (7.5 mph) (6.5 mph) (7.5 mph)
11.3 kph 12.1 kph 11.3 kph 12.1 kph
SP3550
(7.0 mph) (7.5 mph) (7.0 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3511
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3512
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
Europe
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3521
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3522
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3510
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3520
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
Australia
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3522
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 11.3 kph 12.1 kph
SP3550
(5.6 mph) (5.6 mph) (7.0 mph) (7.5 mph)
Crown 2007 PF15813-45 SP 3500 M4.3-7335-045
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ELECTRICAL SYSTEM
Access 123
P2 Default
FF PUF FF PUF
8.9 kph 9.7 kph 8.9 kph 9.7 kph
SP3505
(5.5 mph) (6.0 mph) (5.5 mph) (6.0 mph)
9.7 kph 11.3 kph 9.7 kph 11.3 kph
SP3510
SP3520
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
10.5 kph 11.3 kph 10.5 kph 11.3 kph
SP3550
(6.5 mph) (7.0 mph) (6.5 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3511
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3512
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
Europe
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3521
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3522
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3510
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3520
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
Australia
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3522
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3550
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
M4.3-7335-046 SP 3500 Crown 2007 PF15813-46
148
ELECTRICAL SYSTEM
Access 123
P3 Default
FF PUF FF PUF
(8.0 kph 8.9 kph (8.0 kph 8.9 kph
SP3505
5.0 mph) (5.5 mph) 5.0 mph) (5.5 mph)
8.9 kph 10.5 kph 8.9 kph 10.5 kph
SP3510
SP3520
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
9.7 kph 10.5 kph 9.7 kph 10.5 kph
SP3550
(6.0 mph) (6.5 mph) (6.0 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3511
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3512
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
Europe
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3521
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3522
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3510
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3520
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
Australia
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3522
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3550
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
Crown 2007 PF15813-47 SP 3500 M4.3-7335-047
149
Notes:
150
ELECTRICAL SYSTEM
Wire Guidance
Wire Guidance Sensor bars mounted on centerline at both ends of

truck, near floor, contain coils which act as antennas to
The Wire Guidance System automatically steers truck receive transmitted signal. The closer a coil gets to be-
down aisle without use of guide rails. Line driver pro- ing directly over the wire, the higher the amplitude of
duces set frequency of 5.2 kHz, 6.25 kHz, 7.0 kHz, or signal received by the coil. Using coil signal amplitude
10 kHz, which is transmitted through wire embedded in comparisons, truck will "sense" signal path. With this
floor down middle of each aisle. Generated signal is data, steering is electronically controlled to follow the
transmitted through embedded wire, as shown in Fig- signal.
ure 17183-01.
The wire guidance selector switch (GUS) on the con-
sole selects manual or automatic steering. When in
manual mode, truck steering is controlled by operator.
Steering remains in operator's control when switching
to automatic until guidance signal is detected. When
guidance signal is detected, steering control is auto-
matically changed to guidance system.
To align truck to wire guide signal, turn wire guidance
switch (GUS) to on. Approach angle must be no
greater than 30° and traction speed should be below
2.4 km/h (1.5 mph). Refer to Figure 17185-01. Brakes
are automatically applied when approach angle is ex-
ceeded in automatic mode. If approach speed is
greater than 2.4 km/h (1.5 mph), truck will decelerate
to 2.4 km/h (1.5 mph). Traction speed is limited to
2.4 km/h (1.5 mph) in automatic mode until truck is
aligned with wire. When aligned, acquisition speed limit
is removed and applicable speed vs. height curve will
be in force.
Figure 17183-01
(a) Line Drive Figure 17185-01

(b) Storage Racks
(a) Embedded Wire
(c) Transmitted Signal
(b) Maximum Approach Angle Cannot Exceed 30°
(d) Floor
(e) Epoxy
(f) Wire Embedded in Floor (Saw Cut)
Crown 2008 PF15815-1 SP 3500 M4.3-7335-500
151
ELECTRICAL SYSTEM
Wire Guidance
Some conditions that might cause an automatic slow Operation Modes

down while traveling on wire guidance:
• Low signal strength from wire. Manual

• Truck deviates slightly from wire. When wire guidance selector switch (GUS) is in "man-
ual" position, truck steering is in operator's control.
• End of Aisle Control (EAC) (Optional) is activated.
Automatic
• Corrupted signal due to rebar, electrical conduit
and/or drain pipes beneath the floor. When wire guidance selector switch (GUS) is placed in
"automatic" position, electronics enter Search mode.
Some conditions that might cause an automatic stop At this time guidance signal has not been detected by
while traveling on wire guidance: sensors. The "auto" and "manual" indicators are both
on and traction speed is limited to 2.4 km/h (1.5 mph).
• Signal strength from wire is lost or too low.
Steering control remains in manual mode.
• Acquiring wire at an angle greater than 30°. When either sensor bar detects guidance signal, Auto
Acquisition mode will be indicated by a display change
• Truck deviates too far from wire. and a one second audible alarm. If traction speed at
this time is greater than 2.4 km/h (1.5 mph), truck will
• End of Aisle Control (EAC) (Optional) is activated.
decelerate to 2.4 km/h (1.5 mph). If angle of truck to
• Corrupted signal due to rebar, electrical conduit wire is greater than 30°, brakes will be applied. To re-
lease brakes, guidance selector switch (GUS) must be
and/or drain pipes beneath the floor.
placed in manual position. If angle of truck is within lim-
Each sensor bar contains four coils which act as sepa- its when signal is detected, manual indicator is turned
rate antennas. When the amplitude of guidance signals off and steering is controlled by electronics. Traction
received is compared, the higher amplitude signals are speed is still limited to 2.4 km/h (1.5 mph).
from coils in closer proximity to embedded wire. Sen-
When traveling in either direction, guidance system will
sors mounted on truck electronically "sense" where the
align truck with wire when all parameters are met: truck
truck is in reference to guidance signal. When wire
less than 19 mm (0.75 in) from wire, truck angle less
guidance selector switch (GUS) is in "automatic" mode,
than 1° and steer wheel less than 6° from center. When
steering module provides correct polarity and ampli-
truck is adequately aligned, auto tracking mode is indi-
tude of voltage to steering motor to keep truck centered
cated by a 2 second operation of the alarm. In this
over guidance signal. Feedback from steering feed-
mode truck is automatically guided by electronics and
back encoder (ECR2) verifies steered wheel is turned
acquisition speed limit is removed.
in direction required.
Whenever wire guidance signal strength drops near
minimum required to guide truck, guidance module
outputs a signal to illuminate signal strength light on
display (Signal). Steering module sends signal to trac-
tion controller for 2.4 km/h (1.5 mph) maximum traction
speed. If signal strength returns, signal strength indica-
tor is turned off and traction speed limit is removed.
If there is loss of guidance signal, or if signal strength
is below minimum required to guide truck, guidance
module will output signals to operate alarm and apply
brake. It will also turn the "automatic" indicator off and
turn the "manual" indicator on. Wire guidance selector
switch (GUS) must be placed in "manual" position to
release brake.
M4.3-7335-501 SP 3500 Crown 2008 PF15815-2
152
ELECTRICAL SYSTEM
Wire Guidance
3. Auto Wire Lost will occur if one or more of four sit-

uations are present:
– Guidance signal lost.
– Centerline of truck leaves signal path by more
than 38 mm (1.50 in).
– Angle of truck to guidance signal is more than
1.8°.
– Steer wheel angle is more than 12° during Auto
Tracking. The truck is allowed to deviate more im-
mediately following a travel direction change.
When in Auto Wire Lost, alarm is operated continu-
ously and brake is applied. Guidance selector switch
(GUS) must be placed in "manual" position to release
brakes after this situation occurs.
Sensors
Figure 17187-01
Sensor bars are fastened to adjustable brackets which
(a) Vehicle Angle Calibration Incorrect; Truck Not Tracking in permit adjusting distance between sensor bars and
Straight Line floor. When line driver current output is set to 220 mA,
(b) Vehicle Angle Calibration Correct; Truck Tracking in Straight sensor bar should be level and 82 - 86 mm (3.25 to
Line 3.38 in) from floor. Refer to Figure 17186-01. Voltage
required by sensor bar to operate is 5 volts, between
Three variations to normal operation are encountered terminals 5 (positive) and 3 (negative).
during Auto Tracking mode:
1. Auto Field Strength variation is encountered when
guidance signal received by sensors decreases to
minimum required to continue Auto Tracking
Mode. When entering Auto Field Strength, alarm is
pulsating, field strength indicator is turned on and
traction speed is limited to 2.4 km/h (1.5 mph).
When guidance signal received returns to above
minimum levels, alarm stops pulsating, field
strength indicator is turned off and speed limit is
removed.
2. Auto Track Deviation is encountered if center of
truck leaves guidance signal by 19 - 38 mm (0.75 -
1.50 in), truck's angle is 1 - 1.8° or steer wheel an-
gle is 6 - 12° from center. When this happens,
Figure 17186-01
alarm is sounded (pulsates), and traction speed is
limited to 2.4 km/h (1.5 mph). When truck returns (a) Sensor Bar Height Adjustment
to acceptable tracking characteristics, alarm stops
(b) Sensor Bar
pulsating and is sounded for 2 seconds to indicate
auto tracking mode, and traction speed limit is re- (c) Floor
moved. (d) Truck Center Line
(e) Guide Wire
(f) 83 - 86 mm (3.25 - 3.38 in)
Crown 2008 PF15815-3 SP 3500 M4.3-7335-502
153
ELECTRICAL SYSTEM
Wire Guidance
Calibration (3.25 in). Sensor height is typically not correct upon

shipment, as bars are moved to prevent shipping dam-
age.
Instructions for Peak Coil Search, Wheel Angle,
and Truck Angle Calibration. 1. Key-up truck and toggle brake pedal. Once power
up sequence is complete, follow key sequences in
NOTE Chart 1 - Wire Guidance Calibration.
Before performing wire guidance calibration, verify that

both sensor bars are set to correct height of 82.55 mm
Chart 1 - Wire Guidance Calibration
Display Message Keystroke Display Message Keystroke Display Message

Enter Service Mode
SP 3500 q Service
Service q Level 2
Level 2 q ****
**** qq 2*** q
**** qqq *3** q
**** q **1* q
**** q ***1 Calibrate
Coil Calibration
Calibrate q C1
C1 q or q until C5
C5 q C5.1 Sensor q Sensor Coil C5.1.2
q Sure? N q Sure? Y
Go to Auto When
Sure? Y
Done
2. Perform slow criss-cross maneuver across wire

two times at a small approach angle with little or no
steer tiller motion to complete the peak coil search
calibration. Make certain both sensor bars traverse
completely over the wire each pass. Edge of bars
shall be at least 304.80 mm (12 in) from wire at far
ends of pass. Passes can be made from right-to-
left or left-to-right. Refer to Figure 18596.
M4.3-7335-503 SP 3500 Crown 2008 PF15815-4
154
ELECTRICAL SYSTEM
Wire Guidance
WIRE
WIRE
Keep angle between CL and WIRE

as small as possible
Figure 18596
Crown 2008 PF15815-5 SP 3500 M4.3-7335-504
155
ELECTRICAL SYSTEM
Wire Guidance
3. Once peak coil search is complete, place Guid- DISPLAY MESSAGE => Forks Trailing/Leading;
ance Switch (GUS) in AUTO position to begin Press q to view % complete but not required.
wheel angle calibration.
16. Continue traveling in same direction until beeper
4. Acquire the wire and travel the required distance sounds to indicate travel complete.
FF or PUF.
DISPLAY MESSAGE => Come to stop
DISPLAY MESSAGE => Forks Leading/Trailing;
17. Bring truck to a stop.
Press q to view % complete but not required.
DISPLAY MESSAGE => Switch to Manual
sounds to indicate travel complete. 18. Place GUS in MANUAL position. => Beeper will
sound.
DISPLAY MESSAGE => Switch to AUTO
DISPLAY MESSAGE => Change Direction
19. Place GUS in AUTO position to begin offset null
7. Travel on wire the required distance in the opposite
calibration. => Beeper will sound and truck ac-
direction.
quires wire.
DISPLAY MESSAGE => Forks Trailing/Leading;
20. Travel the required distance FF or PUF.
sounds to indicate travel complete.
10. Place GUS in MANUAL position. => Beeper will
sound.
direction.
DISPLAY MESSAGE => Switch to AUTO
DISPLAY MESSAGE => Forks Trailing/Leading;
11. Place GUS in AUTO position to begin truck angle Press q to view % complete but not required.
calibration. => Beeper will sound and truck ac-
quires wire.
12. Travel the required distance FF or PUF.
sounds to indicate travel complete. 26. Place GUS in MANUAL position. => Beeper will
sound.
Follow Chart 2 - Save Wire Guidance Calibration key
sequence to save wire guidance calibration.
direction.
Chart 2 - Save Wire Guidance Calibration

Save Wire Guidance Calibration
Sensor Coil C5.1.2 q Sensor Coil C5.1 q Save? N
Save? N q Save? Y Calibrate
M4.3-7335-505 SP 3500 Crown 2008 PF15815-6
156
ELECTRICAL SYSTEM
Wire Guidance
Re-key truck for new calibration values to take effect. NOTE

Instructions for X_Offset Calibration X_Offset value is reset to 0 at the start of a new
X_Offset calibration process. X_Offset value is cumu-
NOTE lative among any multiple passes in a given direction,
within a single calibration process.
Before performing wire guidance calibration, verify that
both sensor bars are set to correct height of 82.55 mm NOTE
(3.25 in). Sensor height is typically not correct upon
shipment as bars are moved to prevent shipping dam- Entering the offset distance as right (+) or left (-) for
age. either direction of travel (PUF or FF) is with respect to
operator's right and left when facing forks.
NOTE
NOTE
X_Offset calibration can be performed in conjunction
with C5.1 Peak Coil and Angle calibration, or indepen- Independent offset values can be entered for Forks
dently. First and Forks Trailing directions.
NOTE
Exiting X_Offset calibration without saving leaves ac-
tive the last known calibration values.
1. Key-up truck, toggle brake pedal. Once power up
sequence is complete, follow key sequences in
Chart 3 - X_Offset Calibration to perform X_Offset
calibration.
Chart 3 - X_Offset Calibration

Enter Service Mode
SP 3500 q Service
Service q Level 2
Level 2 q ****
**** qq 2*** q
**** qqq *3** q
**** q **1* q
**** q ***1 Calibrate
X_Offset Calibration
Calibrate q C1
C1 q or q until C5
C5 q C5.1 Sensor q X_Offset C5.2
X_Offset C5.2 q X_Offset C5.2.1 q Sure? N
Sure? N q Sure? Y Travel on wire
Crown 2008 PF15815-7 SP 3500 M4.3-7335-506
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ELECTRICAL SYSTEM
Wire Guidance
2. Acquire the wire and travel FF / PUF the required 6. Measure distance from center of sensor bars to
distance. wire. Press q or q until this desired offset distance
is displayed. Press to keep displayed value.
DISPLAY MESSAGE => Forks Leading/Trailing
DISPLAY MESSAGE => Travel to Continue or Enter
to End
sounds to indicate travel complete. Continuous
travel of 40 ft (480 in) in given direction is required. 7. By traveling to continue calibration, adjustment val-
ues can be verified by repeating the same direction
DISPLAY MESSAGE => Distance Reached Come to
of travel. Subsequent adjustments for a given di-
stop
rection can be entered and accumulate on the pre-
4. Bring truck to a stop. vious X_Offset total for that given calibration pro-
cess.
DISPLAY MESSAGE => Move truck Right/Left
8. Follow key sequences of Chart 4 - Save X_Offset
5. Press q or q to toggle between Right/Left. Press
Calibration to end and save X_Offset calibration
once desired direction is displayed.
values.
DISPLAY MESSAGE => 0.1 in
Chart 4 - Save X_Offset Calibration

Save X_Offset Calibration
Travel to Continue or
X_Offset C5.2 q Save? N
Enter to End
Save? N q Save? Y Calibrate
9. Re-key truck for new calibration values to take ef-

fect.
Refer to InfoPoint Quick Reference Guide for further
information on wire guidance calibration.
M4.3-7335-507 SP 3500 Crown 2008 PF15815-8
158
ELECTRICAL SYSTEM
End Aisle Control (EAC)
End Aisle Control (EAC) EAC system consists of a front bumper sensor bar
which includes four sensors and sensor distribution
The purpose of EAC is to remind operator that the end board.
or intersection of a warehouse aisle is approaching.
Figure 18278 provides a pictorial view of some compo-
This system incorporates magnets in the warehouse
nents involved with end aisle control. Sensor bracket
floor and magnetic sensors on the truck. Upon detec-
containing four sensors is mounted to main frame of
tion of magnets, when approaching end of aisle, sen-
truck, in front bumper. Sensors A1 and B1 activate dur-
sors send a signal to truck's computer to apply a trac-
ing travel in forward (forks leading) direction and sen-
tion plug condition to slow the vehicle. A text message
sors A2 and B2 active in reverse (forks trailing) direc-
indicating EAC zone "entered" is displayed on operator
tion. A text message appears on operator display to
display
provide an indication of when truck enters or operates
End Aisle Control is divided into two modes of opera- in an end of aisle control area.
tion. Auto Guide mode is in force when truck is in wire
Sensors are positioned to place the "A" sensors
or rail guide tracking mode. Traction speed is con-
200 mm (8 in) from truck's centerline and "B" sensors
trolled by fork height versus speed curve. End of Aisle,
305 mm (12 in) from truck's centerline on a standard
Auto Guided mode is in force when a truck, in wire or
application. In a special application the "A" sensors can
rail guide tracking mode, detects magnets while travel-
be positioned any distance more than 200 mm (8 in)
ing toward end of aisle. End of Aisle result is selectable
from truck's centerline provided "B" sensors are a min-
as stop or slowdown via plug or brake.
imum of 100 mm (4 in) from "A" sensors.
A traction automatic speed resume is a selectable fea-
Different sensors must be used for sensing north or
ture. This feature will automatically release traction
south magnetic poles. Sensors for sensing north mag-
speed limit actuated by EAC zone and once truck has
netic poles are standard.
traveled its preset distance beyond EAC magnets.
End Aisle Sensors

Forward Direction
(Forks First)
End Aisle Sensors

Reverse Direction
(Power Unit First)
Figure 18278
Located under battery compartment is a distribution connected to CA602, pins 1 through 14 on wire guid-
module for interconnection of EAC components. Sig- ance module.
nals from sensors and EAC distribution module are
Crown 2007 PF15794-1 SP 3500 M4.3-7335-600
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ELECTRICAL SYSTEM
Wire Guidance Calibration Speeds

For more information on wire guidance calibration
speeds, refer to Wire Guidance.
EAC Zones:
• Zone 1 - Out of Aisle/Entering Aisle
• Zone 2 - Center of Magnets
• Zone 3 - Out of Aisle/Exiting Aisle
Troubleshooting
EAC components are monitored by system software
and will log a fault into memory whenever a problem
with EAC system occurs:
EAC Event Codes:
• 566 - EAC Hardware Fault
• 567-570 - EAC Sensor Latched ON
• 571-572 - EAC Magnet Missed
• 652-659 - EAC Sensor Signal Range Fault
• 660-663 - EAC Sensor Digital Fault
• 664-667 - EAC Weak Magnet Fault
• 668-671 - EAC Sensor Hardware Fault
• 672 - EAC Multiple Sensors Active Fault

Codes 566 through 572 and 652 through 672 all pertain
to EAC system issues.
Two menu items in 1-Button mode can be used to de-
termine fault cause. The first shows state of digital
threshold detection. Any one of four sensors can be an-
alyzed. The state of digital input shall change as truck
passes over its corresponding magnet. The second is
a display of active sensor signal strength. It is pre-
sented as a percentage of full scale. The system has
shown EAC system works reliably with sensors dem-
onstrating a wide variation of reported peak signal
strength.
If issues are realized verify height of sensors above
floor, distance of center line of guidance bars to EAC
sensors and proper magnet positioning. Distance off
floor should be 18 - 25 mm (0.69 - 1.0 in).
M4.3-7335-601 SP 3500 Crown 2007 PF15794-2
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ELECTRICAL SYSTEM
Termination Point Locations
Chart 1 - Access 6 (Wire Guidance Module)
Pin Function Voltage Level Connection

1 EAC Sensor Power 12V CA602-1
2 EAC Sensor Battery Negative CA602-2
3 EAC A1 Test 7V in Test Mode CA602-3
4 EAC A1 Analog 0-5V When Over Magnet CA602-4
0V When Sensing Magnet, 5V When Not
5 EAC A1 Digital CA602-5
Sensing Magnet
6 EAC A2 Test 7V in Test Mode CA602-6
Sensing Magnet
10 EAC B1 Analog CA602-10
Sensing Magnet
11 EAC B1 Digital CA602-11
Sensing Magnet
12 EAC B2 Test 7V in Test Mode CA602-12
13 EAC B2 Analog 0-5V When Over Magnet CA602-13
Sensing Magnet
Crown 2007 PF15794-3 SP 3500 M4.3-7335-602
161
Notes:
162
ELECTRICAL SYSTEM
Wire Guidance
Wire Guidance
The truck steering system should be thoroughly
checked before alignment procedure is attempted. The
system operates through existing truck steering mech-
anism. Slack, lag or excessive wear within this system
will prevent guidance within specifications.
Verify the following:
• Steering feedback encoder is set when drive unit

alignment marks are aligned.
• Steering gears - condition and lubrication.
• Look for load wheel debris such as shrink wrap.
• Steering motor and brushes.
• Steering gearbox - condition and lubrication.
• Drive unit stud and mounting bolts.
• Drive unit thrust bearing and lubrication.
• Drive tire condition and type (poly only).
• Look for drive tire debris such as shrink wrap.
• Load wheel condition, including bearings.
• Look for load wheel debris such as shrink wrap.
• Steer wheel sensor condition, orientation and

height adjustment.
• Load wheel sensor condition, orientation and

height adjustment.
• Sensor bearing and condition.
Crown 2007 PF15816-1 SP 3500 M4.3-7335-800
163
ELECTRICAL SYSTEM
Wire Guidance
(a) Sensor Bar Height Adjustment (j) Sensor Bearing Assembly

(b) Sensor Bar (k) Steered Wheel Sensor
(c) Truck Centerline (l) Load Wheels
(d) Floor (m) Drive Tire
(e) Guidewire (n) Drive Unit Mounting Bolts
(f) Steering Motor (o) Drive Unit Thrust Bearing
(g) Steering Gearbox (p) Drive Unit Stud
(h) Steering Gears (q) Base of Main Frame (Located Under
Platform; Rotated for Clarity)
(i) Steering Feedback Encoder (r) Load Wheel Sensor
Figure 18236
M4.3-7335-801 SP 3500 Crown 2007 PF15816-2
164
ELECTRICAL SYSTEM
Contactor
Contactor Contacts
• In normal operation, the contacts will become
blackened, discolored, and roughened. This will
not interfere with proper operation and cleaning is
not necessary.
• The contacts should be replaced before the silver

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

placed in mating pairs.
Coil
• Remove all electrical connections.
Figure 10554-01 • Resistance reading of the coil should be between

15 - 19 ohms.
The purpose of this information is to instruct the techni-
cian on proper care and maintenance to obtain satis- • If reading does not fall within the limits, replace coil.
factory service from these devices. Crown has tested
and applied these contactors according to the require-
ments of our vehicle. No modifications or changes
should be made in the layout, physical arrangement or
electrical connections without permission from Crown.
CAUTION
Before any inspection, adjustments, servicing, parts re-
placement or any other act is performed requiring
physical contact with the electrical working compo-
nents or wiring of these contactors, disconnect battery,
raise drive wheels clear of floor and place blocks under
truck frame.
Inspection
The following information is intended to assist during
periods of normal maintenance and to provide checks
for maintaining adjustments. As these devices are
tested and adjusted at the factory, they should not nor-
mally require further adjustments. However, if factory
adjustments are tampered with or otherwise changed,
the checks contained in the following information may
be made.
Crown 1992 PF9313-1 Rev. 7/07 SP 3500 M4.4-04.2-001

04 Rev. 7/07
165
ELECTRICAL SYSTEM
Contactor
Component Replacement Coil Replacement

Refer to Figure 5674 and parts breakdown in Parts 1. Disconnect all electrical wiring.
Section of manual when replacing components.
2. Remove four mounting screws that secure contac-
tor to mounting bracket and remove contactor from
truck.
3. Remove two screws (5) and separate contact as-
sembly from coil assembly.
4. Select replacement coil and transfer plunger (9)
from existing coil to replacement coil.
5. Reassemble contact assembly to coil and secure
with two screws (5).
6. Mount contactor on truck and reconnect all electri-
cal wiring removed in step 1.
Figure 5674
Contact Replacement
1. Remove electrical connections to contacts (coils
do not have to be disconnected for this procedure).
2. Remove two screws (5) from top of contact and re-
move contact top cover (6).
3. Remove and replace contacts (contacts always
should be replaced in pairs).
4. Place contact assembly on coils and install top
cover and secure with two screws removed in step
1.
5. Connect electrical wiring removed in step 1.
M4.4-04.2-002 SP 3500 Crown 1992 PF9313-2 Rev. 7/07
04 Rev. 7/07
166
ELECTRICAL SYSTEM
Steering Feedback
Steering Feedback The steered wheel is now in the straight ahead po-
sition.
3. Observe the Wheel counts on the service terminal
Gear Assembly display. Since the steered wheel is in the straight
Whenever assembling the steering feedback gears, it ahead position the display should show an I plus a
is important that all gear backlash be removed. If this is number. If only a number is present, open the
not done, steering accuracy and response is reduced. power unit doors and locate the steering feedback
module. Remove the steering feedback cover.
Refer to Figure 12488-01. Loosen the two screws holding the encoder in
Place the nyliner bearing onto the gear shaft. Next place. Turn the encoder very slowly until the I plus
place one end of the torsion spring into the small hole a number appears on the service terminal display.
on the gear as shown. Slide the 18 T gear onto the gear While maintaining encoder position to keep this
shaft aligning the other end of the torsion spring with display on the service terminal, secure adjustment
the small hole on that gear. Slide the second nyliner with the two screws. Make certain the cleats hold-
bearing onto the gear shaft. Install the third nyliner ing the encoder have their flat surfaces turned
bearing on top as shown. away from the encoder.
Turn the top gear until the larger hole on both gears are 4. Exit "SHOW" menu and disconnect the service ter-
aligned, approximately 2 teeth. Slide a 3.1 mm (1/8 in) minal.
drill bit into the holes from the bottom to keep the gears 5. Install cover, close power unit doors and return to
aligned. operation.
Slide gear shaft up through the power unit. Once the
gears are meshed with the steering gearbox and drive
unit gears, install the flatwasher(s) (AR) and the retain-
CAUTION
ing ring to keep the gear assembly from sliding out. The steering indicators will not represent the proper
Slide the flatwasher onto the encoder shaft and insert steer angle. The steering feedback encoder must be
into the gear shaft assembly. Make sure the extension set to ensure the steered wheel is set to straight ahead
spring is installed. If necessary rotate the gear shaft so position.
the set screw faces straight back to allow for easy ac-
cess for tightening. Tighten set screw to secure en-
coder shaft to gear shaft.
Make certain the set screw is tightened on the flat part
of the encoder shaft. Remove drill bit from gear assem-
bly.
The steer wheel feedback encoder must be set to "in-
dex" when the steered wheel is in the straight ahead
position. To set and check the steering feedback en-
coder:
1. Connect the service terminal to the connector on
the platform below the control module, enter the
"SHOW" menu of terminal operation and select the
"VIEW ENCODER COUNTS" menu. If truck has
not been given a steering command since power
up, steering time-out will be 1 second. If a steering
command has been given since power up, steering
time-out is 2 minutes. To obtain the 1 second time-
out for improved steering alignment efforts, turn
tiller slightly. Time-out will change to 1 second.
2. After time-out, form a straight line with the align-
ment mark on the steered wheel drive unit and the
alignment mark on the drive unit mounting bracket.
Crown 2005 PF13971-1 Rev. 8/06 SP 3500 M4.5-7334-100

01 Rev. 8/06
167
Cover
Extension
Spring
Flatwashers
18 T Gear
Nyliner
Bearing
Torsion
Spring
Set 18 T Gear
Screw & Shaft
Retaining
Ring
Figure 12488-01
168
ELECTRICAL SYSTEM
Control Module
Control Module
The Control Module, located in the operator compart-
ment, contains all operator controls within easy reach.
A planned maintenance program should include
checking these operator controls for binding, sticking
or other unusual operation. An audio check should also
be made. Press buttons or turn twist grip in both direc-
tions slowly, while listening for switch actuation-reset-
ting (signified by a "click"). There should be a "double
click" for two speed lift/lower.
Access
CAUTION
Disconnect battery before performing disassembly pro- Directional & Speed Control Compartment
cedures.
To gain access to components in directional and speed Figure 12546-01
control compartment, remove five mounting screws
from console and lift console from platform wall. Con-
nect a voltmeter from battery negative TP16, or any po- WARNING
sition on CA107, to the distribution panel point that cor-
When making "live" voltage checks, chock load wheels
responds to the normally open side of the switch in
of truck, raise drive wheel clear of floor and place hard-
question. Battery volts should appear after appropriate
wood blocks under truck frame.
switch is closed. If battery volts is not seen, there is an
open circuit, incorrect switch connection or a bad To access remaining switches, remove mounting
switch. screws from control module housing. Lift control mod-
ule from wall and rotate down. While in this position, do
not apply unnecessary pressure to the module which
may damage the wiring harness. Due to weight, some
form of support may be needed.
Reverse disassembly procedure for assembly.
Crown 2007 PF15817-1 Rev. 12/07 SP 3500 M4.5-7335-001

01 Rev. 12/07
169
ELECTRICAL SYSTEM
Control Module
Troubleshooting tained from other side of switch, switch contacts are

making poor contact and should be replaced.
The following instructions are included to help isolate a
problem to the control module prior to disassembly.
Make an audio check of switch actuation and reset as Adjustments
described previously.
Components which are adjustable are contained within
Voltage readings can be made at the platform distribu- directional and speed control compartment.
tion panel to verify switch operation. Remove five
mounting screws from console and lift console from
platform wall. The distribution panel is to the right of the
Accelerator Potentiometer (POT1)
steer tiller. 1. Check or set up throttle potentiometer as follows.
When making voltage checks, battery must be con- From start up display:
nected, key switch cycled "TEST" to "ON", gates – Press "down" 3x to "Service".
closed and brake pedal depressed. Connect negative
meter lead to battery negative TP16, or any position on – Press "right" 1x to "Level 2".
CA107, for all voltage checks. Refer to Chart 1 - Switch – Press "right" 1x to "****". Enter code with "up",
Test Points for test point of each switch. "down" and "right" arrows. Press "return" to "Ana-
lyzer".
– Press "down" 3x to "Calibrate".
Chart 1 - Switch Test Points
– Press "right" 3x to "Sure? N"
Switch Test Points – Press "up" 1x to "Sure? Y" Press "return" to
"PUF Direction".
Brake TP1
– Press "right" 1x to "XX%". Throttle reading
B+ FU1 TP2
should be 50% ± 2%.
ED1 FU7 TP3
2. When installing new potentiometer, before mesh-
RAS1 TP4 ing gears, adjust reading to approximately 50%.
RAS2 TP5 3. Mesh gear teeth, tighten screws on mounting
bracket and proceed as follows:
B+ FU2 TP6
– Loosen potentiometer locknut.
Module Power TP7
– Rotate potentiometer back or forward to obtain
ALM1 TP8
50% ± 2%.
ED1 FU9 TP9
– Secure adjustment with locknut observing that
ED1 FU8 TP10 above range is maintained.
K1 Coil TP11 – Rotate twist grip from stop to stop.
K1 TP12 – Percentage should vary smoothly from approx-
imately 11% to 89% with center position of 50%.
CAN H TP13
– Press "left" 1x to "PUF Dir". Rotate to "full throt-
CAN L TP14
tle fwd" and press "return" to "FF Dir". Rotate to
B NEG TP16 "full throttle rev" and press "return" to "Center".
Press "return" again.
With switch actuated, voltage readings will be battery
volts. If a voltage less than battery volts is measured, it – Press "left" 1x to "Save? N".
could mean a bad connection, faulty switch, pinched – Press "up" 1x to "Save? Y". Press "return" and
wire or anything that could introduce resistance in the key down.
line. For example, if battery volts is read on one side of
a switch, but a voltage less than battery volts is ob-
M4.5-7335-002 SP 3500 Crown 2007 Pf15817-2
170
ELECTRICAL SYSTEM
Control Module
Directional Switches (FS & RS)

1. With twist grip in neutral position, turn adjustment
screws slowly on both directional switches, clock-
wise, until switch activates.
2. Turn both screws 1/2 turn counterclockwise.
3. Observe voltage reading 48% to 52% in center po-
sition and record.
4. Slowly turn twist grip until one of the directional
switches activates (signified by a "click").
5. Record voltage reading on display.
6. Slowly turn twist grip opposite way until other direc-
tional switch activates (signified by a "click").
8. Difference of each reading from nominal center po- Figure 18222
sition reading should be within 2% of each other
(i.e., 3% and 4.2% is OK, 3% and 5.4% is not). Actuator Arm

Component Replacement
1. Remove three screws (index 56) and lockwashers
(index 54).
2. Move switch and bracket assembly over top of
(Refer to Figure 18222) cams and out.
1. Remove three screws (index 56) and lockwashers 3. Remove speed nut (index 57) from rod (index 59)
(index 54). and slide rod out until actuator (index 64) to be re-
placed can be removed.
cams and out. 4. Remove adjusting screw (index 65) and install in
replacement actuator.
3. Remove mounting bolts (index 58) of switch to be
replaced. 5. Slide rod into switch bracket, aligning actuator over
switches so rod goes through pivot point.
4. Transfer wires to replacement switch and tighten
screws. 6. Install speed nut.
5. Assemble switch, insulator and spacer. 7. Move switch and bracket assembly under cam, on
top of mounting posts and secure in place.
6. Secure in place with screws, lockwashers and
nuts. 8. Adjust both switches as described in Adjustments.
7. Move switch and bracket assembly under cam, on

top of posts and secure in place.
8. Adjust both switches as described in Adjustments.
Crown 2007 PF15817-3 SP 3500 M4.5-7335-003
171
ELECTRICAL SYSTEM
Control Module
Potentiometer (POT1)
(Refer to Figure 18223) To Control

Module
1. Loosen screws (index 45) on adjustable mounting
bracket (index 49).
2. Access to lower pivot point is through hole on left
side of directional and speed control compartment.
3. Push potentiometer back so gear teeth unmesh.
4. Slide pinion gear (index 52) off potentiometer
shaft.
5. Disconnect potentiometer pins at JC309, noting lo-
cation for proper installation.
Chart 2 - JC309 Pot Wiring

Figure 18223
Pin Color
Cam, Torsion Spring, Stop
1 Green
2 Orange (Refer to Figure 17855)
3 Violet 1. Remove two cotter pins (index 11).
2. Remove washers (index 12) on outside of housing.
6. Remove insulator (index 51).
3. Make note of physical arrangement of components
7. Pull potentiometer (index 42) from mounting
with respect to each other and arrows on twist grip.
bracket and remove insulator (index 44) and
washer (index 43). 4. Slowly slide twist grip with square shaft to the right.
8. Place insulator and washer, with washer against 5. Replace component in question.
potentiometer, on replacement potentiometer.
6. When assembling, apply grease (Crown no.
9. Slide potentiometer through hole in mounting 063002-025) to inside of torsion spring (index 17).
bracket and assemble insulator (index 51) so small
7. Install one washer (index 12) onto square shaft (in-
diameter slides through hole in bracket.
dex 21).
10. Turn potentiometer so wires are pointing out back
8. Slide cam (index 13) onto shaft (index 21) so cam
of panel.
lobes are toward switches when arrows on twist
11. Slide pinion gear (index 52) on potentiometer shaft grip are toward top.
so gear teeth will mesh completely.
9. Install spacer (index 14).
12. Re-connect wires to JC309.
13. Adjust potentiometer as described in Adjustments.
14. Make certain mounting bracket screws are tight-
ened.
M4.5-7335-004 SP 3500 Crown 2007 Pf15817-4 Rev. 12/07
01 Rev. 12/07
172
ELECTRICAL SYSTEM
Control Module
Part of Platform
Figure 17855
Crown 2007 PF15817-5 SP 3500 M4.5-7335-005
173
ELECTRICAL SYSTEM
Control Module
10. Assemble Stop and Return Assembly (index 15,

16, 17 and 18) before installing on square shaft, as
shown in Figure 18247.
Stop & Return Assembly
Figure 18247
11. Install Stop and Return Assembly (index 15, 16, 17

and 18) on shaft, making certain torsion spring (in-
dex 17) is over tab in Control Module Housing, as
shown in Figure 1347-02.
Figure 1347-02
12. Install spacer (index 19) and slide shaft through

housing making certain split bushing (index 10),
washer (index 12) and bushing (index 8) remain in
housing.
13. Install cotter pin (index 11) in shaft inside direc-
tional and speed control compartment.
14. Install washers (index 12) as required to remove
any lateral movement of twist grip when final cotter
pin is installed.
15. Perform switch and potentiometer adjustments as
necessary, beginning with potentiometer adjust-
ment.
M4.5-7335-006 SP 3500 Crown 2007 Pf15817-6
174
ELECTRICAL SYSTEM
Control Module
Twist Grip 4. Depending on operator preference, position re-

placement grip with lobe toward module or away
(Refer to Figure 17855) from module with arrows up.
1. Remove roll pin (index 3) from each end of twist 5. Trucks are manufactured with lobe toward module.
grip (index 2). 6. Install grip in module.
2. Slide twist grip to the right, out of control module 7. Align key on extension with slot in grip and assem-
housing to access extension (index 1) on end of ble extension to grip.
twist grip.
8. Slide grip onto square shaft, lining up hole in shaft
3. Remove extension from twist grip and remove grip with hole in grip.
from module.
9. Assemble roll pins in each end of grip.
Part of Platform
Figure 17855
Crown 2007 PF15817-7 SP 3500 M4.5-7335-007
175
ELECTRICAL SYSTEM
Control Module
RAS1, RAS2, LOS1, LOS2, HNS,

EDS
When replacing HNS (index 11), key switch will need to
be removed to allow access to mounting screws.
Switch terminals are to be tightened within 388 -
459 Nmm (55 - 65 in oz).
M4.5-7335-008 SP 3500 Crown 2007 Pf15817-8
176
ELECTRICAL SYSTEM
Control Module
Located on Back
of Control Module
Located
on Back of
Control Module
Figure 18224
Crown 2007 PF15817-9 SP 3500 M4.5-7335-009
177
ELECTRICAL SYSTEM
Control Module
Button Return Springs Power Disconnect Button Springs
(Refer to Figure 18224) (Refer to Figure 18225)

To replace Raise, Lower and Horn button return 1. Remove screw, lockwasher and flatwasher from
springs proceed as follows: button post while holding button depressed.
1. Secure control module with a wire, between top 2. Pull button and springs from module.
mounting bolt hole of control module and platform
3. Replace springs, insert button through housing
wall.
and secure in place with screw, lockwasher and
2. Remove three mounting screws (index 4) from flatwasher.
spring plate (index 1).
After assembly, test all controls for proper operation.
3. Lift spring plate from assembly.
4. Raise and lower buttons require two compression
springs (index 10 and 66) and the horn button re-
quires one spring (index 10).
5. Replace spring(s) in question and assemble on re-
spective actuator lever (index 17) spring guide (in-
dex 9).
6. Position spring plate so spring guides locate
springs.
7. Start mounting screws. Mounting screw closest to
key switch also holds wiring harness clamp (index
6).
8. When screws are started and harness clamp is in
place, tighten screws.
9. Remove wire securing control module.
Buttons

1. To replace buttons, remove two screws (index 15)
from button and remove.
2. Position replacement button correctly and secure
in place with screws.
Figure 18225
M4.5-7335-010 SP 3500 Crown 2007 Pf15817-10
178
ELECTRICAL SYSTEM
Battery
Battery Safety Rules

Care and maintenance of battery is very important to 1. Wear protective clothing, such as steel-toed
obtain efficient truck operation and maximum battery shoes, rubber apron, gloves, boots, and goggles
life. when performing any maintenance on batteries.
Do not allow electrolyte to come in contact with
eyes, skin, clothing, or floor. If electrolyte comes in
CAUTION contact with eyes, flush immediately and thor-
oughly with clean water. Obtain medical attention
Gases produced by a battery can be explosive. Do not immediately. Should electrolyte be spilled on skin,
smoke, use an open flame, or create an arc or sparks rinse promptly with clean water and wash with
in vicinity of battery. Ventilate an enclosed area well soap. A baking soda solution (one pound to one
when charging. gallon of water) will neutralize acid spilled on cloth-
Batteries contain sulfuric acid which may cause severe ing, floor or any other surface. Apply solution until
burns. Avoid contact with eyes, skin, or clothing. In bubbling stops and rinse with clean water.
case of contact, flush immediately and thoroughly with
clean water. Obtain medical attention when eyes are 2. Keep vent plugs firmly in place at all times except
affected. A baking soda solution (one pound to one gal- when adding water or taking hydrometer readings.
lon of water) applied to spilled acid until bubbling stops, 3. Do not bring any type of flame, spark, etc., near
neutralizes acid for safe handling and disposal. battery. Gas formed while battery is charging is
Leakage voltage from battery terminals to battery case highly explosive. This gas remains in cells long af-
can cause misleading trouble symptoms with truck ter charging has stopped.
electrical system. Since components of truck electrical 4. Do not lay metallic or conductive objects on bat-
system are insulated from truck frame, leakage voltage tery. Arcing will result.
will not normally affect truck operation unless a short
circuit or breakdown of circuit wire insulation to truck 5. Do not allow dirt, cleaning solution or other foreign
frame occurs. material to enter cells. Impurities in electrolyte has
a neutralizing effect reducing available charge.
A voltage check from battery connector terminal to bat-
tery case should indicate near 0 volts. Typically, how- 6. If battery repair is planned, follow battery manufac-
ever, sum of voltages at both terminals will equal bat- turer's instructions concerning repair practices and
tery volts. This leakage voltage will discharge battery. procedures.
As battery cleanliness deteriorates, usable charge of
battery decreases due to this self discharge.
Checking
Although a leakage voltage reading of 0 volts may not
be possible, a cleaner battery will have more usable Battery electrolyte level should be checked before
charge for truck operation and not affect operation of each charge of battery. Level should be maintained at
electronic devices on unit. 13 mm (0.5 in) above plates or just below lower lip of
filler hole at all times. If low, add distilled water or ap-
proved local supply (consult battery manufacturer) at
end of a charge cycle. Do not overfill. For maximum
battery life, specific gravity readings should be taken
daily on a pilot cell and recorded. A different pilot cell
should be selected on a monthly basis with readings
taken on all cells at semi-annual or annual intervals. Do
not take specific gravity readings immediately after
adding water. Water and electrolyte must be thoroughly
mixed by charging before a reliable reading can be
taken. Normal full charged specific gravity should be
between 1.265 and 1.285.
Crown 2007 PF17159-1 SP 3500 M4.6-7535-001
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ELECTRICAL SYSTEM
Battery
Battery Care 3. Before disconnecting or connecting batteries to

charger, make sure charger is "OFF". If an attempt
Your Crown truck is powered by an electrical storage is made to do this while charger is "ON", serious
battery. Here are a few suggestions which will help you injury to you, battery, and charger could result.
give battery proper care.
4. Before charging, make sure battery cells contain
The battery on your truck is located in front of opera- correct amount of water. Charging batteries with a
tor's platform. low water level might result in damage to cells.
When checking water levels, never use a match or
lighter. Battery fumes are explosive.
5. Before connecting battery cable to truck's recepta-
cle, make sure key switch is off and all controls are
in off position and brakes are applied. Battery ca-
ble must be fully connected before truck is used. If
plug is not making good contact, heat will weld two
parts of battery connector together, making it diffi-
cult to remove and necessary to replace.
6. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal con-
Battery Location tact is essential not only for operation, but also for
proper charging of battery.
Figure 17191-01 7. Battery cover should be closed except when

charging.
1. Charge battery only in areas designated for that
use. 8. Charging requirements will vary depending on use
of truck. Battery should be given an equalizing
2. Make certain charger being used matches voltage charge on a weekly basis. This charge should nor-
and amperage of truck battery. This voltage is mally be an additional three hours at finish rate.
listed on truck data plate and is located on lower
portion of platform. 9. Refer to charger manufacturer's instruction for
specific charging procedures.
10. Make certain battery used meets weight, type, amp
hour, voltage, and size requirements of truck (refer
to data plate). NEVER operate truck with an under-
sized battery or incorrect voltage battery. Refer to
Chart 1 - Battery for battery weights and type.
(a) Data Plate

(b) Lower Right Corner of Mast Side of Platform
Figure 18436
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ELECTRICAL SYSTEM
Battery
Chart 1 - Battery
Battery Weight Battery Type Battery Rating

Minimum Maximum Voltage Hour Rate Capacity
690 kg (1520 lb) 860 kg (1900 lb) “E” 24 5 800
Charging Removing battery from charge:

1. Make certain charger is turned off.
Charging requirements will vary depending on use of
truck. A battery with a specific gravity of 1.160 should 2. Unplug connector using both hands with a straight
be recharged. In some applications, more than one pulling motion.
battery is required to provide ample power to unit dur-
3. Hang up charger cable to prevent damage to ca-
ing service period.
ble. (Broken connectors can cause poor connec-
tions and connector failures).
CAUTION 4. Make daily battery checks and add water as
needed.
Never smoke or bring flame near battery. Gas formed
during charging is highly explosive and can cause seri- 5. Connect battery to truck. Make certain connectors
ous injury. are mated completely.
Consult charger manufacturer's manual covering your
charger for hints on operation and maintenance. Basic
rules are as follows:
Placing battery on charge:

1. Park truck at charging station with forks lowered
and key removed.
2. Make certain charger control is in off position.
3. Connect battery to charger and make certain con-
nectors are mated completely.
4. Set timer for specified time. Set for Normal (Daily
Charge, except one night a week when the Equal-
ize [Weekend] Charge should be used).
5. Check charger ammeter to make certain it shows
charge.
Crown 2007 PF17159-3 SP 3500 M4.6-7535-003
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ELECTRICAL SYSTEM
Battery
Battery Stop Adjustment

To minimize side-to-side (lateral) movement of battery
in truck, battery covers are equipped with adjustable
stops. First, battery must be centered in power unit,
then adjustment screw on each battery retainer should
be adjusted until it contacts battery surface. Tighten
locking screw down on adjustment screw and tighten
jam nut. Do not over tighten locking screw. Once bat-
tery stops are adjusted, battery covers should be re-
movable without loosening battery stop adjustments.
Any time a battery of different size is installed, this ad-
justment is necessary. Refer to Figure 17193-01. (a) Off
(b) On
(c) Test
(d) Turn Key Switch Off
Figure 17194-01
2. Open top cover and disconnect battery.
(a) Top Cover

(b) Battery Cover
(a) Locking Screw and Jam Nut

(b) Adjustment Screw
Figure 17193-01
Figure 17195-01
Battery Removal 3. Remove battery cover (one side only).
4. Position battery roller stand next to truck. Align
CAUTION stand with battery. Battery roller stand should be
same height as truck's battery compartment roll-
Don't allow any metallic object to come in contact with ers, and as long or longer than battery.
top of battery cells. This may cause a short circuit when
removing, installing, or transporting battery. Use an in- 5. Roll battery onto stand. Using approved spreader
sulator (such as plywood) to cover top of battery before bar, lift and move battery to charging area.
and during removal and installation.
1. Turn key switch off.
M4.6-7535-004 SP 3500 Crown 2007 PF17159-4
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ELECTRICAL SYSTEM
Battery
(a) Spreader Bar (a) Spreader Bar

(b) Roll onto Stand (b) Roll into Compartment
Figure 17196-01 Figure 17197-01
Battery Installation WARNING

Battery can slide out and hurt someone if side retainers
CAUTION are not properly installed. Be sure both retainers are in
place and secure.
Don't allow any metallic object to come in contact with
top of battery cells. This may cause a short circuit when 3. Remove roller stand and install battery cover.
removing, installing or transporting battery. Use an in- Make sure battery retainers are properly adjusted
sulator (such as plywood) to cover top of battery before for battery installed.
and during removal and installation.
Make certain same battery or battery of equal weight is
loaded into truck for truck stability. See data plate for
minimum battery weight and type.
1. Check to ensure key switch is turned off. (a) Top Cover
(b) Battery Cover
2. Using approved spreader bar, move battery onto
roller stand and push battery into battery compart-
ment.
Figure 17195-01
4. Connect battery and close top cover.

5. Turn key switch on and check truck operation.
Crown 2007 PF17159-5 SP 3500 M4.6-7535-005
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ELECTRICAL SYSTEM
Battery
Battery Cleaning
Always keep vent plugs tightly in place when cleaning
battery. When properly watered and charged, battery
will remain clean and dry. Brush or blow off any dust or
dirt which may accumulate on them. However, if elec-
trolyte is spilled or overflows from a cell, it should be
neutralized with a solution of baking soda and water
(.37 kg [1 lb] soda to 3.79 l [1 gal] of water). To do this,
remove battery from truck and clean with solution of
soda and water, brushing soda solution beneath con-
nectors and removing grime from covers. Then rinse
battery with cool water from a low pressure supply to
remove soda and loosened dirt. If batteries stay wet
consistently, they may be overcharged or overfilled.
This condition should be investigated and corrected.
Troubleshooting
CAUTION
Only qualified and experienced personnel should per-
form maintenance and repair on batteries.
Records of battery specific gravity readings, charger
used, truck used, etc. can be the most effective trouble-
shooting aid. Contact your dealer for charts designed
specifically for this purpose.
Voltage readings of each cell taken at normal charger
finish rate also indicate battery condition. New batter-
ies will have cell voltages ranging from 2.055 volts to
2.065 volts. Older batteries may range from 2.045 volts
to 2.055 volts. These readings still indicate a battery in
good condition.
A variation of .20 volts may be normal if certain cells
are exposed to higher temperatures during discharge.
Voltage differences that cannot be attributed to battery
age or operating conditions indicate a weak cell(s) and
maintenance is required.
M4.6-7535-006 SP 3500 Crown 2007 PF17159-6
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ELECTRICAL SYSTEM
Motors
Motors
Chart 1 - Traction Motor Information
Traction
021189, 021217 (EE) with Thermal Sensors
Motor Type: AC Induction
Winding Type: Delta
Bearings:
Lubricant Double Row Bearing: Chevron SRI-2
Sensor Bearing: GWB (Ansonic GHY 72)
Stator Winding Resistance:
At 20° C (68° F)
Between any Two Terminals 0.00349 ohm
Direction of Rotation: Bi-directional
Nominal Stator Diameter: 188 mm (7.4 in)
Crown 2007 PF15818-1 SP 3500 M4.7-7335-001
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ELECTRICAL SYSTEM
Motors
Chart 2 - Lift Motor Information
Lift
114330
Brushes:
No. of Brush Holders 4
No. of Brush Assemblies 4
No. of Brush Springs 4
Brush Length - New 28 mm (1.10 in)
Spring Tension on New Brushes 1560 gm (55 oz)
Min. Brush Length - Replace 15 mm (0.60 in)
Spring Tension Before Replacement 992 gm (35 oz)
Commutator:
Max. Diameter - New 54 mm (2.12 in)
Min. Diameter - Reslotting 52 mm (2.05 in)
Min. Diameter - Replace 49 mm (1.93 in)
Bearings:
Lubricant Sealed
Cond. of Performance:
(No Load)
Volts 6
Max. Amperes 27
RPM 3000 min
Field Resistance:
(Each at 25° C [75° F])
Series Ohm .0035
Armature Resistance:
(Each at 25° C [75° F])
Ohm .0045
Measured Between Bars 1 and 8
Frame Diameter: 170 mm (6.7 in)
Wound in: Series
Direction of Rotation: CWDE
M4.7-7335-002 SP 3500 Crown 2007 PF15818-2
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ELECTRICAL SYSTEM
Event Codes
Event Codes To Locate Malfunctioning Components

Component and Wiring Location Maps are provided at
ACCESS Module Listing:
strategic locations to help you quickly determine the
ACCESS 1: Display Control Module (DCM) physical location of items in question.
ACCESS 3: Traction Control Module (TCM) All components are clearly marked at the connection
points.
ACCESS 4: Vehicle Control Module (VCM)
Test Points
ACCESS 5: Steering Control Module (SCM)
Test points referenced in the event code descriptions
ACCESS 6: Guidance Control Module (GCM)
are located on the distribution panel.
Some Troubleshooting Basics
Power Cable Connections
Statistically the majority of malfunctions occur in or at
hardware components, contactors and motors. The
next components to test are connectors, wiring and in- CAUTION
put devices such as switches, potentiometers or en-
coders. The last component to suspect is the motor Due to capacitance voltage present on the motor con-
control system. In all instances, you should begin your trol panel, whenever performing maintenance which
troubleshooting procedure at the driven device, pro- may permit contact with the bus bars and associated
ceed to inputs devices, then, and only then, move on to power cables, discharge capacitor on the traction con-
the control to which these devices attach. trol panel by placing a minimum 100 ohm, 2 watt resis-
tor (062033-030) between positive (+) and negative (-)
of capacitor for 3 or more seconds.
WARNING
Never key "ON" truck with any control connectors dis-
connected. In addition, never remove or connect any
control connectors while truck is keyed "ON".
When a Malfunction Occurs
• Go to the display and access the Level 2: Field

Service Mode as follows.
NOTE
Your monitoring system can be accessed at three lev-
els of authorization:
Level 1: Operator Mode
Level 2: Field Service Mode (Full Truck Operation)
Level 3: Analyzer/Test Mode (No Truck Operation)
This section deals with the Level 2 and Level 3. For
information on Level 1 see the Operators Manual. Re-
fer to ACCESS 1 2 3…System for display information.
No Event Code?
When the truck malfunctions and no event code is dis-
played it usually means the malfunction is not electri-
cal.
If the truck powers up, but a code is not displayed, the
malfunction is probably mechanical or hydraulic rather
than electrical. Information regarding mechanical and
hydraulic troubleshooting is located in the appropriate
section in this Manual.
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ELECTRICAL SYSTEM
Event Codes
Figure 16722-01
a ACCESS 1 Display Control Module (DCM)

b Display Screen
c Battery Retainer Switch Indicator*
d Enter or Return Key - used to navigate in and out of menus
and accept inputs.
e Wire Guidance Display (optional)
f Navigation Keys - up, down, left and right arrows; used to
scroll through menus.
g Operator Improper Sequence Error Indicator*
h Service Required Indicator*
i Battery Discharge Indicator
* NOTE: These three indicators are viewable during initial
key-on, self test and indicator functioning.
ACCESS 1 - Display Control Module (DCM)

ACCESS 3 - Traction Control Module (TCM)
ACCESS 4 - Vehicle Control Module (VCM)
ACCESS 5 - Steering Control Module (SCM)
ACCESS 6 - Guidance Control Module (GCM)
M4.8-7335-002 SP 3500 Crown 2007 PF15819-2 Rev. 3/08
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ELECTRICAL SYSTEM
Event Codes
Notes:
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ELECTRICAL SYSTEM
Event Code 101
Event Code 101 Step 4: CAN communications line test:

Key OFF truck and use a DVOM to check resistance
ACCESS 1 CAN Initialization Error. between CAN_H and CAN_L on platform distribution
panel TP13 and TP14, should be 60 ohm.
All truck functions disabled.
Note: Absence of B- to ACCESS modules on the CAN • If: Greater than 60 ohm.
bus will load the bus and impede CAN communica- – Then CAN bus terminating resistors are open.
tions. Remove CA402 from ACCESS 5 and, using a
Step 1:Check ACCESS 1 CAN wiring. Wire 003 DVOM, check resistance between CA402-4 and
CA302-8 to CA105-2 and wire 004 CA302-9 to CA402-5.
CA105-8.
• If: Greater than 120 ohm.
• If: Wiring is correct and event code continues.
– Then replace ACCESS 5.
– Then proceed to Step 2.
• If: Wiring incorrect.
– Then CAN bus terminating resistors are open.
– Then repair/replace as necessary. Remove CA302 from ACCESS 1 and, using a
DVOM, check resistance between CA302-8 and
Step 2: Check power to ACCESS 1, wire 2941 CA302-9.
CA302-3 to CA103-10 and wire 513 CA302-4 to
CA107-8. • If: Greater than 120 ohm.
• If: Wiring is correct and event code continues. – Then replace ACCESS 1.
– Then proceed to Step 3. Step 5: Check for CAN line short to battery negative,
battery positive and truck frame. Key OFF truck discon-
• If: Wiring incorrect. nect battery, then, using a DVOM, check resistance at
the power unit from CAN_L to -BV bus bar, CAN_L to
– Then repair/replace as necessary.
TP3 on the power unit distribution panel and CAN_L to
Step 3: Check for B- to other ACCESS modules on truck frame. Resistance should be greater than 10,000
CAN bus by verifying power lamps are ON. ohm.
• If: ACCESS has no power. • If: Less than 10,000 ohm.

– Then, using a DVOM, check for B+ and B-. – Then repair/replace wiring as necessary.
Should either be missing check associated wiring,
connector and fuse.
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ELECTRICAL SYSTEM
Event Code 101
Figure 16649
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ELECTRICAL SYSTEM
Event Code 103
Event Code 103 • If: Greater than 60 ohm.

ACCESS 3 CAN Initialization Error.
Step 3: Check for CAN line short to -BV, +BV and truck
All functions disabled. frame. Key OFF truck, disconnect battery and, using a
Note: ACCESS 1 CAN bus communication with DVOM, check resistance at the power unit from CAN_L
ACCESS 3 has not occurred within specified time. to -BV bus bar, CAN_L to TP3 on the power unit distri-
bution panel and CAN_L to truck frame. Resistance
Step 1: Key ON truck, check status of ACCESS 3 should be greater than 10,000 ohm.
power ON lamps.
• If: Less than 10,000 ohm.
• If: ACCESS 3 power lamps are ON and event code
continues. – Then repair/replace wiring as necessary.
• If: ACCESS 3 power lamps are OFF.

– Then check for BV between CA401-1 and -BV
cable.
• If: 24V.
• If: 0V.
– Then check wire 2953 CA401-1 to CA201-5,
fuse FU3 power unit distribution panel.
Step 2: Check CAN communications lines. Key OFF
truck and, using a DVOM, check resistance between
CAN_H and CAN_L should be 60 ohm.
• If: 0 ohm.
– Then short exists between CAN_H and
CAN_L. Check associated wiring, connections and
fuses. Repair/replace as necessary.

Remove CA402 from ACCESS 5 and, using a
CA402-5.


CA302-9.
Figure 16651
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ELECTRICAL SYSTEM
Event Code 104

All truck functions disabled. frame. Key OFF truck, disconnect battery and, using a
power ON lamps.

– Then check for BV between CA304-1 and
CA304-3.
• If: 24V.
• If: 0V.
– Then check wire 2937, CA304-1 to CA103-12;
wire 525, CA304-3 to CA107-9 and fuse FU2
power unit distribution panel. Repair/replace as
necessary.
Step 2: Check CAN Communications Lines. Key OFF
• If: 0 ohm.

CA402-5.


Remove CA302 from ACCESS 1 and, using a Figure 16661
CA302-9.
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ELECTRICAL SYSTEM
Event Code 105
Event Code 105 Step 2: Check CAN communications lines. Key OFF
All truck functions disabled. • If: 0 ohm.
Note: ACCESS 1 CAN bus communication with – Then short exists between CAN_H and
ACCESS 5 has not occurred within specified time. CAN_L. Check associated wiring, connections and
Step 1: Key ON truck, check status of ACCESS 5
power ON lamps. • If: Greater than 60 ohm.
• If: ACCESS 5 power lamps are ON and event code – Then CAN bus terminating resistors are open.
continues. Remove CA402 from ACCESS 5 and, using a
– Then proceed to Step 2. CA402-5.
• If: ACCESS 5 power lamps are OFF. • If: Greater than 60 ohm.
– Then check for BV between CA403-26 and – Then replace ACCESS 5.
CA403-10.
• If: 24V.
– Then replace ACCESS 5. Remove CA302 from ACCESS 3 and, using a
• If: 0V. DVOM, check resistance between CA302-8 and
CA302-9.
– Then check wire 551 CA403-26 to CA401, wire
2966 CA403-10 to CA201-6, fuse FU3 power unit • If: Greater than 60 ohm.
distribution panel. – Then replace ACCESS 1.
frame. Key OFF truck, disconnect battery and, using a
DVOM, check resistance at the power unit from CAN_L
to -BV bus bar, CAN_L to TP3 on the power unit distri-
should be greater than 10,000 ohm.

– Then repair/replace wiring as necessary.
M4.8-7335-008 SP 3500 Crown 2007 PF15819-8 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 105
Figure 16668
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ELECTRICAL SYSTEM
Event Code 106

power ON lamps.

CA601-2.
• If: 24V.
• If: 0V.
wire 552 CA601-2 to -BV bus bar, fuse FU3 power
unit distribution panel.
• If: 0 ohm.
fuses.

CA402-5.


CA302-9.
Figure 16683
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ELECTRICAL SYSTEM
Event Code 111
Event Code 111

ACCESS 1 Software Parameter Error.
Step 1: Download latest software.
Event Code 113

ACCESS 3 Software Incompatible.
All functions disabled.
Step 1: Load ACCESS 3 with compatible software.
Event Code 114

Event Code 115

Event Code 116

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ELECTRICAL SYSTEM
Event Code 123

ACCESS 3 CAN Error.
ACCESS 3 was lost. to -BV bus bar, CAN_L to TP3 on the power unit distri-
power ON lamps.

cable.
• If: 24V.
• If: 0V.
• If: 0 ohm.
fuses.

CA402-5.


CA302-9.
Figure 16684
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ELECTRICAL SYSTEM
Event Code 124

ACCESS 4 CAN Error.
power ON lamps.

CA304-3.
• If: 24V.
• If: 0V.
wire 525 CA304-3 to CA107-9, fuse FU2 power
• If: 0 ohm.
fuses.

CA402-5.


Remove CA302 from ACCESS 1. Check resis-
tance between CA302-8 and CA302-9 using a Figure 16661
DVOM.
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ELECTRICAL SYSTEM
Event Code 125

ACCESS 5 CAN Error.
power ON lamps.

CA403-10.
• If: 24V.
• If: 0V.
2966 CA403-10 to CA201-6, fuse FU3 power unit
distribution panel.
• If: 0 Ohm.
fuses.

CA402-5.


CA302-9.
Figure 16685
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ELECTRICAL SYSTEM
Event Code 126

ACCESS 6 CAN Error.
power ON lamps.

CA601-2.
• If: 24V.
• If: 0V.
wire 552 CA601-2 to B- BB, fuse FU3 power unit
distribution panel. Repair/replace as necessary.
• If: 0 ohm.
fuses.

CA402-5.


CA302-9.
Figure 16683
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ELECTRICAL SYSTEM
Event Code 131
Event Code 131

ACCESS 1 Alarm 1 (ALM1) Driver Shorted.
No action taken.
Step 1: Using a DVOM check for 24V between TP8
and TP7 on platform distribution panel. Energize output
for ALM1 in analyzer mode.
• If: 0V.
– Then remove wire 5917 from CA302-2 and
check for 24V between CA302-2 and TP7 on plat-
form distribution panel. Energize output for ALM1
in analyzer mode.
• If: 0V.
• If: 24V.
– Then check continuity of wire 5917.
• If: Open.
– Then repair/replace wiring.
Figure 16686
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ELECTRICAL SYSTEM
Event Code 133
Event Code 133 CAN_L/CAN_H between TP15 and TP16 and CAN_L/
CAN_H to truck frame. Resistance should be greater
than 10,000 ohm.
Guidance Steer Indicator (GSI) CAN Error.
No truck functions are disabled. • If: Less than 10,000 ohm.
Step 1: Key ON truck, check status of GSI. – Then repair/replace as necessary.
• If: GSI power light is on.

• If: GSI lights are off.

– Then check for 24V between CA201-6 and
CA206-5.
• If: 0V.
– Then check FU3.
• If: 24V.
CA403-26.
• If: 24V.
– Then replace GSI.
• If: 0V.
– Then issue exists in wiring between CA403-10
or CA403-26.
Step 2: Check connection of CAN to GSI.
• If: Correct and event code continues.

– Then key OFF truck and, using a DVOM, check
resistance between CAN_H and CAN_L platform
distribution panels CA105-4 and CA105-10. Resis-
tance should be 60 ohm.
• If: 0 ohm.
CAN_L, repair as necessary.
• If: Greater than 60 to 65 ohm with all connectors

connected.
– Then CAN bus-terminating resistor is missing
or damaged. CAN bus contains 2 terminating re-
sistors, one is located in the ACCESS 5 the other
in ACCESS 1.
Step 3: Check for CAN lines for short -BV, +BV and
Figure 16687
truck frame. Key OFF truck, disconnect battery and,
using a DVOM, check resistance at power unit distribu-
tion panel between CAN_L/CAN_H and -BV bus bar,
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ELECTRICAL SYSTEM
Event Code 134
CAN_H and CAN_L, platform distribution panel TP13
ACCESS 4 CAN Error.
and TP14, should be 60 ohm.
Full speed traction and raise 2 disabled.
• If: 0 ohm.
power ON lamps. – Then short exists between CAN_H and
• If: ACCESS 4 power lamps are ON. fuses.
– Then proceed to Step 2. • If: Greater than 60 ohm.
• If: ACCESS 4 lamps are OFF. – Then CAN bus terminating resistors are open.
CA107-9.
CA402-5.
• If: 24V.
CA304-3.
• If: 24V.
• If: 0V. DVOM, check resistance between CA302-8 and
CA302-9.
– Then issue exists in wiring connected to
CA304-1 to CA304-3. • If: Greater than 120 ohm.
CAN_L/CAN_H between TP15 and TP16 and CAN_L/
than 10,000 ohm.

– Then repair as necessary.
M4.8-7335-018 SP 3500 Crown 2007 PF15819-18 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 134
Figure 16688
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ELECTRICAL SYSTEM
Event Code 301
Event Code 301

ACCESS 1 CAN Error.
Traction and raise disabled.
Step 1: Check CAN wires and connections.
Wire 018 CA401-15 ACCESS 3 to power unit distribu-
tion panel CA204-7, RED wire CA203-3 to platform dis-
tribution panel CA104-3, wire 004 CA105-8 to
ACCESS 1 CA302-9.
tion panel CA204-1, WHITE wire CA203-2 to platform
distribution panel CA104-2, wire 003 CA105-2 to
ACCESS 1 CA302-8.
• If: Wiring and/or connections require repair.

• If: 0 ohm.
fuses.

CA402-5.

Figure 16689
CA302-9.

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Event Code 302
THRU – Then CAN bus terminating resistors are open.

Event Code 303 CA302-9.
ACCESS 3 Internal Short.

Traction disabled. – Then replace ACCESS 1.
Step 1: Key truck OFF then ON.
• If: Event code continues.

Event Code 304

ACCESS 3/ACCESS 4 CAN Error.
tion panel CA204-7, wire 002 CA105-7 to ACCESS 4
CA303-8.
tion panel CA204-1, wire 001 CA105-1 ACCESS 4
CA303-7.

• If: 0 ohm.
fuses.

CA402-5. Figure 16690

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Event Code 305
Event Code 305

CA402-5.
CA402-4.

• If: 0 ohm.
fuses.

CA402-5.

Figure 16695
CA302-9.

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Event Code 306
Event Code 306

CA601-4.
CA601-5.

• If: 0 ohm.
fuses.

CA402-5.

Figure 16696

CA302-9.

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Event Code 307
Event Code 307 Event Code 310

THRU THRU

ACCESS 3 Short. ACCESS 3 Short Between Terminal U and V.
Traction disabled. Traction disabled.
Event Code 307: Short Between -BV and Terminal V. Step 1: Check condition of motor cables.
Event Code 308: Short Between +BV and Terminal W. • If: Cable(s) are shorted.
Event Code 309: Short between -BV and Terminal W. – Then repair as necessary.
Step 1: Check condition of motor cables.
• If: Cables correct.
• If: Cable(s) are shorted.
– Then disconnect traction motor (M1) phase ca-
– Then repair as necessary. bling from ACCESS 3 and Key ON truck.
• If: Cables are correct. • If: Event code continues.
– Then disconnect traction motor (M1) phase ca- – Then replace ACCESS 3.
bling from ACCESS 3 and Key ON truck.

Figure 16697
Figure 16697
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Event Code 313

THRU THRU

ACCESS 3 Short Between Terminal W and V. ACCESS 3 Short Between Terminal W and U.
Step 1: Check condition of motor cables. Step 1: Check condition of motor cables.
• If: Cable(s) are shorted. • If: Cable(s) are shorted.

– Then repair as necessary. – Then repair as necessary.
• If: Cables correct. • If: Cables correct.

– Then disconnect traction motor (M1) phase ca- – Then disconnect traction motor (M1) phase ca-
bling from ACCESS 3 and Key ON truck. bling from ACCESS 3 and Key ON truck.
• If: Event code continues. • If: Event code continues.

– Then replace ACCESS 3. – Then replace ACCESS 3.
Figure 16697 Figure 16697
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Event Code 319
Event Code 319

THRU
Event Code 320

ACCESS 3 Internal Issue.

Event Code 322 Figure 16698
ACCESS 3 BV Low. Event Code 323

Full traction disabled.
ACCESS 3 BV High.
Note: Should event code 322 log with event code 541
then refer to ED system event code 541 first. Note: Should event code 323 log with event code 541
then refer to ED system event code 541 first.
Traction disabled.
Traction disabled.
Step 1: Using a DVOM, check for 24V ACCESS 3 +BV
terminal and -BV terminal. Step 1: Using a DVOM check for 24V ACCESS 3 +BV
terminal and -BV terminal.
• If: Voltage is under 24V.
• If: Voltage is over 24V (i.e. 36V).
– Then check for correct battery, power cable
connections, fuse FU10 and ED2 contactor. – Then check for correct battery.
• If: Battery, power cable connections, FU10 and • If: Battery is 24V.
ED2 are correct.
– Then check feature menu for proper battery
– Then check battery charge level. configuration.
• If: Battery is properly charged. • If: Battery is not configured correctly.
– Then check feature menu for proper battery – Then correct configuration.
configuration.
• If: Battery is not configured correctly.

– Then correct configuration.
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Event Code 324

ACCESS 3 Internal temperature Less than -25°C ACCESS 3 Internal Temperature in Excess of 105°C
(-13°F). (221°F).
Full traction disabled. Traction disabled.
Step 1: Determine air temperature of environment. Step 1: Check mounting of ACCESS 3.
• If: Ambient temperature is below -25°C (-13°F) and • If: Mounting screws are loose.
the truck has set idle for and extended time.
– Then tighten the mounting screws.
– Then ACCESS 3 heat sink must be warmed to
operate with full traction capabilities. • If: Motor M1 is extremely hot.
• If: Ambient temperature is well above -25°C – Then check power cable connections and blow
off any dirt build up.
(-13°F) and event continues.
Event Code 328
Event Code 325 ACCESS 3 Traction Motor (M1) Temperature Sen-
sor (TS1) Above Acceptable Operating Range of
ACCESS 3 Internal Temperature Less than -4°C 165°C (329°F).
(25°F).
No effect.
Traction disabled.
Step 1: Check traction motor setups.
Step 1: Determine air temperature of environment.
• If: Incorrect setups.
• If: Ambient temperature is below -4°C (25°F) and
– Then change.
– Then ACCESS 3 heat sink must be warmed to • If: Setups are correct.
operate. – Then check TS1/M1 lead/cable connections
• If: Ambient temperature is well above -4°C (25°F) and clean dirt off M1.
and event continues. • If: This action does not correct overheating.
– Then replace ACCESS 3. – Then check battery condition.
Note: Extreme duty cycle and/or high ambient temper-
Event Code 326 atures could also cause 328 event code logging.
ACCESS 3 Internal Temperature More than 85°C

(185°F).
No effect.
Step 1: Check mounting of ACCESS 3.
• If: Mounting screws are loose.

• If: Motor M1 is extremely hot.

– Then check power cable connections and blow
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Event Code 329

ACCESS 3 Traction Motor M1 Temperature Sensor ACCESS 3 Encoder ECR3 Count Error.
TS1 Signal Out of Range.
Traction disabled. One or both channels lost at
Traction disabled. ACCESS 3 while truck is traveling.
Step 1: Using a DVOM check TS1 wiring for a short to Step 1: Check for event codes 366, 367, 376 and 377,
truck frame. Check CA411-1 and CA411-2 encoder which indicate that ECR3 power supply or logic ground
wires, CA411-1 wire 579 to B- BB and CA411-2 wire is out of range. If these codes have been logged, re-
105 to CA401-16 to truck frame. solve them before proceeding with procedure below.
• If: Wire(s) are shorted. • If: None of these event codes have occurred.
– Then repair as necessary. – Then proceed to Step 2.
• If: Wire(s) are correct. Note: Use Service Mode 2 to view ECR3 operation.
– Then using a DVOM check TS1 wiring for an Step 2: Key truck OFF then ON.
open. Check CA411-1 and CA411-2 encoder • If: Event code 330 logs.
wires, CA411-1 wire 579 to B- BB and CA411-2
wire 105 to CA401-16. – Then check ECR3 channel A and B wiring.
WHITE and BLUE wires between ECR3 and
CA411-4, -5. Wires 028, 029 between CA411-4, -5
and ACCESS 3 CA401-6, -5.

• If: No event codes slow traction and/or shut downs

continue.
– Then check ECR3 power wiring. RED and
BLACK wires between ECR3 and CA411-3, -6.
Wires 315 and 549 between CA411-3, -6 and AC-
CESS 3 CA401-3 and -4.
• If: Connections are good and slow traction and/or

shut downs continue.
– Then replace M1.
Figure 16699
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Event Code 332
Event Code 332

ACCESS 3 Drive Motor (M1) Rotation More than
4000 RPM.
Traction disabled.
Step 1: Check ECR3 channel A and B wiring. WHITE
and BLUE wires between ECR3 and CA411-4 and -5.
Wires 028 and 029 between CA411-4, -5 and ACCESS
3 CA401-6, -5.
• If: ECR3 channel A and B wiring is correct.

Wires 315, 549 between CA411-3, -6 and AC-
CESS 3 CA401-3, -4.
• If: ECR3 power wiring is correct.

– Then replace ECR3.
Figure 16702
Figure 16702
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Event Code 334

ACCESS 3 BV Under Range. ACCESS 3 BV Over Range.
Full traction disabled. Full traction disabled.
Note: Should event code 334 log with event code 541 Note: Should event code 336 log with event code 541
then refer to ED system event code 541 first. then refer to ED system event code 541 first.
Step 1: Using a DVOM check for 24V on ACCESS 3 Step 1: Using a DVOM check for 24V on ACCESS 3
between +BV terminal and -BV terminal. between +BV terminal and -BV terminal.
• If: Under 24V. • If: Over 24V (i.e. 36V).

– Then check for correct battery, power cable – Then check for correct battery.
connections, fuse FU10 and ED2 contactor.
• If: Battery is 24V.
• If: Battery, power cable connections, FU10 and
ED2 correct.
configuration.
– Then check battery charge level.
• If: Battery is properly charged.
configuration.
Event Code 337
– Then correct configuration. ACCESS 3 24V Battery Voltage Fluctuating.
Note: Battery voltage is dropping excessively under
load.
Step 1: Check ACCESS 3 B- and B+ power cable con-
nections.
• If: Connections in poor condition.

– Then repair/replace.
• If: Connections in good condition.

– Then check condition of battery and/or install a
known good battery and monitor event code 337.
Figure 16698
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Event Code 338
Event Code 338

ACCESS 3 +BV Under Voltage.
Step 1: Check battery status.
• If: Battery has correct voltage and charged.

• If: Battery does not have correct voltage or not

properly charged.
– Then resolve battery issue.
Step 2: Key ON truck and, using a DVOM, check for
24V between CA401-1 and -B on ACCESS 3.
• If: 24V.
– Then proceed with Step 3.
• If: Voltage is above 0V but much less than 24V.

– Then check voltage between CA201-5 and
ACCESS 3 -B.
• If: 24V.
Figure 16704
– Then check wiring. Wire 2953 power unit distri-
bution panel CA201 5 to ACCESS 3 CA401-1.

– Then check condition of power unit distribution
panel.
Step 3: Check voltage between ACCESS 3 +B and -B
terminals.
• If: Voltage is below 24V.

– Then check power cable condition and connec-
tion.
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Event Code 339
Event Code 339

ACCESS 3 +BV Over Voltage.
Steering, traction and hydraulics disabled.
Step 1: Check feature menu for proper battery config-
uration.
• If: Configuration is correct.

– Then check for proper battery.
• If: Battery is correct.

• If: Battery is not correct.

Step 2: Using a DVOM check for 24V between
CA401-1 and ACCESS 3 -B.
• If: 24V.

– Then check voltage between CA201-5 and Figure 16704
ACCESS 3 -B.
• If: 24V. Event Code 340

ACCESS 3 ED2 Contactor Coil Driver Over Current.
bution panel CA201-5 to ACCESS 3 CA401-1.
Step 1: Follow trouble shooting steps for event code
– Then check condition of power unit distribution 541.
panel.
terminals.
• If: Voltage is above 24V but less than 28V and

event code continues.
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Event Code 341

ACCESS 3 P1 Contactor Coil Driver Over Current. ACCESS 3 P2 Contactor Coil Driver Over Current.
Raise disabled. Raise speed 2 disabled.
Step 1: Disconnect wires 2961 and 5923 from P1 con- Step 1: Disconnect wires 2962 and 5924 from P2 con-
tactor coil and, using a DVOM, check resistance of P1 tactor coil and, using a DVOM, check resistance of P2
contactor coil. contactor coil.
• If: Less than 20 ohm. • If: Less than 20 ohm.

– Then replace P1 contactor. – Then replace P2 contactor coil.
• If: 20 ohm and event code continues. • If: 20 ohm and event code continues.
– Then check P1 contactor coil wiring for a short. – Then check P2 contactor coil wiring for a short.
Wire 5923 to ACCESS 3 CA401-18 and wire 2961 Wire 5924 to ACCESS 3 CA401-21 and wire 2962
to power unit distribution panel CA202-6. to power unit distribution panel CA202-7.
• If: Wires are not shorted remove wire 5924 from P2 • If: Wires are not shorted remove wire 5923 from P1
contactor coil. contactor coil.
– Then check for 24V between wire 2961 and – Then check for 24V between wire 2962 and
5923 at P1 contactor coil while depressing raise 1 5924 at P2 contactor coil while depressing raise 2
switch. switch.
• If: 0V. • If: 0V.

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Event Code 343
Event Code 343

ACCESS 3 Lowering Solenoid (SVL) Driver Over
Current.
Raise and lower disabled.
Step 1: Disconnect wire 5925 from SVL coil and, using
a DVOM, check resistance of SVL coil.
• If: Less than 29 ohm.

– Then replace SVL coil.
• If: 29 ohm.
– Then check for 24V between wire 5925 and
wire 2959 (opposite side of SVL coil) while de-
pressing lower switch.
• If: 0V.
– Then remove wire 5925 from connector
CA401-22 and, using a DVOM, check for 24V be-
tween wire 2959 and CA401-22 while depressing
lower switch.
Figure 16707
• If: 0V.
• If: 24V.
– Then key OFF truck reconnect wire 5925 to
SVL. Connect DVOM lead to wire 2959 and TP3 on
the power unit distribution panel. Key ON truck, de-
press lower switch and check for 24V.
• If: 0V.
– Then check wiring at CA201-10 and FU3.
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Event Code 344
Event Code 344

ACCESS 3 Fan2 Driver Over Current.
Step 1: Disconnect wires 29122 and 5908 from Fan2
and, using a DVOM, check for 24V between wire
29122 and wire 5908. Energize output for Fan2 in ana-
lyzer mode.
• If: 0V.
check for 24V between CA401-8 and TP4 on
power unit distribution panel. Energize output for
Fan2 in analyzer mode.
• If: 0V.
• If: 24V.
– Then reconnect wire 5908 and check for 24V
between wire 29122 and TP3 on power unit distri-
bution panel.
• If: 0V.
– Then check connection of wire 29122 to Figure 16708
CA201-8.
Event Code 345
ACCESS 3 ED2 Contactor Driver Open.
Steering and traction disabled.
Step 1: Follow trouble shooting procedure for event
code 541.
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Event Code 346
Event Code 346

ACCESS 3 P1 Contactor Driver Open.
Raise 1 disabled.
Step 1: Disconnect wires 2961 and 5923 from P1 con-
tactor coil and, using a DVOM, check resistance of P1
contactor coil.

– Then replace P1 contactor coil.
• If: 20 ohm - remove wire 5924 from P2 contactor

coil.
– Then check for 24V between wires 2961 and
5923 at P1 contactor coil while depressing raise 1
switch.
• If: 0V.
check for 24V between CA401-18 and TP4 while
depressing raise 1 switch.
• If: 0V.
• If: 24V.
Figure 16709
– Then, using a DVOM, check for 24V between
wire 2961 and TP3 while depressing raise 1
switch.
• If: 0V.
– Then check raise 1 switch and associated wir-
ing.
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Event Code 348
Event Code 348

ACCESS 3 Lowering Solenoid (SVL) Driver Open.
Raise disabled.
Step 1: Disconnect wires 2959 and 5925 from SVL coil
and, using a DVOM, check resistance of SVL coil.

• If: 29 ohm.
5925 while depressing lower switch.
• If: 0V.
– Then disconnect wire 5925 from CA401-22 and
depressing lower switch.
• If: 0V.
Figure 16710
• If: 24V.
TP3 while depressing lower switch.
• If: 0V.
– Then check lower switch and associated wir-
ing.
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Event Code 349

ACCESS 3 FAN2 Driver Open. ACCESS 3 ED2 Contactor Driver Shorted.
Step 1: Using a DVOM check for 24V between wire Step 1: Refer to ED2 trouble shooting procedure for
29122 and 5908 at FAN2 (use analyzer mode to ener- event code 541.
gize output).
• If: 0V.
check for 24V between CA401-8 to TP4 (use ana-
lyzer mode to energize output).
• If: 0V.
• If: 24V.
TP4.
• If: 0V.
– Then check wiring.
Figure 16715
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Event Code 351
Event Code 351

ACCESS 3 P1 Contactor Driver Shorted.
Full traction, auxiliary raise and raise2 disabled.
contactor coil.


coil.
switch.
• If: 0V.
check for 24V between CA401-18 to TP4 while de-
pressing raise 1 switch.
• If: 0V.
Figure 16716
• If: 24V.
switch.
• If: 0V.
– Then check associated wiring.
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Event Code 352
Event Code 352

contactor coil.

– Then replace P2 contactor.

coil.
switch.
• If: 0V.
check for 24V between CA401-21 to TP4 while de-
pressing raise 2 switch.
• If: 0V.
Figure 16717
• If: 24V.
switch.
• If: 0V.
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Event Code 353
Event Code 353

ACCESS 3 Lowering Solenoid (SVL) Driver
Shorted.
Raise disabled.

• If: 29 ohm.
• If: 0V.
depressing lower switch.
• If: 0V.
• If: 24V.
Figure 16718
• If: 0V.
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Event Code 354
Event Code 354

ACCESS 3 FAN2 Driver Shorted.
No action taken.
Step 1: Disconnect wires 29122 and 5908 from FAN2
29122 and wire 5908. Energize output for FAN2 in an-
alyzer mode.
• If: 0V.
power unit distribution panel. Energize output for
Fan2 in analyzer mode.
• If: 0V.
• If: 24V.
between wire 29122 and TP3 on power unit distri-
bution panel.
• If: 0V.
– Then check wiring connection at CA201-8 and
FU4.
Figure 16719
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ELECTRICAL SYSTEM
Event Code 355

ACCESS 3 PWM Driver Over Voltage. ACCESS 3 Detected Open Circuit in ED2 Wiring.
All functions disabled. All functions disabled.
Step 1: Using a DVOM for 24V between CA201-5 and Step 1: Follow the ED System Trouble shooting proce-
TP3 on the power unit distribution panel. dure specified for event code 541.
• If: 0V.
– Then check FU3.
Event Code 357
• If: 24V. ACCESS 3 ED2 Contactor Error.
– Then check for 24V between CA401-1 and All functions disabled.
TP3. Step 1: Check ED2 contact tips.
• If: 0V. • If: Contacts are worn.
– Then repair connection of wire 2953. – Then replace as necessary.
• If: 24V. • If: Contacts correct.
– Then replace ACCESS 3. – Then key OFF truck and check ED2 load bus
connections.
• If: Connections correct.

– Then follow procedures for event code 541.
Figure 16720
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Event Code 358
Event Code 358

ACCESS 3 Pre-Charge Power Limit Out of Range.
Note: Power limit of pre-charge resistor internal to
ACCESS 3 has been exceeded.
Step 1: Check battery.
• If: Battery is correct voltage and charged.

• If: Battery is not correct voltage or not properly

charged.
Step 2: Key ON truck and cycle pedal. Using a DVOM
check for 24V between +BV and -BV power lug on
ACCESS 3.
• If: 24V.
• If: Above 0V but much less than 24V.

– Then check cables to ACCESS 3. Figure 16704

24V between CA401-1 and -BV on ACCESS 3.

ACCESS 3 -BV.
• If: 24V.

panel.
M4.8-7335-044 SP 3500 Crown 2007 PF15819-44 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 359
Event Code 359

ACCESS 3 Pre-Charge Time Limit Exceeded.


properly charged.
• If: 24V.

ACCESS 3 -BV.
• If: 24V.
Figure 16704
Event Code 360
ACCESS 3 Pre-Charge Electrical Error.
panel. All functions disabled.
Note: Resistive load is present on the ED2 bus during
pre-charge this condition is most likely a driver shorted
issue.


charged.
Step 2: Check other events logged along side the 360.
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Event Code 361
Event Code 361 Step 1: Using a DVOM, check for 12 V between wire
315 CA401-3 and TP3 (-B) power unit distribution
panel. When 12 V and event code continues, then
ACCESS 3 Error.
check for 12 V at CA411-3 and TP3 (B-).
• If: 0V.
Step 1: Replace ACCESS 3.
Event Code 362 • If: Less than 12 V and event code continues.
THRU – Then remove wire 315 from CA401-3 and, us-

ing a DVOM, check for 12 V between CA401-3 and
TP3 (-B). When 12 V, then replace ECR3.When
Event Code 363 less than 12 V and event code continues, then re-
place ACCESS 3.
No action taken.

Event Code 364

THRU
Event Code 365

ACCESS 3 Internal 5V Supply Out of Range.

Event Code 366

THRU
Event Code 367

ACCESS 3 +12V Power Supply for Encoder 3
(ECR3) Out of Range.
Figure 16721
Event Code 366: Supply voltage high.
Event Code 367: Supply voltage low.
M4.8-7335-046 SP 3500 Crown 2007 PF15819-46 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 368

THRU THRU

ACCESS 3 15V Power Supply Out of Range. ACCESS 3 Internal 2.5V Reference Voltage Out of
Range.
Step 1: Internal failure.
Event Code 370

THRU
Event Code 371

ACCESS 3 5V Power Supply Out of Range.

Event Code 372

THRU
Event Code 373

ACCESS 3 Internal 227 mV Reference Voltage Out
of Range.

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Event Code 378

THRU
ACCESS 3 Over Current Condition.
Traction disabled.
Event Code 382
Step 1: Disconnect traction motor (M1) phase cabling
from ACCESS 3 and Key ON truck.
ACCESS 3 Short .
• If: Event code continues. Traction disabled.
– Then replace ACCESS 3. Event Code 381: Short between +BV and terminal U.
• If: Event code clears. Event Code 382: Short between -BV and terminal U.
– Then using a DVOM check M1 and cabling for Step 1: Check condition of motor cables.
phase-to-phase and phase-to-frame shorts.
• If: Short circuit exists between U, V, W cables or
frame.
– Then remove phase cabling and check for M1
• If: Cables are correct.
winding shorts to frame. – Then disconnect traction motor (M1) phase ca-
• If: Short exists in M1.
Figure 16723
Event Code 379

THRU Figure 16697
Event Code 380

Traction disabled.

M4.8-7335-048 SP 3500 Crown 2007 PF15819-48 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 383

THRU THRU

ACCESS 3 Short. ACCESS 3 Short.
Event Code 383: Short between +BV and terminal V. Event Code 385: Short between +BV and terminal W.
Event Code 384: Short between -BV and terminal V. Event Code 386: Short between -BV and terminal W.
Step 1: Check condition of motor cables. Step 1: Check condition of motor cables.
• If: Cable(s) are shorted. • If: Cable(s) are shorted.

– Then repair as necessary. – Then repair as necessary.
• If: Cables are correct. • If: Cables are correct.

– Then disconnect traction motor (M1) phase ca- – Then disconnect traction motor (M1) phase ca-
bling from ACCESS 3 and Key ON truck. bling from ACCESS 3 and Key ON truck.

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Event Code 387
Event Code 387 • If: Cables are correct.
THRU – Then disconnect traction motor (M1) phase ca-

Event Code 389 • If: Event code continues.

ACCESS 3 Short Terminal U to V.
• If: Event code clears.
Traction disabled.
Event Code 387: Short U to V.
Event Code 388: Short UL to VH.
Event Code 393
Event Code 389: Short UH to VL.
THRU
Step 1: Check motor cable connections.
• If: Short exists between U and V.

Event Code 395
ACCESS 3 Traction Motor (M1) Short.
• If: No short exists.
Traction disabled.
– Then disconnect motor cables from ACCESS 3
and key ON truck. Event Code 393: Short W to U.
• If: Event code continues. Event Code 394: Short WL to UH.

Event Code 395: Short WH to UL.
– Then repair or replace M1.
THRU – Then disconnect traction motor (M1) phase ca-

Event Code 392 • If: Event code continues.

Traction disabled.
Event Code 390: Short V to W.
Event Code 391: Short VL to WH.
Event Code 392: Short VH to WL.

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ELECTRICAL SYSTEM
Event Code 401
Event Code 401 one located in ACCESS 5 and the other in

ACCESS 1.
ACCESS 4/ACCESS 1 CAN Error. • If: All wiring is correct and event continues.
No action taken. – Then replace ACCESS 1 and/or ACCESS 5.
Note 1: If event code 401 is displayed on ACCESS 1 Intermittent connection test.
issue was caused by an intermittent open wire condi-
tion. Refer to intermittent connection test at the end of • If: Codes 104 or 106 are also displayed.
Step 2.
– Then intermittent connection exists in wiring
Note 2: If event code 401 is flashing on ACCESS 4 but (003 and 004) between ACCESS 1 CA302-9, -8
is not displayed on ACCESS 1, then proceed to Step 1. and platform distribution panel CA105-8, -2. Lo-
Step 1: Key truck ON check status of ACCESS 1 lights. cate and repair/replace as necessary.
Step 3: Check for CAN line for short to -BV, +BV and
• If: ACCESS 1 lights are ON.
truck frame. Key OFF truck and disconnect battery. Us-
– Then issue exists in wiring (003 and 004) being a DVOM, check resistance at the power unit from
tween ACCESS 1 CA302-9, 8 and platform distri- CAN_L to BV bus bar, CAN_L to TP15 and TP16 on
bution panel CA105-8, 2. Check connector mating, power unit distribution panel and CAN_L to truck
connector contact condition, proper contact inser- frame. Resistance should be greater than 10,000 ohm.
tion, contact crimps and wire condition. Check
CAN_H and CAN_L wires are not reversed.
– Then replace wiring as necessary.
• If: ACCESS 1 lights are OFF.
CA302-4.
• If: 24V.
• If: 0V.
– Then issue exists in the wiring connected to
CA302-3 or CA302-4.
• If: Issue continues.

– Then trace wiring from ACCESS 1, CA302-8 to
platform distribution panel CA105-8, -2.
Step 2: Key OFF truck using a DVOM check resistance
between CAN_H and CAN_L platform distribution
panel TP13 and TP14. Resistance should be approxi-
mately 60 ohm.
• If: 0 ohm.
CAN_L. Short may be present in one of the AC-
CESS modules. Find short by unhooking ACCESS
modules from the CAN bus one at a time and
check resistance between CAN_H and CAN_L.

– Then CAN bus terminating resistors are miss-
ing CAN bus contains two terminating resistors, Figure 16967
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ELECTRICAL SYSTEM
Event Code 405
Event Code 405 Step 3: Check CAN line short to -BV, +BV and truck
frame. Key OFF truck disconnect battery, using a
DVOM check resistance at the power unit CAN_L to -
ACCESS 5 CAN timeout.
BV bus bar, CAN_L to TP15 and TP16 on power unit
No action taken. distribution panel and CAN_L to truck frame. Resis-
tance should be greater than 10,000 ohm.
Step 1: Key ON truck check status of ACCESS 5 lights.

– Then repair wiring as necessary.
– Then issue exists in wiring (019 and 020) be-
tween ACCESS 5 CA402-4, -5 and power unit dis- • If: All wiring is correct.
tribution panel CA204-2, -8. Check connector mat-
ing, connector contact condition, proper contact – Then replace ACCESS 5 and/or ACCESS 4.
insertion, contact crimps and wire condition. Verify
that CAN_H and CAN_L wires are not reversed.

-BV.
• If: 24V.
• If: 0V.
– Then issue exists in wiring to CA403-10.
• If: Event continues.

– Then check wiring between ACCESS 5,
CA402-4, -5 and power distribution panel
CA204-8, -2.
Figure 16968
Step 2: Key OFF truck check resistance between
CAN_H and CAN_L at power unit distribution panel
TP15 and TP16. Resistance should be approximately
60 ohm.
• If: 0 ohm.
CESS modules. Find short by unhooking ACCESS
modules from the CAN bus one at a time and

ing. CAN bus contains two terminating resistors,
one located in ACCESS 5 and the other in
ACCESS 1.
M4.8-7335-052 SP 3500 Crown 2007 PF15819-52 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 411
Event Code 411 Step 3: Check CAN line for short to -BV, +BV and truck
frame. Key OFF truck and disconnect battery. Using a
DVOM, check resistance at the power unit distribution
panel CAN_L to BV bus bar and CAN_L to TP15 and
All functions disabled. TP16 and to truck frame. Resistance should be greater
than 10,000 ohm.
Step 1: Key ON truck check status of ACCESS 1
power light. • If: Less than 10,000 ohm.
• If: ACCESS 1 power light is ON. – Then replace wiring as necessary.
• If: ACCESS 1 power light is OFF.

– Then check for 24V to ACCESS 1. Place
DVOM leads +BV on CA302-3 and -BV on
CA302-4.
• If: 24V.
– Then check connector terminals and wiring for
possible intermittence.
• If: 0V.
– Then issue exists in wiring between CA302-3,
CA105-10, CA302-4 and CA107-8 on the platform
distribution panel.
Step 2: Check CAN communication lines.
• If: Event code continues and ACCESS 1 display is

on.
– Then key OFF truck. Check resistance be-
tween CAN_H and CAN_L on either the power unit
or platform distribution panel. Resistance should
be 60 ohm.
• If: 0 ohm.
CESS modules. Find short by unplugging AC-
CESS modules from the CAN bus one at a time
and check resistance between CAN_H and
CAN_L.
Figure 16969
• If: Greater than 60 ohm with all connectors con-
nected.
or damaged, or wiring to the terminating resistor is
open. CAN bus contains two terminating resistors,
one in the ACCESS 5 and the other in ACCESS 1.
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ELECTRICAL SYSTEM
Event Code 413
panel CAN_L to -BV bus bar also CAN_L to TP15 and
All functions disabled. TP16 and CAN_L to truck frame. Resistance should be
greater than 10,000 ohm.
Step 1: Turn the truck on. Verify status of ACCESS 3

– Then check for 24V to ACCESS 3 connect a
DVOM between +BV CA401-1 and -BV power ter-
minal.
• If: 24V.
– Then check connector, terminals and wiring for
• If: 0V.
and CA201-5 on the power unit distribution panel.
• If: Event code continues - ACCESS 1 display is

ON.
– Then key OFF truck and check resistance be-
or platform distribution panels. Resistance should
be 60 ohm.
Figure 16970
• If: 0 ohm.
CAN_L.

nected.
open. CAN bus contains two terminating resistors,
one in ACCESS 5 and the other in ACCESS 1.
M4.8-7335-054 SP 3500 Crown 2007 PF15819-54 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 415
panel between CAN_L and -BV bus bar, CAN_L to
No action taken. TP15 and TP16 and CAN_L to truck frame. Resistance
Step 1: Key truck ON. Check status of ACCESS 5

CA403-26.
• If: 24V.
• If: 0V.
– Then issue exists in wiring connected between
CA403-10 or CA403-26 and/or FU8 on the power
• If: Event code continues and ACCESS 5 lights are

ON.
or platform distribution panel. Resistance should
be 60 ohm.
• If: 0 ohm.
CAN_L. Figure 16971

nected.
– Then CAN bus terminating resistor is missing
open. CAN bus contains two terminating resistors
one in ACCESS 5 and the other in ACCESS 1.
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ELECTRICAL SYSTEM
Event Code 416
panel between CAN_L and -BV bus bar also CAN_L to

CA403-26.
• If: 24V.
• If: 0V.
or CA403-26 and/or FU8 on the power unit distri-
bution panel.

ON.
– Then key truck OFF and check resistance be-
or platform distribution panels. Resistance should
be 60 ohm.
• If: 0 ohm.
CESS modules. Find short by unplugging modules
from the CAN bus one at a time and check resis-
tance between CAN_H and CAN_L.
Figure 16971
nected.
Event Code 421
or damaged, or the wiring to the terminating resis- ACCESS 4 Internal Fault.
tor is open. CAN bus contains two terminating re-
sistors one located in ACCESS 5 and the other in All functions disabled.
ACCESS 1. Step 1: Replace ACCESS 4.
M4.8-7335-056 SP 3500 Crown 2007 PF15819-56 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 422
Event Code 422

ACCESS 4 Potentiometer 1 (POT1) +5V Power Sup-
ply Out of Range.
Step 1: Using a DVOM, check for 5V between wire 701
CA303-4 and TP16 power unit distribution panel.
• If: 5V and event code continues.

– Then check for 5V at CA309-2 and TP16.
• If: 0V.
• If: Less than 5V and event code continues.

– Then remove wire 701 from CA303-4 and, with
a DVOM, check for 5V between CA303-4 and
TP16.
• If: Less than 5V.

• If: 5V.
– Then a short exists in wiring. Repair/replace
wiring as necessary.
Figure 16972
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ELECTRICAL SYSTEM
Event Code 423
Event Code 423

ACCESS 4 Potentiometer 1 (POT1) is Out of Electri-
cal Limits.
Step 1: Enter Service Mode 2 then Analyzer. Select
POT1 A2.3.3 on display menu and view reading on dis-
play.
• If: Approximately 5V or greater.

– Then POT1 is either incorrectly wired, wire be-
tween POT1 and ACCESS 4 is shorted to the truck
frame or an open wire exists. Check condition and
correctness of wiring and connector terminals be-
tween ACCESS 4 CA303-1, -4, -19 and POT1.
• If: Wiring and terminals are correct.

– Then replace POT1.
• If: Between 2.1V and 2.9V.

– Then multi-task handle in center position.

– Then multi-task handle in full forward position.
• If: Between 3.4V and 4.3V. Figure 16973

– Then multi-task handle in full reverse position.
• If: Correct POT1 readings are confirmed.

– Then an intermittent connection in POT1 circuit
might exist. Inspect POT1, wiring to POT1 and ter-
minals in connector at ACCESS 4 CA303-1, -4,
-19.
• If: All check correctly.

• If: Below 0.7V.

– Then POT1 is incorrectly wired, wires between
POT1 and ACCESS 4 are shorted together or a
wire is open. Check condition and correctness of
wiring and connector terminals between
ACCESS 4 CA303-1, -4, -19 and POT1.

M4.8-7335-058 SP 3500 Crown 2007 PF15819-58 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 424

ACCESS 4 Potentiometer 1 (POT1) Does Not Match ACCESS 4 Potentiometer 1 (POT1) Does Not Match
Forward Switch (FS). Reverse Switch (RS).
Step 1: FS/POT1 operation. Enter Service Mode 2 and Step 1: RS/POT1 operation enter Service Mode 2. Se-
select handle analyzer menu. Input status of FS, with lect handle Analyzer menu. Input status of RS, with
handle in neutral, should be "open" as indicated by "0" handle in neutral, should be "open" as indicated by "0"
on display A2.3.7. POT1 reading on display A2.3.3 on display A2.3.6. POT1 reading on display A2.3.3
should be between 2.1 to 2.9 volts. Moving handle to should be between 2.1 to 2.9 volts. Moving the handle
full forward position should toggle switch to "closed", to full forward position should toggle switch to "closed",
display to "1" A2.3.7. Reading for POT1 A2.3.3 should display to "1" A2.3.6. Reading for POT1 A2.3.3 should
go between 4.0 to 4.6 volts. go between 4.0 to 4.6 volts.
• If: Readings are not as listed. • If: Readings are not as listed.
– Then check switch for damaged wiring or phys- – Then check switch for damaged wiring or phys-
ical damage. Wire 2907 to FS and wire 2908 to RS. ical damage. Wire 2907 to FS and wire 2908 to RS.
• If: Damaged. • If: Damaged.

– Then replace switches as needed, taking care – Then replace switches as needed, taking care
to properly route harness. After switch replace- to properly route harness. After switch replace-
ment, calibrate handle. ment, calibrate handle.
• If: POT1 not within limits. • If: POT1 not within limits.
– Then recalibrate handle. – Then recalibrate handle.
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ELECTRICAL SYSTEM
Event Code 426

ACCESS 4 Forward Switch (FS) and Reverse ACCESS 4 Potentiometer 1 (POT1) and Reverse
Switch (RS) Closed at Same Time. Switch (RS) Out of Range.
Step 1: Check FS and RS for damage to wiring or Step 1: Using a DVOM, check for 5V between
switch and mounting. CA303-19 and TP16 on the platform distribution panel.
• If: Damaged. • If: Greater than 5V.

– Then replace switch and calibrate handle. – Then check wires 581 CA303-19, wire 506
CA309-3 and wire 519 CA307-5 for shorts to +BV
• If: Correct. or truck frame.
– Then proceed to Step 2. • If: 0V.
Step 2: Enter Service Mode 2 and select analyzer
menu for FS A2.3.7 and RS A2.3.6. Check status of FS
and RS with handle in neutral position.
• If: Either FS or RS is "1".

– Then select that switch to use in Step 3.
• If: Both FS and RS are "1".

– Then choose either switch and proceed to Step
3.
Step 3: Check switch function by disconnecting output
wire of selected switch, wire 2907 on FS or wire 2908
on RS.
• If: Selected switch display changes to "0" when

switch wire is disconnected.
– Then replace optical switch assembly and cali-
brate handle.
• If: Selected switch display is "1" with handle in neu-

tral.
Figure 16974
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ELECTRICAL SYSTEM
Event Code 429
Event Code 429

ACCESS 4 Encoders ECR1/ECR5 Count Error.
Note: Event code is logged if count between ECR1/
ECR5 is not equal. Possibly due to loss of power and
or Channel A or B of either encoder.
Step 1: Enter Service Mode 2 and select ECR1 A2.3.2
in analyzer menu. View reading on the display.
• If: ECR1 operates.

• If: ECR1 does not operate.


– Then issue may exist due to intermittent ECR1,
ECR5, ACCESS 4 and/or wiring in between these
components. Proceed through Steps 3 and 4, re-
pairing any issues encountered.

Step 3: Key truck OFF. Check steer tiller for slippage Figure 16975
between ECR1, ECR5 and steer tiller. Also check for
damaged or broken wires between ECR1 and ECR5 to
CA318.
• If: Slippage is observed or any wiring issues.

Step 4: Key truck OFF. Check wire and terminals
where ECR1 and ECR5 enter ACCESS 4, CA304-16,
-23.
• If: Wiring and/or terminals issues are found.

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ELECTRICAL SYSTEM
Event Code 429
Step 5: Disconnect CA318 and key truck ON. Using a

DVOM, check for 12V to ECR1 at CA318-4, -3.
• If: Between 11.5V-12.5V.

– Then reconnect CA318 and again check for
12V.
• If: Not between 11.5V-12.5V.

• If: Between 11.5-12.5V.

• If: Not between 11.5V-12.5V with CA318 discon-

nected and ECR1 replaced.
– Then check for 12V at ACCESS 4 between
CA304-18, -19.


– Then check continuity of the harness between
CA318-3 to CA304-18 and CA318-4 to CA304-19.
Figure 16976
M4.8-7335-062 SP 3500 Crown 2007 PF15819-62 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 429
Step 6: Disconnect CA318 and key truck ON. Check

for 12V to ECR5 at CA318-7, -8.

– Then reconnect CA318 and check for 5V.


• If: Not between 11.5V-12.5V with CA318 still dis-

connected.
CA304-20, -21.


CA318-7 and CA304-21 also from CA318-8 and
CA304-20.
Figure 17024
Step 7: Reconnect CA318 and key truck ON. Check for

encoder counts to ECR1 CHA. Connect DVOM be-
tween CA304-16 (-17 on "forks first steer" trucks) and
-19 turn the steer tiller slowly.
• If: Voltage slowly changes from 0.5V to 11.5V.

• If: Voltage does not change back and forth from

0.5V to 11.5V.
– Then check for ECR1 CHA for 0.5V-11.5V be-
tween CA318-1, -4.

– Then check wire harness between CA304 and
CA318.
• If: Voltage does not change from 0.5V to 11.5V.

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ELECTRICAL SYSTEM
Event Code 429
Step 8: Key truck ON. With CA318 and CA304 con-

nected, check ECR1 CHB encoder counts. Connect a
DVOM between CA304-18, -19 and slowly turn the
steer tiller.


– Then check voltage for CH B between
CA318-2, -4.

– Then check wire harness between CA304 to
CA318.

Figure 17025
M4.8-7335-064 SP 3500 Crown 2007 PF15819-64 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 429

nected, check ECR5 CHA for encoder counts. Connect
a DVOM to CA304-22 (-23 on "forks first steer" trucks)
and -20 and slowly turn the steer tiller.
• If: Voltage changes from 0.5V to 11.5V.


– Then check ECR5 CHA voltage between
CA318-5, -8.

CA318.

nected, check ECR5 CHB encoder counts. Connect
DVOM between CA304-23 (-22 on "forks first steer"
trucks) and -20 and slowly turn the steer tiller.
• If: Voltage changes from 0.5V to 11.5V and event

code continues.
– Then replace ACCESS 4. Figure 17026

– Then check ECR CHB voltage between
CA318-6, -8.

CA318.

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ELECTRICAL SYSTEM
Event Code 430
Event Code 430

ACCESS 4 Encoders ECR1/ECR5 Turn Rate Error.
Note: Event is logged should rate difference between
ECR1/ECR5 occur. ECR1/ECR5 turn at the same rate
through the steer tiller cause for this event code could
be ECR slippage, failure, open or intermittent wiring
between ECR1/ECR5 and ACCESS 4.



– Then issue may be due to intermittent ECR1,
ECR5, ACCESS 4 and/or wiring in between these
components. Proceed through Steps 3 and 4, re-
pairing any issues encountered.

– Then proceed to Step 3. Figure 16975
Step 3: Key truck OFF. Check steer tiller for slippage

CA318.

-23.
• If: Wiring and/or terminal issues are found.

M4.8-7335-066 SP 3500 Crown 2007 PF15819-66 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 430


12V.



CA304-18, -19.


CA318-3 and CA304-18 also CA318-4 to
CA304-19.
Figure 17025
Step 6: Disconnect CA318 and key truck ON to check
for 12V to ECR5 at CA318-7, -8. Step 7: Reconnect CA318 and key truck ON to check
for encoder counts to ECR1 CHA. Connect DVOM be-
• If: Between 11.5V-12.5V. tween CA304-16 (-17 on "forks first steer" trucks) and
– Then reconnect CA318 and check for 5V. -19 and turn the steer tiller slowly.
• If: Not between 11.5V-12.5V. • If: Voltage slowly changes from 0.5V to 11.5V.
– Then replace ECR5. – Then proceed to Step 8.
• If: Between 11.5V-12.5V. • If: Voltage does not change back and forth from
0.5V to 11.5V.
• If: Not between 11.5V-12.5V with CA318 still dis- tween CA318-1, -4.
connected.
CA304-20, -21. – Then check wire harness between CA304 and
CA318.
– Then check harness continuity between
CA318-7 and CA304-21, CA318-8 and CA304-20.
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ELECTRICAL SYSTEM
Event Code 430
Step 8: Key truck ON with CA318 and CA304 con- Step 9: Key truck ON. With CA318 and CA304 con-
nected check ECR1 CHB encoder counts. Connect a nected, check ECR5 CHA for encoder counts. Connect
DVOM between CA304-18, -19 and slowly turn the a DVOM to CA304-22 (-23 on "forks first steer" trucks)
steer tiller. and -20 and slowly turn the steer tiller.
• If: Voltage slowly changes from 0.5V to 11.5V. • If: Voltage changes from 0.5V to 11.5V.
– Then proceed to Step 9. – Then proceed to Step 10.
• If: Voltage does not change from 0.5V to 11.5V. • If: Voltage does not change from 0.5V to 11.5V.
– Then check voltage for CHB between – Then check ECR5 CHA voltage between
CA318-2, -4. CA318-5 and -8.
– Then check wire harness between CA304 to – Then check wire harness between CA304 to
CA318. CA318.
– Then replace ECR1. – Then replace ECR5.
–
Figure 17025
M4.8-7335-068 SP 3500 Crown 2007 PF15819-68 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 430

code continues.

CA318-6 and -8.

CA318.

Figure 17026
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ELECTRICAL SYSTEM
Event Code 431
Event Code 431

ACCESS 4 Encoders ECR1/ECR5 Direction Error.
Note: ECR1/ECR5 turn at the same time, should a dif-
ference in direction occur due to a wiring error or slip-
page event code 431 will be logged.
Step 1: Enter service mode 2 and select ECR1 A2.3.2


Step 2: Enter service mode 2 select ECR5 A2.3.2 in
analyzer menu. View reading on the display.

– Then the issue may be due to intermittent
ECR1, ECR5, ACCESS 4 and/or wiring in between
these components. Proceed through Steps 3 and
4, repairing any issues encountered.

CA318.
• If: Slippage is observed or any wiring issues. Figure 17877
– Then repair as necessary. Step 5: ECR1 test. Disconnect CA318 and key truck
ON. Using a DVOM check for 12V to ECR1 between
Step 4: Key truck OFF. Check ECR1/ECR5 wire con-
CA318-3, -4.
nections at ACCESS 4. ECR1 CA304-18, -16, -17, -19
and ECR5 CA304-21, -22, -23, -20. • If: Between 11.5V/12.5V.
• If: Wire issues exist. – Then key truck OFF and reconnect CA318 and
again check for 12V.
• If: Not between 11.5V/12.5V.
• If: Between 11.5V/12.5V.

M4.8-7335-070 SP 3500 Crown 2007 PF15819-70 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 431
Step 6: ECR5 test. Disconnect CA318 and key truck Step 7: Connect CA318 and CA304, key truck ON.
ON. Using a DVOM check for 12V to ECR5 between Connect a DVOM between CA304-11, -19 and slowly
CA318-7, -8. turn the steer tiller.
• If: Between 11.5V/12.5V. • If: Voltage changes from 0.5V to 11.5V.

– Then key truck OFF and reconnect CA318 and – Then proceed to Step 8.
• If: Voltage does not change.
– Then check for CHA voltage between
– Then replace ECR5. CA318-1, -4.
• If: Between 11.5V/12.5V. • If: Voltage changes from 0.5 to 11.5V.

– Then proceed to Step 7. – Then check wire harness from CA304 to
CA318.

Figure 17937
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ELECTRICAL SYSTEM
Event Code 431
Step 8: With power on and CA318/CA304 connected,

check for encoder counts to ECR1 CHB. Connect
meter between CA304-12, -19 then slowly turn the
steer tiller.


– Then check for CHB voltage between
CA318-2, -4.

CA318.

Figure 17938
M4.8-7335-072 SP 3500 Crown 2007 PF15819-72 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 431
Step 9: With vehicle power ON and CA318/CA304

connected, check for encoder counts to ECR5 CHA.
Connect meter between CA304-7, -20 then slowly turn
the steer tiller.
• If: Voltage from 0.5V to 11.5V.


– Then check voltage for CHA between
CA318-5, -8.

CA318.

connected, check for encoder counts to ECR5 CHB.
the steer tiller.

code continues.

– Then check for voltage to CHB between
CA318-6, -8.

CA318.

Figure 17939
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ELECTRICAL SYSTEM
Event Code 432

ACCESS 4 Height Encoder 4 (ECR4) Power Supply ACCESS 4 5V Power Supply Out of Range.
Out of Range.
Full traction and high speed raise disabled.
Step 1: Key truck OFF the ON.
Step 1: Connect DVOM leads between CA303-12 and
-BV then key truck ON. • If: Event code continues.
• If: Voltage is not between 4.75V and 5.5V. – Then replace ACCESS 4.
– Then disconnect wire from CA303-12 and

check voltage at CA303-12.
• If: Voltage is between 4.75V and 5.5V with wire re-

moved.
– Then short exists in wiring or ECR4. Check wir-
ing between ECR4 and CA303-12 thru -15. Verify
that insulation is not cut and shorted to frame.

• If: Voltage is not between 4.75-5.5V with wire re-

moved.
Figure 17878
M4.8-7335-074 SP 3500 Crown 2007 PF15819-74 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 433
Notes:
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ELECTRICAL SYSTEM
Event Code 435
Event Code 435 Step 5: Disconnect CA317 using a DVOM check volt-
age to ECR4 between CA317-3, -4.
ACCESS 4 Height Encoder 4 (ECR4) Reset Error. • If: 5V.
Full traction and raise speed 2 disabled. – Then reconnect CA317 and proceed to Step 6.
Step 1: Fully lower platform then raise approximately
three feet and lower.
• If: Not 5V.
– Then remove wire 703 and 516 from CA303
• If: Event code repeats.
and using a DVOM check voltage between pins
– Then proceed to Step 2. CA303-12, -15.
• If: Event code does repeat. • If: 5V.
– Then resume truck operation and monitor. – Then check all wiring. Wire 703 CA303-12 to
CA317-3 and wire 516 CA303-15 to CA317-4.
Step 2: Enter service mode 2 analyzer menu and go to
A2.3.1.1, fully lowered raise platform and observe dis- • If: Not 5V.
play.
• If: Height in inches changes.
• If: Height in inches does not change.

A2.3.10. A fully lowered raise platform approximately
three feet at 18 inches the height reset switch (HTGRS)
state should change from closed to open.
• If: State does not change.

– Then check HTGRS and associated wiring.
Step 4: Disconnect CA317 and check encoder wiring
for damaged crimps. If necessary remove wires from
connector for inspection.
• If: Wiring crimps are damaged.

– Then repair or replace ECR 4 as necessary.
Pin 1: White
Pin 2: Blue
Pin 3: Red
Pin 4: Black
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Event Code 440
Step 6: Check ECR4 channel wiring. Wire 007 Event Code 440
CA317-1 to CA303-13, wire 008 CA317-2 to
CA303-14.
ACCESS 4 Zone Select (ZSS) Switch Wiring Open.
• If: Wiring is correct and event code continues. Raise disabled.
– Then disconnect CA317, remove white and Note: If the zone select option is enabled in the truck
blue wires from JC317-1 and JC317-2. Connect a features the truck requires that one of the three outputs
DVOM from white (ECR4 CHA) to -BV, key ON from the switch be closed. This condition indicates that
truck and check voltage. Reading should be either the feature is enabled and none of the three outputs
0V or 5V depending on position of ECR4. Perform are closed or the wire feeding the switch is open.
the same test on the blue wire (ECR4 CH B).
Step 1: Check zone select switch.
• If: Not 0V or 5V.
• If: Zone switch is broken.
– Then replace as necessary.
• If: 0V or 5V.
• If: Zone switch is enabled and truck is not equipped
– Then reconnect wiring. with zone select.
• If: 0V or 5V and event code continues. – Then access service level 2 mode and disable
zone select feature.
• If: Zone switch is enabled and is present.
– Then check wiring between zone select switch
and ACCESS 4.

Figure 17879
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Event Code 441
Event Code 441

ACCESS 4 Zone Select (ZSS) Switch Wiring
Shorted.
Raise disabled.
Note: If the zone select option is enabled in the truck
features the truck requires that one of the three outputs
from the switch be closed. This condition indicates that
more than one of the switch outputs are closed simul-
taneously and therefore the truck can not see the re-
quested zone.
Step 1: Check condition of wiring between switch and
CA303-23, CA304-13, -14.
• If: Wires are shorted.

• If: Wires are correct.

Step 2: Using a DVOM check the ZSS for internal
shorts. Each individual internal switch must be isolated
from the other.
• If: Switch is shorted.

– Then replace ZSS switch.
• If: Switch is correct and event code continues.

Figure 17880
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Event Code 442
Event Code 442

ACCESS 4 Zone Select Switch (ZSS) Detected, but
Feature Not Enabled.
Raise disabled.
Note: If truck has zone select option refer to Step 1. If
truck does not have zone select option, then refer to
Step 2.
Step 1: Enter service mode 2 and proceed to features
and enable zone select.

Step 2: Enter service mode 2 go to features and zone
select.
• If: Zone select is enabled.

– Then disable.
• If: Zone select is disabled.

– Then connect a DVOM to TP7 on platform dis-
tribution panel and check for 24V between
CA303-23, CA304-13, -14.
• If: 24V is not present at any point.

• If: Any terminal is shorted to negative.

– Then repair short as necessary.
Figure 17881
Event Code 443

ACCESS 4 Invalid Zone Select Setup.
Raise disabled.
menu, enter correct cutout configuration setups.

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Event Code 445
Event Code 445

ACCESS 4 (lifting fork option only) PVLF Driver
Open.
Nothing disabled.
Step 1: Disconnect wires 29129, 29130 and 5938 from
PVLF coil using a DVOM check resistance of PVLF
coil.

– Then replace PVLF coil.
• If: 29 ohm.
– Then check for 24V between wires 29129,
29130 and 5938 while depressing lifting forks
lower switch.
• If: 0V.
check for 24V between CA304-4 and TP7 on the
platform distribution panel while depressing lower
switch.
• If: 0V.
• If: 24V.
– Then check for 24V between wire 29129,
29130 and TP3 on the power unit distribution
panel.
• If: 0V.
ing.
• If: 24V.
– Then check connection of CA325, CA701, and
CA809.
Figure 17882
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Event Code 446
Event Code 446

ACCESS 4 (Lifting Fork Option Only) PVLF
Shorted.
Nothing disabled.
coil.

• If: 29 ohm.
– Then, with coil disconnected, disconnect wire
5941 from CA304-4 and check for 24V between
PC304-4 and TP7 on the platform distribution
panel.
• If: 24V.
– Then wire 5941, 5936, 5938, or the mast cable
red wire is shorted to +BV repair/ replace.
• If: 0V.
Figure 17883
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Event Code 447
Event Code 447

ACCESS 4 (Lifting Fork Option Only) SV1 Shorted.
Nothing disabled.
Step 1: Disconnect wires 29130 and 5937 from SV1
coil using a DVOM check resistance of SV1 coil.

– Then replace SV1 coil.
• If: 29 ohm.
5942 from CA304-5. Check for 24V between
panel.
• If: 24V.
– Then wire 5942, 5935, 5937 or mast cable
green wire is shorted to +BV repair/ replace.
• If: 0V.
Figure 17884
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Event Code 448

THRU
ACCESS 4 Travel Alarm (ALM2) Driver Shorted.
Event Code 452
Step 1: Disconnect wire 5915 from CA304-7. Check for
24V between PC304-7 and TP7 on the platform distri-
ACCESS 4 Internal Driver Shorted.
bution panel.
Event Code 449 and 452: Traction and raise disabled.
• If: 24V.
Event Code 450: Raise disabled.
– Then wire 5915 is shorted to +BV repair/ re-
place. Event Code 451: Nothing disabled.
• If: 0V.
Figure 17885
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Event Code 453
Event Code 453

ACCESS 4 Chain Break.
Hydraulics disabled.
Step 1: Check lift chain.
• If: Correct.
• If: Broken.
Step 2: Check chain break switch wiring.
• If: Correct.
– Then check wire 29123, CA303-3 to CA331
and wire 29124, CA331 to CA103-14 and cable as-
sembly between harness and switches. Using a
DVOM, check for 24V between CA303-3 and TP7
on platform distribution panel.
• If: 24V.
• If: 0V.
– Then check terminal conditions.
Figure 17027
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Event Code 460
Event Code 460 Step 4: Check for CAN line short to -BV, +BV and truck
frame. Key truck OFF and disconnect battery. Using a
THRU DVOM, check resistance at the power unit distribution
panel CAN_L to -BV bus bar then CAN_L to TP3 on the
platform distribution panel and CAN_L to truck frame.
Event Code 462 Resistance should be greater than 10,000 ohm.
ACCESS 5 CAN Error. • If: Less than 10,000 ohm.
Event Code 460: ACCESS 5 receiving packets too – Then repair/replace wiring as necessary.
fast.
Event Code 461: ACCESS 5 receiving short packets.
Event Code 462: ACCESS 5 receiving long packets.
No action taken.
Step 1: Verify correct ACCESS modules are in place
on the truck.
• If: Any new ACCESS modules have recently been

installed.
– Then ensure they are properly connected and
have correct software.
Step 2: Determine if logged event code is associated
with specific truck functions.
• If: Event code is logged when a specific function is

started or stopped.
– Then check the function's load and suppres-
sion (for example, if event code is logging when
ED1 contactor opens or closes check ED1 contac-
tor coil and suppression).
Step 3: Check CAN communication lines. Key truck
OFF using a DVOM measure resistance between
Figure 17886
CAN_H and CAN_L on either the power unit or plat-
form distribution panels, resistance should be 60 ohm.
• If: 0 ohm.
CAN_L. Locate short circuit and repair. A short
may exist in an ACCESS. Determine this condition
by disconnecting ACCESS from the CAN bus one
at a time and measure resistance between CAN_H
and CAN_L.

nected.
– Then a CAN bus-terminating resistor is open,
damaged or wiring to terminating resistor is open.
CAN bus contains two terminating resistors, one
located in ACCESS 5 and the other in ACCESS 1.
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Event Code 463
ACCESS 6 CAN Error. • If: If less than 10,000 ohm.
fast.
No action taken.
on the truck.

installed.

started or stopped.
Figure 17886
• If: 0 ohm.
by disconnecting the ACCESS from the CAN bus
one at a time and measure resistance between
CAN_H and CAN_L.

nected.
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Event Code 466
fast.
Event Code 469: ACCESS 1 receiving duplicate ID.
No action taken.
on the truck.

installed.

started or stopped.
sion (for example if event code is logging when
Step 3: Check CAN communication lines. Key truck Figure 17886
• If: 0 ohm.
by disconnecting ACCESS from the CAN bus one
at a time and measure resistance between CAN_H
and CAN_L.

nected.
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Event Code 470
fast.
Event Code 473: ACCESS 4 receiving duplicate ID.
No action taken.
on the truck.
• If: New ACCESS modules have recently been in-

stalled.

started or stopped.
Step 3: Check CAN communication lines. Key truck Figure 17886
• If: 0 ohm.
may exist in an ACCESS). Determine this condi-
tion by disconnecting the ACCESS from the CAN
bus one at a time and measure resistance between
CAN_H and CAN_L.

nected.
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Event Code 473
Notes:
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Event Code 501
Event Code 501 Step 2: Intermittent communication event has occurred

between ACCESS 1 and ACCESS 5. Check for addi-
tional event codes.
ACCESS 5 Communication (CAN) with ACCESS 1
Timeout. • If: Event codes 301 or 401 are logged.
Traction and hydraulics disabled. – Then disconnect plug CA302 and, using a
Note 1: Intermittent disruption of CAN communication DVOM, check for 24V between wire 513 CA302-4
between ACCESS 5 and ACCESS 1 will log event and wire 2941 CA302-3 on the plug.
code 501 (ACCESS 5 will flash event code 501).
ACCESS 1 must receive event code 501 from
• If: 24V.
ACCESS 5 to illuminate the service required indicator – Then check CAN wiring between ACCESS 1
(wrench shaped light). Illumination of the indicator and platform distribution panel. Wire 003 between
shows communication between ACCESS 5 and CA302-8 and CA105-2 also wire 004 between
ACCESS 1 has been intermittently disrupted. CA302-9 and CA105-8.
Note 2: Complete loss of CAN communication be- • If: Event codes 305, 405 have been logged.
tween ACCESS 5 and ACCESS 1 after power up and
initialization will log event code 501. ACCESS 5 will – Then check CAN bus wiring between power
flash event code 501. Should this condition exists CAN unit distribution panel and ACCESS 5. Wire 019
communication between ACCESS 5 and ACCESS 1 is CA402-4 to CA204-2 and wire 020 CA402-5 to
disabled, ACCESS 1 will not log event code 501 and CA204-8.
the wrench light will not illuminate.
Step 3: Communication lost between ACCESS 1 and
Step 1: Determine which ACCESS is indicating the 5. ACCESS 5 is flashing 501 event code. Key truck
event. OFF then ON.
• If: ACCESS 1 displays the wrench and event code • If: ACCESS 1 does not turn ON.
501 is logged.
– Then using a DVOM check for 24V between
– Then proceed to Step 2. wire 2941 CA103-10 and wire 513 CA107-8.
• If: ACCESS 1 has no wrench. Traction, hydraulics • If: 0V.

and steering are disabled and ACCESS 5 is flash-
– Then check wiring and connections. Wire 2941
ing event code 501.
– Then proceed to Step 3. CA107-8.
• If: 24V and ACCESS 1 does not turn ON.

• If: ACCESS 1 turns ON wrench illuminated and

logs event codes 305 and 405.
– Then issue exists in CAN wiring between
power unit distribution panel and ACCESS 5.
Check wire 019 CA402-4 to CA204-2 and wire 020
CA402-5 to CA204-8.
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Event Code 501
Figure 16724
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Event Code 503
Event Code 503

Timeout.
Traction and hydraulics disabled.
Step 1: Check power to ACCESS 3.

– Then issue exists in wiring between power unit
distribution panel and ACCESS 3, check wiring
and connections. Wire 018 CA401-15 to CA204-7
and wire 017 CA401-23 to CA204-1.
• If: Wiring is correct.

– Then clean connections.

– Then issue exists in the power wiring between
power unit distribution panel and ACCESS 3. Us-
ing a DVOM check for 24V between CA401-1 and
ACCESS 3 -BV.
• If: 24V.
• If: 0V.
– Then issue exists in wiring between ACCESS 3
and power unit distribution panel check wiring and
Figure 16725
connections. Wire 2953 CA401-1 to CA201-5.
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Event Code 504
Event Code 504

Timeout.

– Then issue exists in wiring between platform
and wire 002 CA303-8 to CA105-7.


– Then issue exists in power wiring between plat-
form distribution panel and ACCESS 4, check wir- Figure 16726
ing and connections. Using a DVOM check for 24V
between CA304-1 and -BV.
• If: 24V.
• If: 0V.
and platform distribution panel check wiring and
connections. Wire 2937 CA304-1 to CA103-12 and
wire 525 CA304-3 to CA107-9.
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Event Code 505
Event Code 505 • If: ACCESS 6 lights are OFF.

ACCESS 5 CAN Reset. form distribution panel and ACCESS 6, check wir-
No action taken. ing and connections. Using a DVOM check for 24V
between CA601-1 and CA601-2.
Note: Should a reset occur the truck will restore func-
tionality without any changes in performance. There is • If: 24V.
no need for service intervention with occasional occur-
rences. However if this event becomes an issue, then – Then replace ACCESS 6.
follow Step 1 below. • If: 0V.
Step 1: Check CAN connections between ACCESS 5
and power unit distribution panel. Wire 019 CA402-4 to
and power unit distribution panel check wiring and
connections. Wire 2972 CA601-1 to CA201-6 and
• If: Wiring is correct. wire 552 CA601-2 to -BV.
Figure 16727
Event Code 506

ACCESS 5 /ACCESS 6 CAN Error.

– Then issue exists in wiring between platform Figure 16728
and wire 022 CA601-5 to CA204-9.

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Event Code 511
Event Code 511 • If: Less than 5V.
THRU – Then remove wire 706 from CA403-20 and, us-

ing a DVOM, check for +5V between CA403-20
and -B.
Event Code 512
• If: 5V (+/- 0.1V).
ACCESS 5 Internal Issues. – Then issue exists in ECR2 or wiring. Recon-
All functions disabled. nect wire 706 and proceed to Step 2.
Step 1: Replace ACCESS 5. • If: Less than 5V.

– Then remove wire 704 from CA403-21 and, us-
Event Code 513 ing a DVOM, check for +5V between CA403-21
and -B.
THRU
Step 2: Unplug CA410 (ECR2) and, using a DVOM,
check for +5V between CA403-20 and ACCESS 5 -B.
Event Code 514 • If: Less than 5V.
ACCESS 5 Internal Issues. – Then issue exists in wiring between ACCESS 5

CA403 and CA410. Check wire 706 between
No action taken. CA410-4 and CA403 20 also wire 540 between
Step 1: Replace ACCESS 5. CA410-2 and CA403-12.
• If: 5V.
Event Code 515 – Then replace ECR2.
THRU
Event Code 521

ACCESS 5 Internal Issues.
Event Code 522

THRU
Event Code 523

ACCESS 5 +5V Power Supply Out of Range.
Steering and traction disabled. PDS/Forks First (522).
Step 1: Using a DVOM, connect the negative lead to
Figure 16729
-B on ACCESS 5 and with the positive lead check for
+5V at CA403-20 and CA403-21.
• If: 5V (+/- 0.1V) and event code continues.

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Event Code 526
Event Code 526 Step 1: Check FU6.
THRU • If: FU6 in good condition.

– Then check condition of ED2 contacts.
Event Code 527 • If: ED2 contacts in good condition.
ACCESS 5 Brake +BV Out of Range. – Then check for 24V between CA403-7 and
-BV.
Event Code 526: Full traction disabled. This event code
is logged when either inner or outer brake coil is above • If: 24V and event code continues.
range.
Event Code 527: Traction disabled. This event code is
logged when both inner and outer brake coils are below
range.
Step 1: Check status of event codes 540, 528, 529,
530 and 531, if any of these codes have been logged
resolve them before proceeding to 526 and 527.
• If: Only event codes 526 and 527 are constantly

logged.
Event Code 528

ACCESS 5 Inner Brake Coil +B Out of Range.
Note: Check for event code 540 and condition of ED2
contacts also if any other event codes have been
logged relating to these areas resolve them before con-
tinuing.
Inner Brake +BV above range. Full traction disabled.
Step 1: Check battery voltage.
• If: 36V, 48, 80V.

– Then install 24V battery.
Figure 16758
Event Code 529
tinuing.
Inner Brake +BV under range. Traction disabled.
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Event Code 530
Event Code 530

Note: Check for event code 540 and condition of ED
tinuing.
• If: 36V, 48, 80V.

Event Code 531

tinuing.
Inner Brake +BV under range - traction disabled.
Step 1: Check FU5.
• If: FU5 in good condition. Figure 16759
• If: ED2 contacts in good condition.

-BV.

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Event Code 532
Event Code 532

ACCESS 5 +5V Power Supply Voltage Out of
Range.
No action taken.
Step 1: Check for 5V between CA403-27 and -B.
• If: 5V (+/- 0.1V).

– Then monitor for event codes 540 and 541.
• If: Not 5V.

check voltage between ACCESS 5 and -B.
• If: 5V.
– Then reconnect wire 705 to CA403-27 and pro-
ceed to Step 2.
• If: Not 5V. Figure 16760

Step 2: Unplug CS1 from CA406 and check for 5V be-
tween CA406-A and -B.
• If: Not 5V.

– Then check wire connections between
ACCESS 5 and CA406.
• If: 5V.
– Then replace CS1.
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Event Code 533
Event Code 533

Range.
No action taken.
• If: 5V (+/- 0.1V).

• If: Not 5V.

• If: 5V.
ceed to Step 2.
• If: Not 5V. Figure 16760

• If: Not 5V.

ACCESS 5 and CA406.
• If: 5V.
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Event Code 534

THRU
ACCESS 5 Battery Current Sensor Improperly
Installed.
Event Code 535 Note: Check for event code 537 if logged resolve it
first.
ACCESS 5 Battery Current Out of Range.
No action taken.
Note: Check for event codes 532, 533, 536 and 537 if
Step 1: Enter Service Mode 2 and view CS1 sensor
any of these event codes have been logged resolve
input. Command full traction then plugging while view-
first.
ing CS1 values.
• If: Values are negative during traction acceleration.
Step 1: Check wiring between ACCESS 5 and CS1.
– Then check installation of CS1 to bus bar and
• If: Wiring is correct. wiring between ACCESS 5 and CS1.
– Then replace CS1. • If: CS1 installation is correct and event continues.
• If: CS1 installation is incorrect.

– Then correct.
Figure 16760
Figure 16760
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Event Code 537

THRU
ACCESS 5 Current Sensor 1 (CS1) Zero Reading
Out of Range.
Note: Check for event codes 532 and 533. If either Event Code 539
event has been logged, then resolve first.
ACCESS 5 BDI Battery Voltage Out of Range.
No action taken.
Note: Check for event code 540. If logged, then re-
Step 1: Step off truck to allow ED2 contacts to open,
solve first.
wait 2 minutes for ED2 bus to discharge then using a
DVOM check voltage between CA403-24 and -B. Event Code 538: Traction disabled.
• If: Voltage is between 2.4V/2.6V and the event Event Code 539: Full traction, auxiliary raise, auxiliary
code continues. lower and raise disabled.
– Then replace ACCESS 5. Step 1: Check FU2. Replace if open.

Step 2: Check for 24V between CA202-3 and
• If: Voltage is above or below 2.4V/2.6V.
CA206-5.
check for 2.4V/2.6V between wire 104 and -B.
• If: 24V and event continues.
• If: Voltage is between 2.4V/2.6V.
CA403-25.
– Then replace the ACCESS 5.
• If: 0V.
– Then check wiring between CA202-3 and
– Then replace CS1. CA403-25.
Figure 16762
Figure 16761
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Event Code 540
Event Code 540

ACCESS 5 Battery Voltage Out of Range.
Note: ACCESS 5 monitors +BV steering motor input
for correct battery voltage.
Step 1: Using a DVOM check battery voltage.
• If: 24V and battery is known to be good.

• If: 12V, 36V or 48V.

– Then install correct 24V battery.
Step 2: Check the status of FU1 through FU9.
• If: Correct status and event continues.

• If: Any fuse is open.

– Then replace it.
Figure 16763
Step 3: Key ON the truck and check ED contactor op-
eration.
• If: Contactor pulls in (even for only a short time-1/3

second) and the ED coil wiring and contacts ap-
pear to be in good condition.
• If: Contactor does not pull in and the ED bus is not

connecting to ACCESS 5.
– Then follow the procedure of event 544.
Step 4: Key OFF truck and remove the power cable
from ACCESS 5 +B terminal. Connect DVOM between
the +B cable and -B on ACCESS 5; key ON the truck
and check for 24V.
• If: 24V with ED pulled in (about 1/3 second).

– Then key OFF truck and reinstall ACCESS 5
+B power cable. Connect DVOM between AC-
CESS +B and -B key ON truck and check for 24V.
• If: Not 24V or 24V and event code 540 continues.

• If: Not 24V when ED is pulled-in.

– Then issue exists in ED contact wiring follow
procedure for event 541.
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Event Code 540
Notes:
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Event Code 541
Event Code 541 Step 3: Key ON truck. Using a DVOM check for 24V
between ED2 coil + terminal and -BV.
ACCESS 5 ED2 Contactor Failed to Energize. • If: 24V.
All functions disabled. – Then ED2 coil supply is correct, proceed to
Step 1: Key ON truck. Depress brake pedal to energize Step 4.
ED2 contactor.
• If: 20V.
• If: ED2 fails to energize.
– Then ACCESS 3 switch is open, replace
– Then proceed to Step 2. ACCESS 3.
• If: ED2 energizes. • If: 3V.
– Then, using a DVOM, check for 24V between – Then ACCESS 3 ED2 switch is correct, replace
-B and +B on ACCESS 5 also between -B and ED2 contactor.
CA403-7, CA403-9.
• If: 0V.
• If: Greater than 24V.
– Then key OFF truck and check for correct bat- check for 24V between wire 2967 and -BV.
tery.
• If: 24V.
• If: Each test point is 24V.
– Then clear event codes and key ON truck.
• If: 0V.
– Then check wiring between +BV battery termi-
– Then replace ACCESS 5. nal and CA403-18.
• If: Each test point is less than 24V. Step 4: Key OFF truck. Remove wire 5920 from ED2
coil. Using a DVOM, check resistance of ED2 coil.
– Then turn key OFF. Remove CA403 and +B
cable from ACCESS 5, using a DVOM check for • If: 0 ohm.
shorts between CA403-7 (ACCESS pin) (typical – Then remove wire 5920 from ED2 -BV coil ter-
10,000) and -B terminal, CA403-9 (ACCESS pin) minal. Using a DVOM, check resistance of ED2
(typical 10,000) and -B terminal also between +B coil.
terminal and -B terminal (typical 40,000).
• If: 29 ohm.
• If: Resistance is below value shown.
– Then reconnect wire 5920 and proceed to Step
– Then replace ACCESS 5. 5.
• If: Resistance value is correct. • If: Resistance is not correct.
– Then issue exists in ED2 load bus wiring. – Then replace ED2.
Step 2: Key OFF truck check fuses FU1 through FU9. Step 5: Check resistance between ED2 +BV coil con-
• If: Fuses not functioning correctly. nection and CA403-19.
– Then replace as necessary. • If: 0 ohm.

• If: Not 0 ohm.

– Then repair wiring between ED2 +BV coil con-
nection and CA403-19.
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Event Code 541
Step 6: Enter Service Mode 2. Select ED2 test output

menu to activate ACCESS 5/ACCESS 3 ED2
switches. Connect a DVOM between ED2 -BV coil con-
nection and -BV. Check for 24V with no active
switches.
• If: 0V.
check for 24V.
• If: 24V.
– Then ACCESS 3 is shorted, replace
ACCESS 3.
• If: Not 24V.

– Then ACCESS 5 switch open, replace
ACCESS 5.
• If: 20V.
– Then activate ACCESS 5 switch and check
voltage while holding Enter Button.
• If: 20V.
– Then ACCESS 5 is open, replace ACCESS 5.
• If: 24V.

– Then ACCESS 5 switch is shorted (ED may
pull-in), replace ACCESS 5.
• If: 24V. Figure 16764

ACCESS 3.
Step 7: Activate ACCESS 3 ED2 switch and check
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Event Code 542

ACCESS 5 +BV Power Supply Not Present. ACCESS 5 ED2 Turn ON Error.
Step 1: Key OFF truck and check fuses FU5, FU6 and Step 1: Follow procedure for event code 541, ED2 sys-
FU11. tem troubleshooting.
• If: Fuses are correct.

Event Code 545
• If: Fuse(s) are open. ACCESS 5 ED2 Turn OFF Error.
– Then replace as necessary. All functions disabled.
Step 2: Check power supply wiring from TP5 to Step 1: Follow procedure for event code 541, ED2 sys-
CA403-7, CA403-9 and +BV power terminal. tem troubleshooting.
Event Code 546

THRU
Event Code 548

ACCESS 3 ED Load Bus Pre-charge Error.
Event Code 546: General ED pre-charge error.
Event Code 547: ACCESS 3 pre-charge power out of
range.
Event Code 548: ACCESS 3 pre-charge error.
Step 1: Using a DVOM, check resistance from ED bus
(output contact) to -BV.

– Then remove bus load fuses one at a time until
the resistance increases to normal value of 1000
ohm.
• If: ED bus resistance returns to normal.

– Then note last fuse removed and replace all
others to verify bus resistance remains the same.
Figure 16765
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Event Code 549
Event Code 549

ACCESS 3 Chain Slack.
Traction and lower disabled.
Note: Prevents issue(s) logging check lift chain adjust-
ments.
Step 1: Enter Service Mode 2 and select CHS3/CHS4.
• If: Switch shows closed.

– Then status is normal, event code may have
occurred due chain adjustments.
• If: Switch shows open.

– Then check chain adjustment (see Platform in
Service and Parts Manual).
• If: Chain adjustment is correct and event code con-

tinues.
– Then check CHS3/CHS4 adjustment.
• If: CHS3/CHS4 adjustment is correct.

– Then check CHS3/CHS4 resistance, should be
0 ohm.
• If: CHS3/CHS4 resistance is correct and event

code continues.
– Then check CHS3/CH4 wiring. ACCESS 3
CA401-11 wire 2973 to CA414-1, CA201-7 wire
2954 to CA415-1, CA401-20 wire 2974 to
CA416-1, CA201-8 wire 2955 to CA417-1.
Figure 16766
Event Code 551

ACCESS 5 Parameter Error.
No action taken.
Step 1: Turn key OFF then ON.

– Then truck is operation ready.

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Event Code 552
Event Code 552 Step 2: Check steer wheel synchronization, enter Ser-
vice Mode 2 and select analyzer menu to view encoder
THRU counts. Rotate steer tiller in both directions while view-
ing counts, ECR2 counts should change smoothly and
continuously as steer wheel moves. Record ECR2
Event Code 553 counts once steer wheel is at zero position.
ACCESS 5 Parameter Error. • If: ECR2 counts erratic change or no change.
No action taken. – Then check wiring, wire 025 between

CA403-13 and CA410-1, wire 026 between
Step 1: Load default parameters and configure as re- CA403-14 and CA410-3, blue wire between
quired. CA410 and ECR2, orange wire between CA410
and ECR2.
Event Code 554 • If: Wiring is correct and event code continues.
ACCESS 5 EAC Parameter Error. – Then replace ECR2.
No action taken. • If: ECR2 is correct and event code continues.

Step 1: Drive truck over EAC magnets to reset data. – Then replace ACCESS 5.
• If: Event code clears. • If: ECR2 counts change smoothly but count does
not match wheel position.
– Then perform ECR2 alignment.
Event Code 555

THRU
Event Code 556

ACCESS 5 Encoder 2 (ECR2) Out of Range.
Traction disabled.
Note: Check status of event codes 522 and 523 if
logged then resolve them before proceeding to 555
and 556.
Step 1: Using a DVOM check for +5V between
CA410-2 and CA410-4. Figure 16767
• If: Less than 4.75V or more than 5.25V.

– Then follow procedures for event codes 522
and 523.
• If: 5V.
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Event Code 557
Event Code 557

ACCESS 5 Encoder 2 (ECR2) Index Error.
Note 1: ECR2 count indicates the wheel has passed
through zero position, but index signal has not indi-
cated the same.
Note 2: Check status of event codes 522 and 523 if
logged resolve them before proceeding to event code
557.
CA410-2 and CA410-4.

and 523.
• If: 5V.
Step 2: Check ECR2 index wiring, wire 027 between
CA403-23 and CA410-5 and yellow wire between
Figure 16768
ECR2 and CA410.

– Then check steer wheel synchronization, enter
Service Mode 2 and select analyzer menu view en-
coder counts. Rotate steer tiller in both directions
while viewing counts, ECR2 counts should change
smoothly and continuously as steer wheel moves.
Record ECR2 counts once steer wheel is at zero
position.
• If: ECR2 counts erratic change or no change.

– Then check wiring, wire 025 between
CA403-14 and CA410-3, blue wire between
CA410 and ECR2 and orange wire between
CA410 and ECR2.

• If: ECR2 is correct and event code continues.

• If: ECR2 counts change smoothly but count does

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Event Code 558
Event Code 558 • If: ECR2 counts change smoothly but count does
THRU
– Then perform ECR2 Alignment.
Event Code 561

ACCESS 5 Encoder 2 (ECR2) Error.
Traction and steering disabled.
Note 1: Event will occur if there is no wheel movement
upon command.
logged resolve them before proceeding to 558, 559,
560 and 561.
Step 1: Using a DVOM, check for +5V between
CA410-2 and CA410-4.

and 523.
Figure 16767
• If: 5V.
Step 2: Check wire connections between ACCESS 5
A1 and A2 terminal and M3.

Step 3: Check steer wheel synchronization, enter Ser-
vice Mode 2 and select analyzer menu view encoder
counts. Rotate steer tiller in both directions while view-
ing counts, ECR2 counts should change smoothly and
continuously as steer wheel moves. Record ECR2
counts once steer wheel is at zero position.
• If: ECR2 count change is erratic or not at all.

CA410 and ECR2.


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Event Code 562

ACCESS 5 Steering Error. ACCESS 5 /ACCESS 6 Communication Error.
Traction and steering disabled. Traction disabled.
Note: Check status of event codes 540, 524 and 525 if Note: ACCESS 5 has received a wire guidance com-
logged resolve them before proceeding to 562. mand from the guidance switch but has not received
communication from ACCESS 6.
Step 1: Key OFF truck and unplug battery, remove +B
and -B cables from ACCESS 5. Install a jumper be- Step 1: Verify that truck has guidance feature.
tween +B and -B using a DVOM check the following:
Terminal A1 to +B = 15,000 ohm. • If: Feature is installed.
Terminal A1 to -B = 15,000 ohm. – Then check access wiring.
Terminal A2 to +B = 15,000 ohm.
Terminal A2 to -B = 15,000 ohm. • If: Feature is not installed.
Terminal A1 to A2 = 30,000 ohm.
– Then access the features menu and turn guid-
• If: Any are 5000 ohm below the value shown. ance off.
– Then replace ACCESS 5. • If: Event continues.
• If: Readings are correct. – Then refer to event code 506.
– Then reconnect cables and check A1 and A2

cables for a short. Event Code 564
• If: Cables are correct and the event continues.
ACCESS 5 Wire Guidance Enable Error.
Traction disabled.
Note: ACCESS 5 received a wire guidance command
from the guidance switch but wire enable setup is not
active.
Step 1: ACCESS features menu and turn ON wire
guidance.
Figure 16769
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Event Code 565
Event Code 565

ACCESS 5 /ACCESS 3 Traction Encoder 3 (ECR3)
Error.
Traction disabled. One or both channels lost at AC-
CESS 5 in idle or traveling.
Note: Check status of event codes 330 and 565 - both
pertain to ECR3. If logged, then resolve them before
proceeding with 565.
Step 1: Clear event log; key OFF truck; key ON truck
and request traction.
• If: Event 565 is logged.

– Then check wiring between FSB CA408 and
ACCESS 5 CA403.

– Then replace FSB.


– Then check wiring between FSB CA408 and Figure 17944
ACCESS 3 CA401.

Event Code 566
– Then replace FSB. ACCESS 5 EAC Enable Error.
• If: Event continues. Full traction disabled.
– Then replace ACCESS 3. Note: EAC feature enabled, hardware not detected.
Step 1: Verify truck has EAC feature.
• If: Truck does not have EAC feature.

– Then enter features menu and disable EAC.
• If: Truck has EAC feature.

– Then check for event code 105 if logged check
connections to ACCESS 6.
• If: Connections are correct.

– Then check for event code 506 if logged refer
to procedures for event code 506.
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Event Code 567
Event Code 567

ACCESS 5 EAC Sensor Latched On Error.
Note 1: EAC sensor event code ID: 1A.
Note 2: Check status of event codes 625 and 626 - if
logged, then resolve before proceeding to 567, 568,
569 or 570.
Note 3: To perform test position truck away from EAC
magnets.
ACCESS 6 CA602-5 wire 052 and -BV.
• If: 0V.
– Then check for a test voltage between

Figure 16703
• If: 0V.
– Then remove wire 052 from EAC distribution
panel CA607-3, check for 5V between wire end
and -BV.
• If: 5V.
– Then replace EAC distribution panel.
• If: 0V.
– Then remove wire 052 from EAC ACCESS 6
CA602-5, check for 5V between CA602-5 and -BV.
• If: 0V.
• If: 5V.
– Then check wiring between ACCESS 6
CA602-5 wire 052 and EAC distribution panel
CA607-3.
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Event Code 568
Event Code 568

Note 1: EAC sensor event code ID: 1B.
569 or 570.
magnets.
• If: 0V.

Figure 16778
• If: 0V.
and -BV.
• If: 5V.
• If: 0V.
CA602-11, check for 5V between CA602-11 and
-BV.
• If: 0V.
• If: 5V.
CA607-9.
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Event Code 569
Event Code 569

569 or 570.
magnets.
• If: 0V.

Figure 16779
• If: 0V.
and -BV.
• If: 5V.
• If: 0V.
CA602-8, check for 5V between CA602-8 and -BV.
• If: 0V.
• If: 5V.
CA607-6.
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Event Code 570
Event Code 570

Full traction Disabled.
569 or 570.
magnets.
• If: 0V.

Figure 16806
• If: 0V.
and -BV.
• If: 5V.
• If: 0V.
-BV.
• If: 0V.
• If: 5V.
CA607-12.
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Event Code 571
Event Code 571 Step 3: Re-key truck in normal mode. Acquire wire/rail
and stop truck outside the EAC zones, remain idle with
THRU foot on brake. Wait 20 seconds for diagnostics to exe-
cute.
Event Code 572 • If: Sensors fail.

– Then a 500 or 600 event code will be logged.
ACCESS 5 EAC Magnet Error. Follow procedures for that event code.
• If: Time elapses and no event occurs.
Event Code 571: Inner magnet error event code.
– Then system is correct; continue to monitor.
Event Code 572: Outer magnet error event code.
Step 1: Drive truck out of guided aisle then re-enter.
• If: Event clears.

– Then monitor.
• If: Event repeats.

Step 2: Enter Service Mode 2 and select View EAC
Sensor Status in EAC monitor menu A2.5.4 and
A2.5.5. Acquire wire/rail position truck in EAC zone,
display state of corresponding sensors. Slowly drive
over EAC magnets while viewing sensor state on dis-
play. State will be "closed" if not detected, "open" if de-
tected.
• If: Any magnet fails detection.

– Then check wiring of corresponding sensor.

– Then perform the same test over another mag-
net in the aisle.
• If: Test passes.

– Then check the magnet in the floor. Using a
piece of metal, pass it over the magnet attraction
should be strong. Compare it to another magnet
and if there is a dramatic different in the magnetic
attraction replace the magnet.
• If: All four magnets are detected.

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Event Code 573
Event Code 573 • If: Not 0V or 5V.
THRU – Then replace ECR4.
• If: 0V or 5V.
Event Code 574 – Then reconnect wiring.
ACCESS 4 Height Encoder 4 (ECR4) Count Error. • If: 0V or 5V and event code continues.
Full traction and raise 2 disabled. – Then replace ACCESS 4.
Event Code 573: Event code will log if the platform fails
to lower within an allotted time after operator com-
mand. This event may occur during a lower command
and chain slack condition.
to raise within an allotted time after operator command.
Step 1: Disconnect CA317, check encoder side wiring.
Make sure there are not broken crimps on the encoder
wiring into connector.
• If: Wiring crimp broken or damaged.

Step 2: Disconnect CA317, using a DVOM check for
5V between CA317-3 and CA317-4.
• If: 5V.
– Then reconnect CA317 and proceed to Step 3.

Figure 16780-01
and, using a DVOM, check for 5V between pins
CA303-12 and CA303-15.
• If: 5V.
– Then check wiring. Wire 703 CA303-12 to
CA317-3, wire 516 CA303-15 to CA317-4.

Step 3: Check ECR4 channel wiring. Wire 007
CA317-1 to CA303-13, wire 008 CA317-2 to
CA303-14.

– Then disconnect CA317, remove white and
blue wires from JC317-1 and JC317-2. Connect a
DVOM from white (CH A) to -BV, key ON truck and
check voltage. Reading should be either 0V or 5V
depending on position of ECR4 disc. Perform the
same test on the blue wire (CH B).
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Event Code 576
Event Code 576 Step 1: Key OFF truck and, using a DVOM, check re-
sistance of inner coil. Unplug CA407, place DVOM
THRU leads between CA407-2 and CA407-3 on the brake coil
side, typical resistance at room temperature is 3.5
ohm.
Event Code 581
• If: Resistance is significantly less than 3.5 ohm.
ACCESS 5 Brake Current or Resistance Error. – Then replace inner brake coil.
Event Code 576: Traction disabled. Inner brake low
current.
• If: Resistance is close to 3.5 ohm and event contin-
ues.
Event Code 577: Traction disabled. Inner brake hot.
Event Code 578: Full speed traction disabled only. In-
ner brake resistance high.
Event Code 579: Traction disabled. Outer brake low
current.
Event Code 580: Traction disabled. Outer brake hot.
Event Code 581: Full speed traction disabled only.
Outer brake resistance high.
Figure 16782
Step 1: Allow brake assembly to cool then remove
brake from traction motor and disassemble to the level
that coils can be inspected. Event Code 586
Step 2: Inspect coils for heat damage. ACCESS 5 Brake Load Error.
• If: Lamination material has broken down. Traction disabled.
– Then replace brake coils. Note: Inner coil error.
• If: Coils do not appear to be damaged. Step 1: Key OFF truck and, using a DVOM, check re-
– Then, with coils at room temperature, use a leads between CA407-2 and CA407-3 on the brake coil
DVOM and check resistance, typical resistance of side, typical resistance at room temperature is 3.5
inner coil is 3.5 ohm outer coil 1.5 ohm. ohm.
• If: Either coil is significantly above value. • If: Resistance is close to 3.5 ohm and event contin-
– Then replace coil. ues.
Event Code 582
THRU
Event Code 585

ACCESS 5 Brake Current Out of Range.
Figure 16782
Traction disabled.
Event Code 582 and 583: Inner brake resistance low.
Event Code 584 and 585: Outer brake resistance low.
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Event Code 587

ACCESS 5 Brake Load Error. ACCESS 5 Brake Supply Voltage Error.
Note: Outer coil error. Note 1: Brake power supply voltage error could result
from a failure of ED2 contact close.
Step 1: Key OFF truck and, using a DVOM, check re-
sistance of outer coil. Unplug CA407 place DVOM Note 2: Fuse 6 circuit.
leads between CA407-1 and CA407-4 on the brake
Step 1: Check fuse 6.
side typical resistance at room temperature is 1.5 ohm.

• If: Open.
– Then replace fuse 6.
– Then replace outer brake coil.

• If: Correct.
ues. – Then using a DVOM check for 24V between
CA403-7 and B-.
– Then check wiring. Wire 2902 CA206-4 to ED2
contactor, wire 2956 CA202-2 to CA403-7.
Figure 16782
Figure 16783
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ELECTRICAL SYSTEM
Event Code 589

THRU
ACCESS 5 Brake Supply Voltage Error.
Traction disabled.
Event Code 591
Note 1: Brake power supply voltage error could result
ACCESS 5 Brake Driver Error.
Note 2: Fuse 5 circuit.
Step 1: Event code 589 check fuse 5.
Event Code 590: Inner brake driver error.
• If: Open. Event Code 591: Outer brake driver error.
– Then replace fuse 5. Step 1: Refer to procedure for event 588 and 589. Use
event code that corresponds to the specific driver (in-
• If: Correct.
ner or outer brake coil).
– Then using a DVOM check for 24V between Step 2: Refer to procedure for event 586 and 587. Use
CA403-9 and -BV. event that code corresponds to the specific driver (in-
• If: Less than 24V. ner or outer brake coil).
– Then check wiring. Wire 2902 CA206-4 to ED2 • If: Results of Steps 1 and 2 do not indicate a brake
contactor, wire 2957 CA202-1 to CA403-9. voltage error or shorted brake load.
Event Code 592

THRU
Event Code 593

Traction disabled.
Event Code 593: Outer brake driver error.
Step 1: Refer to procedure for event 582, 583, 584,
585. Use event code that corresponds to the specific
driver (inner or outer brake coil).
• If: Results of Steps 1 and 2 do not indicate a brake

low resistance.
Figure 16785
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Event Code 594

ACCESS 5 Proportional Flow Valve (PVL) Load ACCESS 5 Proportional Flow Valve (PVL) Driver
Error. Error.
Hydraulics disabled. Raise disabled.
Step 1: Key OFF truck and remove connector CA403 Step 1: Enter Service Mode 2 and select PVL monitor
from ACCESS 5, using a DVOM check resistance be- menu A3.4.10. Raise platform then lower the display
tween wire 2958 and 5926. will indicate percentage of PVL (lower valve) duty cy-
cle.
• If: Resistance is 25 to 35 ohm.
• If: Display indicates a duty cycle but the platform
does not lower.
• If: Resistance is 0 ohm. – Then check wiring. Wire 5926 CA403-2 to PVL
– Then disconnect wires from PVL coil and check coil, wire 2958 CA403-11 to PVL coil and wire 2960
resistance at coil. CA201-9 to PVL coil.
• If: 0 ohm. • If: Wiring is correct and event code continues.
– Then replace PVL. – Then replace ACCESS 5.
• If: 25 to 35 ohm.
– Then check wire 5926 CA403-2 to PVL coil,
wire 2958 CA403-11 to PVL coil, wire 2960
CA201-9 to PVL coil.
Figure 16784
Figure 16784
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ELECTRICAL SYSTEM
Event Code 596

ACCESS 5 Proportional Flow Valve (PVL) Load ACCESS 5 Proportional Flow Valve (PVL) Driver
Error. Error.
Raise disabled. Hydraulics disabled.
Step 1: Key OFF truck and remove connector CA403 Note: Shorted driver event could be due to outside
from ACCESS 5, using a DVOM check resistance be- short, CA403-2 to -BV or internal short in ACCESS 5.
tween wire CA403-11 and CA403-2.
• If: 25 to 35 ohm. 24V between wire 5926 at PVL coil and -BV.
– Then check wire 5926 CA403-2 to PVL coil, • If: Not 24V.
– Then remove wire 2958 from CA403-11, key
ON truck using a DVOM check for 24V between
• If: Wiring is correct and event code continues. wire 5926 and B+.
– Then replace ACCESS 5. • If: 24V.

• If: Not 24V.

– Then check wiring. Wire 2960 PVL to CA201-9,
wire 2958 PVL to CA403-11.
Figure 16784
Figure 16784
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Event Code 601
Event Code 601

ACCESS 6 CAN Error.
Traction disabled.
Step 1: Verify source of event code.
• If: ACCESS 6 flashes code but is not displayed by

ACCESS 1.
ACCESS 6 and power unit distribution board.
Check connectors CA601, CA204 and wiring. Wire
021 CA601-4 to CA204-3 and wire 022 CA601-5 to
CA204-9.
• If: ACCESS 1 displays event code 601.

– Then check ACCESS 1 power ON light.
• If: ACCESS 1 power ON light is illuminated.

ACCESS 1 and platform distribution panel. Check
connectors CA302, CA105 and wiring. Wire 003
CA105-8.
• If: ACCESS 1 power ON light is OFF.

distribution panel and ACCESS 1. Check wire Figure 16786
2941 CA302-3 to CA103-10.
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Event Code 603
Event Code 603

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
CA204-9.


017 CA401-23 to CA204-1 and wire 018 CA401-15
to CA204-7.

distribution board and ACCESS 3. Check wire
2953 CA401-1 to CA201-5. Figure 16787
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Event Code 604
Event Code 604

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
CA204-9.


ACCESS 4 and platform distribution panel. Check
connectors CA303, CA105 and wiring. Wire 002
CA105-1.

Figure 16788
2937 CA304-1 to CA103-12.
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ELECTRICAL SYSTEM
Event Code 605
Event Code 605

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
CA204-9.


CA204-8.

2966 CA403-10 to CA201-6. Figure 16789
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Event Code 611
Event Code 611

THRU
Event Code 612

ACCESS 6 Internal Error.
Event Code 621

THRU
Event Code 628

Traction disabled.
Event Code 631

ACCESS 6 Wire Guidance Sensor Amplifier Self-
Test Error.
Traction disabled.
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Event Code 632
Event Code 632 Step 2: Enter Service Mode 2 and view GS2 sensor
values (A2.5.3) drive slowly over the wire, values
should increase and decrease while traversing the
ACCESS 6 Load Wheel Sensor Bar GS2 Guidance
wire.
Issue.
Traction disabled. • If: Any of the four coil signals fail to indicate the
presence of the wire.
Note: Event code 632 will also log if wire guidance fea-
ture is enabled and sensor bar(s) are not present. – Then check the wiring corresponding to that
coil for a short or an open issue per the diagrams.
Step 1: Check sensor bar 5V supply. Connect DVOM
positive lead to CA602-22 and negative to -BV and key • If: Wiring is correct.
ON truck.
– Then replace GS2.
• If: 5V.
– Then sensor bar power supply is correct, pro-
ceed to Step 2. – Then replace ACCESS 6.
• If: 0V.
– Then remove wire 717 from CA602-15 (steer
wheel sensor bar GS1), check for 5V between
CA602-22 and -BV.
• If: 5V.
– Then issue exists in GS1 bar or the wiring from
ACCESS 6 to GS1. Repair/replace as necessary.
• If: 0V.
– Then remove wire 718 from CA602-22 (load
CA602-22 and -BV at ACCESS 6.
• If: 0V.
• If: 5V.
– Then issue exists in GS2 or the wiring from
Figure 16790
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ELECTRICAL SYSTEM
Event Code 633
Event Code 633 Step 2: Enter Service Mode 2 and view the GS1 sensor
values (A2.5.1) driving slowly over the wire, values
ACCESS 6 Steer Wheel Sensor Bar (GS1) Guidance
wire.
Error.
Traction disabled. • If: Any one of the four coil signals fail to indicate the
coil for a short or an open issue per the diagrams.
Step 1: Check sensor bar 5V supply. Connect DVOM
positive lead to CA602-15 and negative to -BV and key • If: Wiring is correct.
ON truck.
– Then replace GS1.
• If: 5V.
– Then sensor bar power supply is correct, pro-
ceed to Step 2. – Then replace ACCESS 6.
• If: 0V.
CA602-22 and -BV.
• If: 5V.
• If: 0V.
• If: 0V.
• If: 5V.
Figure 16790
M4.8-7335-130 SP 3500 Crown 2007 PF15819-130 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 636

ACCESS 6 Guide Angle Beyond Acceptable Angle. ACCESS 6 Wire Guidance Signal Loss at Both Sen-
sor Bars.
Traction disabled.
Traction Disabled.
Note 1: Event code 636 could log if truck is driven be-
yond end of wire in auto guide. Step 1: Check for event codes 632/633.
Step 1: If event code 636 is logged by driving beyond • If: Event code 632 or 633 has been logged.
the end of the wire in auto guide system operation is
correct. – Then resolve these event codes before con-
tinuing.
• If: Event code 632/633 was also logged.
• If: Event code 632 or 633 has not been logged.
– Then follow procedures for these event codes
before continuing. – Then check line driver power.
• If: Event code 636 was logged while in aisle. • If: Line driver correct.
– Then check alignment of ECR2, condition of – Then check guide wire condition breaks may
sensor bars and wire guidance calibration. be present.
• If: ECR2 requires realignment.

– Then calibrate truck.
• If: Event code was not due to alignment or calibra-

tion.
– Then using the Crown field strength meter
(Part Number 112953) check wire guide field
strength (6.25 KHz, 168ma to 190ma, 5.2KHz
100ma - 118ma).
• If: Field strength is correct and event code contin-

ues.
– Then check floor surface.
Note 2: Floor surface irregularities, corrupted signal
due to rebar, metal pipes, underground electrical wiring
in metal and/or plastic conduit. Any of these issues can
affect wire guidance performance, which could be lo-
calized (i.e. section in one aisle) or wide spread.
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ELECTRICAL SYSTEM
Event Code 638
Event Code 638

THRU
Event Code 639

ACCESS 6 Loss of Wire Guidance Signal from One
Sensor Bar.
Traction disabled.
Step 1: Check for event codes 632/633.
• If: Event code 632 or 633 has been logged.

– Then resolve event code 632/633 before con-
tinuing.
• If: Event code 638 (load wheel sensor bar GS2)

continues.
CA602-27, wire 119 CA604-2 to CA602-26, wire
118 CA604-7 to CA602-25 and wire 117 CA604-8
to CA602-24.
• If: Event code 639 (steer wheel sensor bar GS1)

continues.
CA602-20, wire 115 CA603-2 to CA602-19, wire
114 CA603-7 to CA602-18 and wire 113 CA603-8 Figure 16791
to CA602-17.
• If: Event code 638 or 639 continues.

– Then replace corresponding sensor bar.
• If: Event code continues after replacement of sen-

sor bar.
M4.8-7335-132 SP 3500 Crown 2007 PF15819-132 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 652

THRU THRU

ACCESS 6 EAC Sensor Out of Range. ACCESS 6 EAC Sensor Digital Signal Error.
Event Code 652 and 653: Sensor A1 over/under range. Event Code 660: Sensor A1 digital signal error.
Event Code 654 and 655: Sensor B1 over/under range. Event Code 661: Sensor B1 digital signal error.
Event Code 656 and 657: Sensor A2 over/under range. Event Code 662: Sensor A2 digital signal error.
Event Code 658 and 659: Sensor B2 over/under range. Event Code 663: Sensor B2 digital signal error.
Step 1: Enter Analyzer Mode and select view EAC sig- Step 1: Enter Analyzer Mode select view EAC digital
nal levels (A2.5.3 - A2.5.6). The signal value displayed signal state (A2.5.3 - A2.5.6). Digital state shall indicate
represents the signal strength in percentage of full "opened" if the magnet is not sensed and "closed" if it
scale for the activated sensor. Display will hold the is sensed. Acquire the wire and slowly drive over the
peak sensed value until next magnet detection cycle magnet in the position of failed sensor while viewing
occurs. sensor digital state.
Acquire wire and slowly drive over the magnet in the
position of failed sensor while viewing sensor signal • If: Digital state switches from "opened" to "closed"
strength. Signal strengths tend towards the lower back to "opened" as sensor passes over the mag-
range value, rather than the upper. net.
• If: Signal is close to 100% and event continues. – Then digital sense is working properly, enter
Button Mode select view EAC signal level corre-
– Then check sensor wiring per diagram. sponding to event code.
• If: Wiring is correct. • If: Signal is close to 40%.

– Then replace EAC sensor that corresponds – Then strength is close to lower range thresh-
with event code. old, check sensor wiring per diagram and inspect
magnet location and floor conditions around the
• If: Signal is close to 40%. magnet.
– Then strength is close to lower range thresh- • If: Correct and event code continues.
old. Check sensor wiring per diagram and inspect
magnet location and floor conditions around the – Then replace EAC sensor that corresponds
magnet. with event code.
• If: Correct. • If: Digital state shows "opened" and does not
change when sensor passes over the magnet.
– Then replace EAC sensor that corresponds
with event code. – Then check magnet is present and the sensor
wiring is correct per the diagram.
• If: Correct.
with event code.

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ELECTRICAL SYSTEM
Event Code 664

THRU
ACCESS 6 Multiple EAC Sensors Active.
Event Code 667
Step 1: Check EAC sensors for damage.
ACCESS 6 EAC Magnet Field Strength Out of • If: Sensor(s) is damaged.
Range.
Step 1: Check magnet location(s) for improper installa-
• If: Sensor(s) are not damaged.
tion and/or damage (i.e. wrong pole, positional align- – Then move truck away from EAC zone where
ment, floor crack through magnet, etc.). all sensors should be inactive. Check digital signal
voltage from CA602-5, -8, -11 and -14 to -BV.
Event Code 668 • If: Digital signal is less than 1V.
THRU – Then remove the corresponding digital signal
wire from CA602. Check the voltage at ACCESS 6
CA602 where the digital signal wire was removed.
Event Code 671
ACCESS 6 EAC Sensor Self-Test Error. – Then replace ACCESS 6.
• If: Greater than 3.5V.
Event Code 668: Sensor A1.
– Then check voltage at the corresponding test
Event Code 669: Sensor B1. signal at CA602.
Event Code 670: Sensor A2. • If: CA602 pin 0V.
Event Code 671: Sensor B2.
– Then replace the corresponding EAC sensor.
Step 1: Check sensor(s) wiring and connections as it
applies to event code(s). • If: CA602 pin greater than 5V.
• If: Wiring and/or connections incorrect. – Then replace ACCESS 6.

with event code.

Figure 16792
M4.8-7335-134 SP 3500 Crown 2007 PF15819-134 Rev. 3/08
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BRAKE SYSTEM
321
Notes:
322
BRAKE SYSTEM
Brake
Brake Braking Force

There are two sources of drive wheel braking, a 3 step, When a brake request is made by releasing the brake
spring applied, electromagnetically released, friction pedal, switch BRS1, located below the platform floor is
disc brake on the drive motor armature shaft, and mo- activated. "ACCESS 3" microprocessor determines the
tor braking, typically called regenerative braking. amount of braking force to be applied. The braking
force is split between the motor regenerative braking
When a brake request is made the operator depresses
and the 3-step disc brake. The forward and reverse
the brake pedal, which activates a switch (BRS1). The
brake force can be independently adjusted through the
"ACCESS 3" microprocessor then determines the
display (Performance Menus, P6, Braking).
amount of braking force to be applied based on the pro-
grammed truck weight (includes battery and maximum
allowable fork load) and the maximum allowable speed
for the particular travel direction and fork height. The
braking force is split between the motor regenerative
braking and the 3 step friction brake. The motor regen-
erative portion is made as large as practical in order to
reduce wear on the 3 step friction brake. The forward
and reverse brake force can be further electronically
adjusted through the display in order to address tire
slide for the particular floor condition in the application.
Figure 18183-01
1 Part of Platform
2 BRS1 Switch
3 Brake
4 Drive Motor
5 ACCESS 3 Module
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BRAKE SYSTEM
Brake
Brake Force Adjustment 7. To adjust braking force in the forks first (FF) or
power unit first (PUF) direction, use the display to
1. Braking force should be checked under the follow- adjust performance settings FF Braking or PUF
ing conditions: Braking (Performance Menus, P6, Braking). Ad-
justing to a higher number will increase braking
– Forks lowered.
force (reduce stopping distance). Adjusting to a
– On a floor surface typical of application. lower number will decrease braking force (increase
stopping distance or reduce tire slide).
– Both forward and reverse travel directions.
– With and without a load.
Brake Adjustment
2. Brake force should be adjusted to produce the
shortest possible stopping distance without caus-
ing the braking wheel to slide or the load to become Air Gap Adjustment
unstable. A brake setting of 6 or 7 is typical for a The "air gap", referred to on this truck, is the distance
properly functioning brake system on smooth dry between the brake armature and the electromagnet
concrete floors. For reference, a typical stopping body with brakes applied. Refer to Figure 18184-01. As
distance when traveling at 8 km/h (5 mph) in the the brake pads and rotor wear normally, the air gap will
power unit first direction, with no load is approxi- increase and should be readjusted, or parts checked
mately 2.1 meters (7.0 feet). Travel speed at the and replaced, when it exceeds 1.0 mm (0.040 in).
point of brake application can be displayed using
the display (Performance Menus, P6, Braking).
NOTE
3. If floor conditions are such that tire slide occurs or
a more/less aggressive stop is desired, braking If the air gap measures more than 1.0 mm (0.040 in),
force can be increased or decreased with a corre- the brake may not release properly. If the brake pad
sponding increase or decrease in stopping dis- thickness is less than 2.8 mm (0.110 in), the brake
tance. pads and rotor should be replaced.
The customer shall verify that the stopping dis- 1. Chock load wheels. Open power unit doors to ac-
tance in any part of the application doesn't prevent cess brake assembly.
the operator from performing a specific task safely,
or result in braking characteristics that are signifi- 2. Release brake, using drive/tow switch. Refer to
cantly different from other similar vehicles being Control of Hazardous Energy section of this man-
used in the facility. An alternative is for the cus- ual.
tomer to train the operator to reduce travel speed 3. Using low pressure air, remove any dirt between
and/or allow for longer stopping distances. armatures and magnet body.
4. If brake force adjustments are necessary, verify 4. To minimize the risk of possible damage to the en-
the settings in steps 5 and 6 before proceeding to coder, remove encoder.
step 7.
5. With a 22.2 mm (0.875 in) open end wrench,
5. Using the display, verify truck model (Features loosen the top nut.
Menu, F5, Truck Model), vehicle weight (Features
Menu, F10 Truck Weight), and service load (Fea- 6. Using a 28.5 mm (1.125 in) open end wrench, turn
tures Menu, F11, Max Load Weight) are correct. the 28.5 mm (1.125 in) hex nut down until the air
Information for these settings can be found on gap is 0.13 mm (0.005 in) at its tightest location.
truck’s data plates. One complete turn of the nut will change the gap
1.4 mm (0.056 in) or 1/6 (60 degrees) turn will
6. Verify the drive brake torque gap setting is correct change gap 0.235 mm (0.009 in).
(refer to Brake Torque Gap for GVW chart).
7. Torque 22.2 mm (0.875 in) hex nut to 122 Nm
(90 ft lb).
8. Apply brake, using drive/tow switch.
9. Remove chocks and check operation.
M5.0-7335-002 SP 3500 Crown 2007 PF15820-2 Rev. 3/08
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BRAKE SYSTEM
Brake
Figure 18184-01
1 Drive Motor 7 Rotor

2 Torque Adjuster Plate 8 Brake Parts
3 Adjuster Disc 9 Armature
4 Electromagnet 10 Torque Adjuster Cap
5 Air Gap 11 1 1/8 in Hex Nut
6 Motor Shaft 12 7/8 in Hex Nut
Torque Gap Adjustment NOTE

The "torque gap", referred to on this truck, is the dis- Refer to the capacity plate for truck GVW as equipped
tance between the torque adjuster plate and the elec- with maximum battery and capacity load.
tromagnet. Refer to Figure 18184-01. The torque plate
is factory preset and no adjustment is required, how-
ever, through routine maintenance it may be necessary
to replace components and the gap may need to be
reset to factory specifications. The torque gap will vary
with each trucks Gross Vehicle Weight (GVW).
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BRAKE SYSTEM
Brake
Chart 1 - Brake Torque Gap for GVW
Torque Gap GVW (capacity load and

maximum battery)
mm (in) kg (lb)
0.00 (0.00) greater than 6509 (greater than 14350)
0.51 (0.02) 6214 - 6508 (13700 - 14349)
1.02 (0.04) 5919 - 6213 (13050 - 13699)
1.52 (0.06) 5625 - 5918 (12400 - 13049)
2.03 (0.08) 5330 - 5624 (11750 - 12399)
2.54 (0.10) 5035 - 5329 (11100 - 11749)
3.05 (0.12) 4740 - 5034 (10450 - 11099)
3.56 (0.14) 4445 - 4739 (9800 - 10449)
4.06 (0.16) 4150 - 4444 (9150 - 9799)
4.57 (0.18) 3856 - 4149 (8500 - 9149)
5.08 (0.20) less than 3855 (less than 8500
M5.0-7335-004 SP 3500 Crown 2007 PF15820-4 Rev. 3/08
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BRAKE SYSTEM
Brake
Rotor and Brake Pad Replacement Brake Assembly

Tools are available from Crown to permit replacement Before assembling brake, inspect all components for
of the pads on the brake pad assembly. When used wear, grooves, nicks or other damage. If any abnormal
with a press, these tools allow the correct positioning of wear or damage appears that may affect brake opera-
the pads and correct setting of the rivets. A press is tion, replace with new parts. Assemble brake as fol-
required to insure the rivets provide the compression lows:
strength needed to keep brake pads stationary.
1. Turn torque adjuster plate down as far as possible
to reduce spring force. Place adjuster disc on
torque adjuster plate.
2. Apply a light coat of multipurpose grease
Riveter Base (063002-024) to the motor end cap threads and on
top of the torque adjuster plate.
3. Position magnet body on the motor so the coil
wires are positioned as shown in Figure 18189-01.
Apply blue thread locking adhesive (061004-026)
to the three 7.9 mm (0.312 in) screws and secure
magnet to motor with screws.
4. Assemble springs, inner and outer armatures to
magnet body. Apply a light coat of multipurpose
Riveter
grease (063002-024) to entire bottom of brake pad
plate assembly. Be careful not to contaminate
brake pads with grease.
Figure 18186-01 5. Install compression spring over armature shaft.
To disassemble rotor and brake pad assembly: 6. Slip rotor on motor shaft, hub first. Thread 28.5 mm
1. Block load wheels, disconnect battery and open (1.125 in) hex nut onto motor shaft. Turn nut down
power unit doors. until the rotor moves down and almost touches the
brake pads. Proper air gap adjustment will be
2. Disconnect brake connector from CA407. made later.
3. Remove retaining ring, washers and two hex nuts. 7. Thread the 22.2 mm (0.875 in) hex nut onto motor
4. Remove rotor and brake pad assembly. shaft. Add flatwasher(s) and install retaining ring
on motor shaft.
5. Follow Brake Assembly procedure when reassem-
bling the brake. 8. Set torque adjuster gap to its original factory set-
ting. See torque gap adjustment procedures.
9. Connect wire harness to brake assembly.
10. Adjust air gap. See air gap adjustment procedures.
11. Check brake operation and stopping distance. See
adjustment procedures in truck settings section of
this manual.
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BRAKE SYSTEM
Brake
Figure 18189-01
1 Drive Motor 11 Brake Pad Assembly

2 Spring 12 1 1/8 in Hex Nut
3 5/16 in Screw 13 Flatwasher
4 Inner Armature 14 Retaining Ring
5 24 Volt Wire Position 15 7/8 in Hex Nut
6 Magnet Body 16 Rotor
7 Adjuster Disc 17 Brake Pad
8 Torque Adjuster Plate 18 Rivet
9 Screw 19 Outer Armature
10 Compression Spring
M5.0-7335-006 SP 3500 Crown 2007 PF15820-6 Rev. 3/08
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328
BRAKE SYSTEM
Brake
Chart 2 - Troubleshooting
Problem Probable Cause Remedy

Brakes will not release Air gap greater than 1.0 mm (0.040 in) Adjust
Open circuit in brake circuitry or wiring Inspect floorboard switches
and all associated wiring
Armatures movement restricted by dirt or Clean with low pressure air
foreign material
Brake drag Air gap less than 0.25 mm (0.010 in) Adjust
Brake pad mounting plate or rotor distorted Replace
foreign material
Brakes grab Incorrect stopping distance adjustment Adjust (Refer to traction setup
PUF brake and FF brake)
Brake dust or foreign material restricting Clean with low pressure air
movement
Stopping distance too long Incorrect stopping distance adjustment Adjust (Refer to traction setup
PUF brake and FF brake)
Brake pads loose or soiled with grease Replace
Abnormal noise and chatter Brake pad mounting plate or rotor distorted Replace
when brakes applied
Brake pads worn out, loose, soiled with Replace
grease or foreign material embedded
Abnormal braking force for lift Rotor thin, cracked or spline worn Replace
height or brakes applied without
Wire Guide Trucks: Guide wire lost power or Troubleshoot wire guidance
request
truck off guide wire system
Open circuit in brake circuitry or wiring Check all switches and
associated wiring
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329
Notes:
330
STEERING
331
Notes:
332
STEERING
Steering
Steering
Steering Indicator
Lights Enhanced
with Optional LED
Access 1
Access 5
Figure 18207
The electronic power steering utilizes a servo motor to Steering Direction

steer the drive wheel. Movement of the steering wheel
turns the steering command encoder (ECR1) anc The truck will turn in the direction the steering wheel is
ECR5 which sends data to the platform Access 1 dis- rotated when traveling forward or power unit first direc-
play module (DCM). This information is converted to a tion. If your truck is equipped with wire guidance, the
direction, rate and position signal. This information is truck will be automatically steered once the guide wire
compared with the position and direction information is acquired. Refer to Electrical Maintenance for wire
that is received from the power unit steering feedback guidance operation.
encoder (ECR2). A composite signal representing the
difference is calculated in the power unit Access 5
steer control module (SCM) and is then applied to the
steering motor (M2). Travel speed and lift height may
be limited in relation to steer wheel position.
Crown 2007 PF15821-1 SP 3500 M6.0-7335-001
333
STEERING
Steering
Steering Wheel Direction Indicator The second and third indicator on either side being
glowing indicates a steer angle between 35 and 60 de-
Optional five indicator lights around the power unit end grees in the indicated direction. When the third indica-
of the truck image on the display panel provide a visual tor on either side of the center indicator is the only indi-
indication of approximate steer wheel turn angle. When cator "ON", the steer angle is between 60 and 90
the center indicator only is glowing green, the angle of degrees.
the steered wheel from straight ahead is within ± 1 de-
Steering will be limited to no more than 10 degrees of
gree. If the center indicator and first indicator to either
straight ahead if the forks are raised 4570 mm (180 in)
side of the center are glowing, the steered wheel angle
or more. An alarm will sound and a message will be
is between 1 and 9 degrees in the indicated direction.
displayed (on the display panel) informing you that
The first indicator next to the center indicator being the
steering is limited.
only indicator "ON" indicates steered wheel position
between 10 and 34 degrees in the indicated direction. If steering is positioned beyond 10 degrees of straight
ahead and raise is selected, an alarm will sound notify-
ing you that raise is limited to 4570 mm (180 in). A
message will be displayed (on the display panel) in-
forming you that lift is limited to 4570 mm (180 in). To
raise the forks higher, you must steer the truck no more
than 10 degrees from straight ahead travel.
CAUTION
If the drive tire is physically turned while the truck is

"OFF", on power up, the steering indicators will not rep-
resent the proper steer angle. The steering wheel must
be rotated so drive unit and encoder pass through in-
Steer Angle Indicator dex to reset the electronics.
Figure 3303-02
M6.0-7335-002 SP 3500 Crown 2007 PF15821-2
334
STEERING
Steering
Steering Wheel Adjustment ment to this friction block. If the steering wheel rotates
after the operator removes his hand, then the friction
To prevent the steering wheel from rotating "Free block needs to be replaced. This is located behind the
Wheeling", after the operator's hand has been re- steering wheel. To gain access, you must first remove
moved, a friction block is used to keep the steering the six screws securing the console cover on. With the
wheel from rotating. The friction block is tightened cover removed, the steering command assembly will
against the steering wheel shaft. There is no adjust- be visible. Refer to Figure 17865.
Part of
Platform
Figure 17865
Crown 2007 PF15821-3 SP 3500 M6.0-7335-003
335
STEERING
Steering
Steering Motor Gearbox

The steering motor gearbox should be filled to the level
indicator plug on the end of the gearbox with DTE 24
lubricant. Capacity of the gearbox is 0.95 liter (2 pints).
Refer to Figure 3246-01.
Fill Plug
Level Indicator Plug
Figure 3246-01
M6.0-7335-004 SP 3500 Crown 2007 PF15821-4
336
LIFTING MECHANISM
337
Notes:
338
LIFTING MECHANISM
Mast
Mast Shim Basics

Your truck is equipped with either a TL or TT style mast The mast is designed to be at its tightest point when
assembly. Masts are constructed of hot rolled carbon fully extended and loosest when fully lowered. This al-
steel I-beams welded to flat formed plates. They tele- lows the mast column rollers to move freely as the mast
scope on alloy steel column rollers. extends while providing maximum stability when fully
extended. Each mast is designed to be wider at the
bottom than the top. If the mast was shimmed so that it
TL Mast was tight when fully lowered, it would not fully extend
because of mast channel to column roller binding at
(Not Available On SP3570/80/71/81) about 75% of lift height causing detrimental effects to
the mast channel. The mast should only be checked for
The TL mast is a two stage mast assembly using two
tightness when near full extension.
lift cylinders mounted to the bottom of the main frame
and at the top of the 2nd stage mast. The lift chain is To add shims behind the column roller, the column
anchored at the top of the main frame and routed over roller must be removed and shims added behind the
the 2nd stage mast and anchored to the bottom of the column roller on the roller stud. Refer to Figure
platform. Refer to Lifting Mechanism for lift chain rout- 17000-01.
ing.
Control cables are routed from the distribution panel
mounted in the power unit, to the top of the main frame
and over the top of the 2nd stage mast through a series
of pulleys and secured on the platform and connected
to CA104 and CA106 on the platform. Refer to Electri-
cal for control cable routing.
TT Mast
The TT mast is a three stage assembly using two lift
cylinders mounted to the bottom of the main frame and
secured at the top of the 2nd stage mast and a free lift
cylinder mounted on the 3rd stage mast. The lift chain
is anchored at the top of the main frame, routed over
the 2nd stage mast and secured at the bottom of the
3rd stage mast. Another lift chain is secured in the mid-
dle of the 3rd stage mast, routed over the free lift cylin- (a) Top of Main Frame
der yoke and anchored to the bottom of the platform. (b) Shims 0.80 mm (0.03 in) AR
Refer to Lifting Mechanism for lift chain routing. (c) Column Roller 100 mm (4 in) Diameter
mounted in the power unit, to the top of the main frame Figure 17000-01
and over the top of the 2nd stage mast. Control cables
Shim (060030-085) size used is 0.8 mm (0.031 in)
are then run through a series of pulleys mounted to the
thick. When shims are installed it is always ideal to
bottom of the 3rd stage mast and routed over the free
have an equal number of shims on each column roller
lift cylinder yoke to the platform and connected to
stud. Often times this is not possible. If an unequal
CA104 and CA106 on the platform. Refer to Electrical
number of shims are required, it is very important that
for control cable routing.
an equal distribution of shims per side be followed. Re-
A hydraulic hose is run off a tee connector at the bot- fer to Figure 17001. An example would be two shims
tom of the left lift cylinder and routed over the top of the
on each roller stud of the left column rollers and one
2nd stage mast down to the bottom of the free lift cylin-
each on the right side column roller studs. If the shims
der mounted on the 3rd stage mast. Refer to Hydraulic
are not installed in this manner, mast tilting will occur.
for hydraulic hose routing.
Crown 2007 PF15797-1 SP 3500 M7.0-7335-001
339
LIFTING MECHANISM
Mast
(a) Part of Platform

(b) Not Adjustable
(b) 2 Shims (Platform)
(c) 1 Shim (Platform)
(d) 2 Shims (Platform)
(d) 2 Shims (Mast)
(e) 2 Shims (Mast)
(e) 1 Shim (Mast)
(f) 1 Shim (Mast)
Figure 17001 Figure 17002-01
M7.0-7335-002 SP 3500 Crown 2007 PF15797-2
340
LIFTING MECHANISM
Mast
screws securing bottom of the lift cylinders to the main

WARNING frame.
Wear appropriate protective items such as safety
glasses, steel-toe shoes, etc. whenever performing
maintenance work. To avoid injury, DO NOT place fin-
gers, hands, arms or feet through mast or position
them at pinch points. Make sure lifting device is suffi-
ciently rated to lift various parts of the mast sections
either individually or as a group. Make sure that the
blocking material is strong enough to withstand the
weight. Never work under or around a truck that is not
securely blocked. Refer to Control of Hazardous En-
ergy Lockout/Tagout for lifting and blocking proce-
dures.
TL Mast Column Roller Removal

(TL Mast Not Available On SP3570/80/71/81)
Before starting the mast column roller removal for
shimming, it is a good idea to review Shim Basics and 150 mm
Mast Testing portions of this chapter. To determine (6.0 in)
where shims are required on the mast, the mast must
be fully extended and each column roller checked for
proper tolerance. Refer to Shim Measurements (Toler-
ances).
The truck must be in an area with enough overhead Hardwood Block
clearance to fully extend the mast. Make lifting equip- (Block Both Outriggers
ment connections to the top of the mast assembly. The and Power Unit)
equipment used to lift and move the mast assembly
must be of sufficient capacity or size to safely handle Figure 10066-02
the mast assembly. Lifting equipment such as hoists or Attach lifting device to the 2nd stage mast, raise ap-
other lift trucks with insufficient capacity may break or proximately 40 mm (1.5 in). Once the top of the mast
become unstable and an unsafe condition may arise, clears the lift cylinders, lean the lift cylinders in towards
which must be prevented. The weight of the TL mast the middle of the truck. Refer to the mast clears the lift
assembly is 800 - 1100 kg (1750 - 2350 lb). Platform cylinder, lean the lift cylinders in towards the middle of
weight including forks is 500 - 750 kg (1100 - 1650 lb) the truck. Refer to Figure 0334P-01.
Power unit weight including battery is 1650 - 1900 kg
(3650 - 4130 lb).
Disconnect battery.
If necessary for repairs, remove platform. For platform
removal and shimming procedures refer to Platform
and Control of Hazardous Energy Lockout/ Tagout.
Using a lifting device, raise the load wheels 150 mm
(6.0 in) and block each outrigger and power unit. Avoid
wire guidance sensors under the power unit skirt edge
if present on truck. Refer to Figure 10066-02.
Remove screws securing top of the lift cylinders to the
2nd stage mast. Refer to Figure 17003-01. Loosen
Crown 2007 PF15797-3 SP 3500 M7.0-7335-003
341
LIFTING MECHANISM
Mast
NOTE
Column rollers at the bottom of the 2nd stage mast are
a larger diameter column roller. Make sure these col-
umn rollers are only installed on the bottom of the 2nd
stage mast.
Figure 0334P-01
Raise platform using a lifting device 75 - 130 mm (3.0 -

5.0 in) and block. Refer to Figure 10064-02.
(a) Top of 2nd Stage Mast

(b) Lift Cylinders
Figure 17003-01
Remove column rollers and note number of shims on

each roller stud. Remove column rollers carefully.
Many times shims cling to the back of the column roll-
ers and fall off after removal.
Refer to Shim Basics.
Block Platform
75 - 130 mm (3.0 - 5.0 in)
Figure 10064-02
Using a lifting device, lower the 2nd stage mast to ex-

pose the column rollers. This should also expose the
column rollers at the top of the main frame.
M7.0-7335-004 SP 3500 Crown 2007 PF15797-4
342
LIFTING MECHANISM
Mast
TT Mast Column Roller Removal

shimming, it is a good idea to review Shim Basics and
Mast Testing portions of this chapter. To determine
ances).
The truck must be in an area with enough overhead
clearance to fully extend the mast. Make lifting equip-
ment connections to the top of the mast assembly. The
must be of sufficient capacity or size to safely handle
the mast assembly. Lifting equipment such as hoists or
other lift trucks with insufficient capacity may break or
become unstable and an unsafe condition may arise,
which must be prevented. The weight of the TT mast
assembly is 1050 - 1850 kg (2350 - 4100 lb). Platform
weight including forks is 500 - 750 kg (1100 - 1650 lb)
Power unit weight including battery is 1650 - 1900 kg (a) Top of Main Frame
(3650 - 4130 lb).
(b) Chain Anchor
WARNING Figure 17005-01
Wear appropriate protective items such as safety Remove control cable pulleys and free lift hose pulley
glasses, steel-toe shoes, etc. whenever performing on 2nd stage mast and secure to one side.
gers, hands, arms or feet through mast or position Lower 3rd stage mast to expose column rollers on the
them at pinch points. Make sure lifting device is suffi- bottom of the 3rd stage mast and top of the 2nd stage
ciently rated to lift various parts of the mast sections mast.
WARNING
securely blocked. Refer to Control of Hazardous En- When lowered, the platform will rest on top of the out-
ergy Lockout/Tagout chapter for lifting and blocking riggers. Keep feet and hands clear when platform is be-
procedures. ing lowered.
Disconnect battery. Remove column rollers and note number of shims on
If necessary for repairs, remove platform. For platform each roller stud. Remove the column rollers carefully.
removal and shimming procedures, refer to Platform Many times shims will cling to the back of the column
and Control of Hazardous Energy Lockout/Tagout. roller and fall off after removal.
Using a lifting device, raise the load wheels 150 mm Remove screws securing top of the lift cylinders to the
(6.0 in) and block each outrigger and power unit. Avoid 2nd stage mast. Remove hydraulic hose guide on the
wire guidance sensors under the power unit skirt edge lift cylinder and secure to one side. Loosen screws that
if present on truck. Refer to Figure 10066-02. secure bottom of the lift cylinders to the main frame.
Using a lifting device, raise the 3rd stage mast enough
to loosen the lift chain anchored to the 3rd stage mast.
Remove nuts from chain anchors at top of main frame.
Remove chain anchors and secure to one side.
Crown 2007 PF15797-5 SP 3500 M7.0-7335-005
343
LIFTING MECHANISM
Mast

(b) Lift Cylinders
(c) Hydraulic Hose Guide (TT Only)
Block 3rd Stage Mast
75 - 130 mm (3.0 - 5.0 in)
Figure 17006-01 Figure 10067-02
Attach a lifting device to the 3rd stage mast and raise Attach lifting device to the 2nd stage mast and raise
75 - 130 mm (3.0 - 5.0 in) and block. approximately 40 mm (1.5 in). Once the top of the mast
clears the lift cylinders, lean the lift cylinders in towards
NOTE the middle of the truck. Refer to Figure 0334P-01.
The 3rd stage mast and platform are connected. When With the use of a lifting device, lower the 2nd stage
the 3rd stage mast is raised the platform will also be mast to expose the column rollers. This should also ex-
raised. pose the column rollers on the bottom of the 2nd stage
mast and the column rollers on the top of the main
frame.
M7.0-7335-006 SP 3500 Crown 2007 PF15797-6
344
LIFTING MECHANISM
Mast
Shim Measurements (Tolerances)

Once the mast has been reassembled, the mast col-
umn roller travel and clearance should be checked.
Extend the mast to its maximum lift height, and then
lower the mast so the column rollers are 25.4 mm
(1.0 in) away from the stops. This will ensure the mast
does not twist. The reason the mast must be raised is
to bring it to its tightest point. When fully lowered, it is
at its loosest point.
WARNING
them at pinch points.
(a) Bottom of 2nd Stage Mast

(b) Shims 0.80 mm (0.03 in) AR CAUTION
(c) Column Rollers 115 mm (4.5 in) in Diameter Make sure the platform the maintenance person rides
on is secure and the individual is using an operator har-
Figure 17004-01 ness.
NOTE With the use of a man-up vehicle, check all mast col-
umn rollers (four on TL masts and eight on TT masts).
To check column roller(s) with the mast extended, use
a pry-bar to shift the mast channels to one side. This
will force the opposite side tight against the mast chan-
stage mast.
nel. This is necessary to seat each column roller
Remove column rollers and note number of shims on against the roller stud shoulder to allow for an accurate
each roller stud. Remove the column rollers carefully. column roller to channel clearance measurement.
Many times shims cling to the back of the column roll- Once the mast has shifted, retain slight pressure to
ers and fall off after removal. keep the mast from slipping back.
See Shim Basics. Measure the distance between the channel and the
column roller; 10 mm (0.375 in) from the channel face,
refer to Figure 17007-01. Always measure from the
side the column rollers are canted toward. If the dimen-
sion is greater than 0.8 mm (0.031 in) then a shim
needs to be added behind the column roller, refer to
Figure 17007-01. If the dimension is 0.000 and it does
not appear to be too tight, proceed in checking the re-
maining column rollers. The test procedure after as-
sembly will determine if the column rollers with the
0.000 clearance will require shim removal.
Crown 2007 PF15797-7 SP 3500 M7.0-7335-007
345
LIFTING MECHANISM
Mast
with a cloth. Spray the channel with a thin coat of paint.

This will allow a visible indication of where the column
rollers are traveling. Repeat as required.
(a) Pry Bar

(b) Feeler Gauge
Channel Should Only Show Wear Here
Figure 17007-01
Figure 0337P-01
Accurate measurements can only be checked from one
side. Once the previously described dimensions are Once the mast meets requirements, grease the mast
obtained, the mast channel column rollers will be within channels (063003-024). When the mast is raised to
tolerance. When adjustment is required, try to even out near full extension, it should not lean left or right; it
the number of shims per side. Example: two shims should appear even and straight. If a leaning condition
right, two shims left. Refer to Shim Installation and exists, it is a sign the shimming is too loose or unbal-
Shim Basics and Figures 17001-01 and 17002-01. anced and will need to be readjusted, refer to Shim Tol-
erance.
Proceed to check the remaining column rollers. For
platform column rollers measurements, refer to Plat-
form. Flaking
It is not uncommon for a new mast to appear as if it's
Mast Testing (Assembled) flaking or peeling. This appearance is an indication the
column rollers are seating to the mast channel and is
Once the mast is assembled there are a few tests that considered normal. Eventually this condition will disap-
can be made to verify that mast column rollers are trav- pear. Grease applied to the mast channel will retain
eling correctly. these particles.
Inspect each channel for column roller tracking path.
The only area that should show wear is the back por- Shim Removal
tion of the I-beam where the column roller travels. Re-
fer to Figure 0337P-01. The I-beam should not show Under certain circumstances it may be necessary to re-
signs of any cutting or grooving. If cutting or grooving is move shims after the mast is assembled. When neces-
evident, it will normally take place at the side of the col- sary, refer to the following procedures.
umn roller; 10 mm (0.375 in) from the channel face. If
this type of wear is evident, a shim will have to be re-
moved, refer to Shim Removal. WARNING
Once a readjustment has been made by removing or Wear appropriate protective items such as safety
adding shims, a recheck of the mast channel will be glasses, steel-toe shoes, etc. whenever performing
required. To see the new wear pattern, clean the chan- maintenance work. To avoid injury, DO NOT place fin-
nel with a solvent that will remove grease and wipe dry
M7.0-7335-008 SP 3500 Crown 2007 PF15797-8
346
LIFTING MECHANISM
Mast

them at pinch points. WARNING
Top Column Rollers glasses, steel-toe shoes, etc. whenever performing
(Refer to Figure 3329-01) gers, hands, arms or feet through mast or position
Completely lower the mast. them at pinch points.
To access the shims behind the column rollers, use a Make sure lifting device is sufficiently rated to lift vari-
pry bar to push the column roller out. ous parts of the mast sections either individually or as
a group. Make sure that the blocking material is strong
Locate a shim and push it away to isolate it from the enough to withstand the weight. Never work under or
remaining shims. around a truck that is not securely blocked. Refer to
Using a hammer and small chisel, break the shim and Control of Hazardous Energy Lockout/Tagout chapter
remove from roller stud. for lifting and blocking procedures.
Bottom Column Rollers Mast Removal

(Refer to Figure 3329-01) The mast assembly and platform can be removed from
the truck as one unit. However, if the platform needs to
Raise the mast to a position where the column roller be removed first, refer to Platform and Control of Haz-
that requires a shim to be removed is accessible. ardous Energy Lockout/Tagout for platform removal
Support and block the mast. Refer to Control of Haz- procedures.
ardous Energy Lockout/Tagout. Raise platform and remove forks. Refer to Platform for
Locate a shim and push it away to isolate it from the fork removal procedures.
remaining shims. Disconnect battery and chock wheels.
Using a hammer and small chisel, break the shim and
remove from roller stud.
CAUTION
Don't allow any metallic objects to come in contact with
the top of the battery cells. This may cause a short cir-
cuit when removing, installing or transporting the bat-
tery. Use an insulator (such as plywood) to cover the
top of the battery before and during the removal and
installation process.
Remove battery from power unit. Refer to Battery and
Control of Hazardous Energy Lockout/Tagout for bat-
tery removal procedures
Using a lifting device, raise the truck, block the power
unit and main frame assembly on both sides of the
truck so the load wheels are just off the floor.
CAUTION
The power unit, if not blocked, will fall to the floor once
the mast assembly is removed. The power unit should
Isolate Shim be blocked so it remains parallel with the floor.
& Remove
Figure 3329-01
Crown 2007 PF15797-9 SP 3500 M7.0-7335-009
347
LIFTING MECHANISM
Mast
Attach Strap or Chain

to All Top Braces
(a) Wheel Chock

(b) Hard Wood Blocks (Block Both Sides
of Main Frame and Power Unit)
Figure 17008-01
Attach a strap or chain to all top cross braces so all

mast sections can be lifted at once. Refer to Figure
10587-01.
Attach sufficiently rated lifting device to strap/chain
around all top cross braces on mast sections to be re-
Figure 10587-01
moved. Refer to Figure 10587-01.
Disconnect hydraulic lines to lift cylinders and catch
and clean up all oil spillage. Secure hydraulic lines out
of the way.
Disconnect control cables connected to the distribution
board located in the power unit. Note location and rout-
ing of cables.
Disconnect limit switches from distribution board and
secure out of the way if present on truck.
Secure height sensor on back of platform if present on
truck. Refer to Platform.
Using a lifting device apply tension to the strap/chain
that is connected to the top of the mast assembly.
M7.0-7335-010 SP 3500 Crown 2007 PF15797-10
348
LIFTING MECHANISM
Mast
NOTE
Shims may be in place when the main frame is secured
to the power unit. Note location and number of shims
used. These shims must be installed in the same loca-
tion at assembly.
Remove six screws that mount the mast assembly to
the power unit. When installing these screws apply
thread locking adhesive (061004-019) and torque to
325 - 353 Nm (240 - 260 ft lb).
Lift and remove mast assembly from truck.
Mast Assembly
Reverse the above procedures for installing the mast
on the truck.
Crown 2007 PF15797-11 SP 3500 M7.0-7335-011
349
Notes:
350
LIFTING MECHANISM
Lift Chains
Lift Chains
Lift chains are highly important components on fork lift
trucks. The chain system on your mast was designed
for efficient, reliable transmission of lifting force from
hydraulic cylinder(s) to the mast, platform (if present)
and forks. Safe, uninterrupted use of your lift truck de-
pends on the proper care and maintenance of the lift
chains.
Most complaints of unsatisfactory chain performance
can be traced directly to inadequate maintenance.
Highly stressed precision chains require periodic main- Roller and Leaf
tenance to deliver maximum service life. Chain Wear Scale
Inspection
After every 100 hours of truck operation, lift chains
should be inspected and lubricated. When used in an
extremely corrosive environment, inspect chains every
50 working hours. During inspection, check for the fol-
lowing:
Wear
As the chain flexes on and off pulleys, the joints gradu- Figure 16844
ally wear.
Chain wear can be measured by using a 106440 wear
The "stretch" a chain develops during usage is due to scale or a steel tape (Refer to Figure 16844). When
material being worn off of pin outside diameter and pin chains have elongated 3%, as represented on scale
hole inside diameter on the inside plates. "A" (19 mm [0.75 in] or 25 mm [1.0 in] pitch chain) or
scale "B" (16 mm [0.625 in] pitch chain) of the wear
scale, they should be discarded. On chain with 19 mm
(0.75 in) between pins, for example, 305 mm (12.0 in)
of chain contains 16 pitches or links. When 16 pitches
measure 314 mm (12.375 in) the chain should be re-
placed. On chain with 16 mm (0.625 in) between pins,
20 pitches or links equal 318 mm (12.5 in). When 20
pitches measure 327 mm (12.875 in) the chain should
be replaced. Crown currently uses 16 mm (0.625 in)
pitch (20 links in 318 mm [12.5 in]), 19 mm (0.75 in)
pitch (16 links in 305 mm [12.0 in]) and 25 mm (1.0 in)
pitch (12 links in 305 mm [12.0 in]) chain. When check-
ing chain wear, be sure to measure a segment of chain
that operates over a pulley. Do not repair chain(s) by
cutting out the worn section and splicing in a new
piece. If part of a chain is worn, replace lift chain(s). If
truck has a matched set of lift chains replace both
chains at same time.
Crown 1984 PF5856-1 Rev. 7/07 SP 3500 M7.5-18.0-001

08 Rev. 7/07
351
LIFTING MECHANISM
Lift Chains
Corroded Chain
(with Stress-Corrosion Cracks)
With Forks Lowered Figure 16846

Check Either Front Heavy motor oil serves both as a joint lubricant and
or Rear Pulley for corrosion inhibitor. During inspection, carefully exam-
Chain Wear ine external chain surfaces for the presence of an oily
film. Under certain operating or environmental condi-
tions it may be necessary to oil chains more frequently
than 100 hour intervals. In all cases, the external sur-
face of the chain must be protected with a film of oil.
Corroded chains should be inspected for cracked
plates. Outside plates are particularly susceptible to
stress corrosion cracking. If chains are heavily rusted
Figure 16845
or corroded they should be removed from the mast for
a thorough inspection for cracked plates. If plates are
Rust and Corrosion cracked, both chains on the truck must be replaced. Oil
Chains used on lift trucks are highly stressed precision chains when they are reinstalled on the mast.
components. It is very important that "as-manufac-
tured" ultimate strength and fatigue strength be main- Cracked Plates
tained throughout the chain service life.
The most common cause of plate cracking is fatigue
Corrosion will cause a major reduction in the load-car- failure. Fatigue is a phenomenon that affects most met-
rying capacity of lift chain or roller chain because cor- als and many plastics. After many repeated heavy
rosion causes side plate cracking. loads the plates may crack and the chains will eventu-
It is extremely important to protect lift chains from cor- ally break.
rosion, whether in service or in storage. The initial fac-
tory lubrication on chains is an excellent rust and cor-
rosion inhibitor. Factory lube is applied in a hot dip tank
to insure complete penetration into the joint. Do not
steam clean or degrease new chains. After the chain Fatigue Cracks
has been placed in service, factory lube must be sup-
plemented by a maintenance lubrication program.
Refer to applicable lubrication and adjustment section Figure 16847
for your particular truck series and/or the lubrication in-
formation later in this section. Fatigue cracks are almost always found through the pin
holes perpendicular to the pitch line. (Refer to Figure
16847) Contrast this failure mode to the random fail-
ures caused by stress-corrosion cracking. (Refer to
Figure 16846) If any fatigue cracks are discovered dur-
ing planned maintenance (PM) inspections, both lift
chains should be replaced. Many apparently sound
plates will be on the verge of cracking, making chain
failure very likely.
M7.5-18.0-002 SP 3500 Crown 1984 PF5856-2 Rev. 7/07
08 Rev. 7/07
352
LIFTING MECHANISM
Lift Chains
Tight Joints
All joints in lift chain should flex freely. Tight joints resist
flexure, increase internal friction, thus increasing chain
tension required to lift a given load. Increased tension
accelerates wear and fatigue problems. Refer to Figure
16848.
Tight Joints Protruding & Turned Pin
Tight joints in lift chains can be caused by: Chain Side Wear
1. Bent pins or plates,
A continuous wear pattern on pin heads and outside
2. Rusty joints, plates indicates misalignment. Misalignment can be
caused by two different factors: unequal chain tension
3. Peened plate edges.
or nonalignment between pulleys and chain anchors.
Oil rusty chains and replace chains that appear bent or
peened. Peening of plate edges may be caused by • Unequal Chain Tension - When a lift chain is in-
worn pulleys, unusually heavy loads, or chain sliding stalled or adjusted, care should be taken to "load"
past a guide or obstruction in the mast. the chains evenly. When changing fork heel height
or platform height for example, the chain anchors
should be loosened until both forks come in contact
Protruding or Turned Pins
with the floor. At this point both chains should dis-
Heavily loaded chains operating with little lube gener- play the same tension or slack. The chain anchor
ate tremendous friction between pin and plates (pin nuts should be tightened an equal number of revo-
and bushing in roller chain). In extreme cases, the fric- lutions on both chain anchors to put equal tension
tional torque in the joint can actually turn pins in the on chains. When the desired height setting is
press-fit outside plates. achieved the locking nut should be tightened to se-
cure setting.
If chain is allowed to operate in this condition, the pins
slowly work out of the chain, causing chain failure. • Non Alignment of Lifting Components - Non
Turned pins can be quickly spotted because the flats alignment of the pulley and chain due to incorrect
on the "V" heads are no longer in line. Refer to Figure shimming of the mast or bent or damaged mast or
16849, pin has turned 45 degrees. Chains with turned cylinder components can also contribute to chain
or protruding pins should be replaced immediately. side wear. A check for this condition is to place the
Never attempt to repair the chain by driving pins back truck on a level area in your maintenance area. Af-
into the chain. ter supporting the fork carriage, disconnect each
end of the lift chain at the chain anchor and visually
inspect its alignment with the anchor slots.
Crown 1984 PF5856-3 Rev. 7/07 SP 3500 M7.5-18.0-003

08 Rev. 7/07
353
LIFTING MECHANISM
Lift Chains
Lift Chain Lubrication tremely severe service, may require more frequent lu-
brication to maintain an oil film on all chain surfaces.
The most important consideration in field maintenance
In dusty operating conditions, lubed chains will gather
of lift chains is LUBRICATION. Hard working, heavily
dust. Even under these conditions wear life will be
loaded chains cannot be expected to give satisfactory
greatly improved by periodic lubrication. Joints may ac-
wear life without scheduled periodic lubrication. Like all
quire a "paste" made up of oil and dirt, but joint wear
bearing surfaces, the precision-manufactured, hard-
will still be much less than if the chain is allowed to run
ened-steel, joint-wearing surfaces require a film of oil
dry with metal-to-metal contact between pins and
between mating parts to prevent rapid wear.
plates.
Maintaining an oil film on all chain surfaces will:
At 100 hour intervals, clean chains to remove accumu-
• Minimize joint wear (chain stretch). lation of dirt-and lubricate immediately. (Do not steam
clean chains.)
• Prevent corrosion.
• Reduce the possibility of pin turning.
• Minimize tight joints in roller chain. Lubricant
• Promote smooth, quiet chain action.
• Lower chain tension by reducing internal friction in

the chain system.
Heavy motor oil is an excellent chain lubricant-even
used motor oil is adequate to lubricate exposed lift
chains.
Laboratory wear tests show SAE 40 oil to have greater
ability to prevent wear than SAE 10 oil. Also, SAE 40
oil is superior to hydraulic fluid or automatic transmis-
sion fluid. Generally, the heaviest (highest viscosity) oil Figure 16850
that will penetrate the joint works best.
Laboratory wear testing shows dry film lubes to be less Lift Chain Replacement
effective in preventing joint wear than fluid petroleum
The first step in chain replacement is to find the chain
based products.
part number in your service manual parts list.
Some aerosol spray lubes, such as Crown part number
An important factor in ordering replacement chain from
063001-009, are effective, more convenient and less
the truck manufacturer is that special chains may be
messy than applying motor oils.
specified for your truck with certified minimum ultimate
Whatever method is used, the oil must penetrate the strength.
chain joint to prevent wear. Applying oil to external sur-
If the unit is equipped with two strands, replace chains
faces will prevent rust, but oil must flow into the live
as a pair. It will be virtually impossible to maintain uni-
bearing surfaces for maximum wear life. (Refer to Fig-
form loading between the strands if a new chain is put
ure 16850).
into service opposite an old chain. The joints in the old
Apply oil to chains with a narrow paint brush. A plastic chain will have worn through the hardest layer of the
liquid detergent bottle makes a handy lube applicator. case-hardened pin. Therefore, the wear rate on the old
Flood the chain with oil over its entire length every chain will be greater than that on the new chain, greatly
lube-inspection period. complicating the problem of maintaining equal chain
tension.
Frequency of lubrication will vary with operating condi-
tions and environment. The best estimate of lube pe- The new chain will wear more slowly, causing it to bear
riod is 100 hours actual operating truck time. Trucks the major portion of the load, resulting in premature
parked outdoors, used in freezers or trucks in ex- wear and fatigue failure.
M7.5-18.0-004 SP 3500 Crown 1984 PF5856-4 Rev. 7/07
08 Rev. 7/07
354
LIFTING MECHANISM
Lift Chains
Never steam clean or degrease new chains. The man- 2. A support ring (flatwasher) with an inside diameter
ufacturer's grease is effective in reducing wear and cor- slightly greater than the pin diameter and a height
rosion. If the original factory lube is dried out or wiped equal to the head height of the pin.
off, soak the new chain in heavy engine oil for at least
3. Grinding wheel.
0.5 hour prior to installing on truck.
4. Pin punch with a diameter slightly less than the pin
After the existing chains have been removed from the
diameter, hammer or pressing equipment.
mast, very carefully inspect chain anchors and
sheaves. Broken, cracked, or worn anchors must be
replaced. Replace worn sheaves, and check sheave Disconnect Procedures:
bearings for wear. Do not paint the replacement chain (Refer to Figure 16851)
before or after it has been installed. Paint will help pre-
vent corrosion, but will prevent oil from reaching the pin 1. Grind the top head of the pin flush with the pin link
surface for good joint lubrication. plate. Be careful not to grind or damage the pin link
plate.
Install the new chains, using new anchor pins. Existing
pins may contain invisible fatigue cracks that could 2. Position the support ring over opening of the work
lead to pin failure. After chains have been connected to surface. The support ring serves to support the
the anchors, adjust chain tension to obtain proper fork bottom pin link plate and avoids damage to chain
or platform height. components while driving the pin through the
chain.
Correct chain installation and mast adjustment will in-
crease chain service life. 3. Stand the chain on its side and seat pin in the sup-
port ring.
Chain Anchors and Pulleys 4. Remove the pin from the chain through the top pin
link plate.
An inspection of the chain system should include a
close examination of chain anchors, anchor tension
devices and pulleys.
Check chain anchors for wear, breakage, and radial
misalignment. Anchors with worn or broken fingers
should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain.
When chain is misaligned, the load is not distributed
uniformly between the plates-prolonged operation will
result in premature fatigue failure.
Pulleys with badly worn flanges and outside diameter
should be replaced. Heavy flange wear indicates chain
misalignment. Investigate cause by checking chain
tension and mast shimming. (1) Support Ring
(2) Grind Pin Flush with Link Plate
Leaf Chain Disconnect (3) Grinding Wheel
To minimize the risk of damaging (cracking, etc.) the (4) Pin Link Plate
chain, refer to the following when disconnecting leaf (5) Work Surface Knock Out Aperture
chain.
Tools Required: Figure 16851
1. A sturdy work surface with an opening slightly

greater than the pin diameter, and should be thick
enough to allow the pin to extend beneath the work
surface as it is driven through the bottom pin link
plate.
Crown 1984 PF5856-5 Rev. 7/07 SP 3500 M7.5-18.0-005

08 Rev. 7/07
355
Notes:
356
LIFTING MECHANISM
Fork Inspection
Fork Inspection
Allowable Wear Thickness Chart 1
WARNING Standard Fork Allowable 10% Wear
Thickness Fork Thickness
The following causes of fork failure may mean loss of
equipment, damaged materials, bodily injury or loss of mm in mm in
life. Make an inspection and measurement of the forks 31.5 1.25 28.5 1.12
at each planned maintenance interval to check for
wear, overload, fatigue, bends, etc. Refer to “Lubrica- 38.0 1.50 35.0 1.38
tion and Adjustment” chapter. 44.5 1.75 39.5 1.56
51.0 2.00 46.0 1.81
WARNING 57.0 2.25 51.0 2.00
• Use the proper fork for how it was designed to be 63.5 2.50 57.0 2.25
used.
• Avoid using fork extensions.
• Do not modify forks.
If using the fork wear calipers, refer to the following:
• Only qualified personnel should make repairs.
• Visually inspect forks each work day. Refer to Figure 16854-01. The fork wear calipers have
two measuring points or jaws. The inside jaws (2) mea-
sure 10% less than the outside jaws (1).
Abrasion
Abrasion gradually reduces the thickness of the fork.
Be sure the fork thickness is within specifications. Do
not allow forks to rub the floor during normal operation.
If forks rub floor, check lift chain adjustment. Fork wear
at the heel must not exceed 10 percent of the original
thickness. At this point forks are adequate for approxi-
mately 80 percent of rated capacity. Refer to Chart 2.
Use fork wear calipers, part no. 107330, or a measur-
ing instrument such as a vernier or good 160 mm
(6.0 in) scale. For allowable fork wear thickness, refer
to Chart 1.
Figure 16854-01
1 Outside Jaws 100% (Fork Shank)

2 Inside Jaws 90% (Fork Blade)
Refer to Figure 16855-01. To set the outside jaws,

measure the thickness of the middle of the shank (this
point receives almost no wear). Set the calipers to the
“feel” of the shank by lightly tapping on them with a
metal object.
NOTE
Care should be taken when using the calipers to hold
them square across the shank or an incorrect reading
will result.
Crown 1988 PF7393-1 Rev. 11/08 SP 3500 M7.8-04.2-001

05 Rev. 11/08
357
LIFTING MECHANISM
Fork Inspection
Figure 16856-01
1 Fork Shank Cross Section
Figure 16855-01 Once the outside jaws are set, check to see if the inside
jaws of the calipers pass over the flanks of the fork
1 Fork Blade blade at any point between the end of the taper and the
2 Fork Shank heel of the fork blade. After checking the blade, re-
3 Measure Here to Set Outside Jaws check the caliper setting by measuring the shank again
making sure the setting was not inadvertently changed.
Figure 16857-01
1 Fork Blade Cross Section
M7.8-04.2-002 SP 3500 Crown 1988 PF7393-2 Rev. 11/08
05 Rev. 11/08
358
LIFTING MECHANISM
Fork Inspection
Figure 16858-01
1 Chart 2 - Wear vs. Capacity

2 Percentage Reduction in Fork Blade Thickness
3 Percentage Remaining of Specified Fork Capacity
Overloading
Know the capacity of the forks and truck. Fork capacity
and load center is stamped on the fork. Refer to Figure
16859-01. Overloading can cause permanent defor-
mation or serious fatigue conditions.
Figure 16859-01
1 Location of Capacity and Load Center Rating
Crown 1988 PF7393-3 Rev. 11/08 SP 3500 M7.8-04.2-003

05 Rev. 11/08
359
LIFTING MECHANISM
Fork Inspection
Fatigue
A fatigue crack will normally start in the heel area of the
fork. Cracks can usually be detected in the early stages
by inspection of the heel area. Check for cracks that
transverse the fork in an area up to 130 mm (5.0 in)
either side of the outer heel radius. These cracks are a
sign that the area has weakened and the fork needs to
be replaced. Make a visual inspection for cracks each
work day. If a more accurate inspection is necessary,
use dye penetrants or magnaflux fork.
Figure 16861-01
1 93° Maximum
Use a carpenter’s square to check the fork. Refer to

Figure 16862-01. Hold the square against the shank
staying above the radius of the heel as shown. Mea-
sure the distance closest to the radius of the heel of the
fork blade and square (2). Add 31.8 mm (1.25 in) to this
measurement and record. If the distance between the
end of the square and blade (3) is greater than this cal-
culation, replace blade (fork is deformed more than
93°).
Figure 16860-01
1 130 mm (5.0 in)

2 130 mm (5.0 in)
Bent or Twisted Forks

Overloading, glancing blows against solid objects or
picking up loads unevenly can bend or twist a fork,
making fork replacement necessary. The maximum al-
lowable difference in fork tip elevation from one fork to
another is 3% of the fork length. Figure 16862-01
The angle between the top of the fork (blade) to the 1 609 mm (2.0 ft)
back surface of the vertical leg (shank) shall be less
2 “x”
than 93°. Any angle greater will require fork repair or
replacement. The fork manufacturer or service techni- 3 “x” + 31.8 mm (1.25 in)
cian with the expertise of equal competence are the
only parties that should attempt to make such repairs.
M7.8-04.2-004 SP 3500 Crown 1988 PF7393-4 Rev. 11/08
05 Rev. 11/08
360
LIFTING MECHANISM
Fork Inspection
Hanger
Check for cracks or damage to the fork pins and the
area of fork attachment. Check carriage for excessive
wear or cracks. Repair or replace parts if necessary.
Check condition of fork locking pin, spring, cam, etc. for
proper operation (if forks are so equipped).
Figure 16863
1 Check Locking Pin, Spring, etc.

2 Check for Cracks Under Hanger
Crown 1988 PF7393-5 Rev. 11/08 SP 3500 M7.8-04.2-005

05 Rev. 11/08
361
Notes:
362
LIFTING MECHANISM
Fork
Fork Blade Measurement

Fork wear calipers have two measuring points or jaws.
The inside jaws measure 10 percent less than the out-
Fork Inspection side jaws. Refer to Figure 9237-01
equipment, damaged materials, bodily injury or loss of
life. At each planned maintenance interval an inspec-
tion and measurement of the forks must be made to
check for wear, overload, fatigue, bends, etc. Outside Jaws Inside Jaws
100% 90%
WARNING
Use the proper fork for how it was designed to be used.
Avoid using fork extensions. Figure 9237-01
Do not modify forks. Only qualified personnel should
To set the outside jaws, use a measuring instrument
make such repairs.
such as a vernier or machinist 152 mm (6.0 in) scale
Inspect forks visually each work day.
and set outside jaws at 51 mm (2.0 in). Refer to Figure
9238-01.
Abrasion
Abrasion gradually reduces the thickness of the fork. them square across the shank or an incorrect reading
Be sure fork thickness is up to standard. Do not allow will result.
forks to rub the floor during normal operation (if forks
do rub floor, check lift chain adjustment). Fork wear at
the heel must not exceed 10 percent of the original
mately 80 percent of rated capacity (refer to Chart 2).
Crown has a fork wear calipers (part no.107330) avail- Set at 51 mm (2.0 in)
able for use or a measuring instrument such as a ver-
nier or machinist 152 mm (6.0 in) scale may be used.
For allowable fork wear thickness refer to Chart 1.
Figure 9238-01
Chart 1 Fork Thickness Once the outside jaws are set, check to see if the inside
jaws of the calipers pass over the fork flanks between
Standard Fork Allowable 10% Wear the two ends of taper or between the end of taper and
Thickness Fork Thickness end of fork depending on how your fork was manufac-
tured (check thickest part of fork). If the inside jaws
mm in mm in pass over the fork flanks, replace fork. Refer to Figures
32.0 1.25 28.5 1.12 9239-01 and 9240-01.
38.0 1.50 35.0 1.38

44.5 1.75 40.0 1.56
51.0 2.00 46.0 1.81
57.0 2.25 51.0 2.00
63.5 2.50 57.0 2.25
If using the fork wear calipers refer to the following:
Crown 1988 PF7392-1 Rev. 8/06 SP 3500 M7.8-07.2-001

01 Rev. 8/06
363
LIFTING MECHANISM
Fork
calipers square across the bore or an incorrect reading

will result.
Check Fork Rotate

Wear Here Calipers 180°
Mounting
Support
Check Fork
Wear Here
Figure 9239-01
Figure 9242-01
After the jaws are set, remove caliper and using a mea-
suring instrument such as a verniers or machinist
152 mm (6.0 in) scale, measure across the outside
jaws. The maximum allowable measurement for the
Fork mounting support bore is 43.7 mm (1.72 in) and
Cross Section 42.7 mm (1.68 in) for the platform bore.
Figure 9240-01
Mounting Support And Platform Bore Mea-

surement
To check for elongation (wear) of the mounting support
and platform bore, the outside jaws of the fork wear cal-
ipers are used by rotating the legs of the calipers so
that the jaws are on the outside.
Use Outside Jaws

for Bore Measurement
Figure 9241-01
Check the mounting support and platform bore by plac-

ing the outside jaws into the bore and locate the largest
diameter of the bore by rotating the calipers 180 de-
grees. Set the jaws to the feel of the bore by lightly tap-
ping on them with a metal object. Be careful to hold the
M7.8-07.2-002 SP 3500 Crown 1988 PF7392-2 Rev. 8/06
01 Rev. 8/06
364
LIFTING MECHANISM
Fork
Wear vs. Capacity

Percentage Reduction in Fork Thickness
Percentage Remaining of Specified Fork Capacity
Figure 9243-01
Overloading Fatigue
Know the capacity of the forks and truck. Fork capacity The entire fork should be visually inspected for fatigue
and load center is stamped on the fork (refer to Figure cracks each work day. Normally, a fatigue crack will
9244-01). Overloading can cause permanent deforma- start in an area about the mounting support of the fork.
tion or serious fatigue conditions. Pay particular attention for cracks that transverse the
fork in an area up to 130 mm (5.0 in) either side of the
mounting support. Fatigue cracks are a sign that an
area of the fork has weakened and the fork needs to be
replaced. If a more accurate inspection is necessary,
dye penetrants can be used or magnaflux fork. Refer to
Figure 9245-01
Location of
Capacity and
Load Center
Rating
Figure 9244-01
Figure 9245-01
Crown 1988 PF7392-3 Rev. 8/06 SP 3500 M7.8-07.2-003

01 Rev. 8/06
365
LIFTING MECHANISM
Fork

another is 3% of the fork length. Cord
The maximum deformation from fork straightness shall String
be less than 183 degrees. Any angle greater will re-
quire fork repair or replacement. The fork manufacturer
or technicians with the expertise of equal competence
Cord String
are the only parties that should attempt to make such
repairs. Refer to Figure 9246-01.
Figure 9247-01
Hanger
183 Degrees Check for cracks or damage in the area of fork attach-
Max. ment. Check platform and fork rod for excessive wear
or cracks. Repair or replace parts if necessary.
Figure 9246-01 Bottom View

of Platform
To check the fork for straightness, a cord string, car-
penters chalk line or a straight edge 1220 mm (48.0 in)
or longer can be used. For an example of checking fork
straightness, a cord string will be used here (refer to
Figure 9247-01).
Figure 9248-01
CAUTION
When performing any type of inspection, adjustment,
maintenance, etc. beneath the platform, blocks should
be positioned under each side of the platform. Refer to
Control Of Hazardous Energy Lockout/Tagout and
chapter M9.0 for lifting and blocking procedures.
Measure 610 mm (24.0 in) from both sides of the cen-
ter of the mounting support and mark edge of fork. Hold
cord string taunt between these two points being sure
the string at both points is even with the top of fork.
Measure the maximum perpendicular distance from
the cord string to top of fork. If this measurement is
greater than 32 mm (1.25 in), the fork is deformed
more than 183 degrees and should be replaced. Refer
to Figure 9247-01.
M7.8-07.2-004 SP 3500 Crown 1988 PF7392-4 Rev. 8/06
01 Rev. 8/06
366
CYLINDERS
367
Notes:
368
CYLINDERS
Mast and Free Lift Cylinders

The mast and free lift cylinders (shown in Figure
17013) are single acting ram type cylinders. When lift
is selected, pressurized oil enters the bottom of the cyl-
inders forcing the ram to extend. When lowering, the
weight of the mast assembly, platform and load forces
the oil out to retract the cylinders.
(a) Mast Cylinders

(b) Free Lift Cylinder
(TT Only)
Figure 17013-01
Located in the bottom of the mast and free lift cylinders

(refer to Figure 18211) are velocity fuses. These de-
vices monitor oil flow. Should a break occur in a hy- (a) O-Ring (1) Wiper Ring
draulic line, excess oil flow from the cylinder will force
(b) Retaining Ring (2) Cap
the velocity fuse piston down blocking oil flow, thereby
locking the ram in place. (c) Poppet (3) Packing Rod
(d) Spring (4) Collar
(e) Cylinder (5) Piston
(f) Bleed Screw (6) Bushing
(g) Seal (7) Screw
Ram (8) Velocity Fuse Cartridge
Figure 18211
Crown 1994 PF10326-1 Rev. 11/07 SP 3500 M8.0-7330-001

03 Rev. 11/07
369
CYLINDERS
Inspection Disassembly
Great care and cleanliness should be exercised in the
WARNING disassembly and assembly of any hydraulic cylinder.
Wipe all surfaces clean of dirt and oil before attempting
AVOID HIGH PRESSURE FLUIDS-Escaping fluids un- disassembly.
jury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pres- CAUTION
When cleaning piston, be sure to clean seal seating ar-
eas. Protect eyes and face when using compressed
air.
hand.
Any fluid injected into the skin under high pressure Care should be taken when removing the ram from the
should be considered as a serious medical emergency cylinder tube to prevent damage. After cylinder compo-
despite an initial normal appearance of the skin. There nents are disassembled and seals, o-rings and wipers
is a delayed onset of pain, and serious tissue damage are removed, thoroughly wash all metallic parts in sol-
may occur. Medical attention should be sought imme- vent and blow dry with low air pressure. As the cylinder
diately by a specialist who has had experience with this is repaired, be aware of component part condition. Re-
type of injury. place a worn or damaged part. In addition, correct or
replace a part that may be causing other premature
Before disconnecting the battery and initial cylinder re-
wear. If slight scoring of the tube and/or ram is evident,
pair, a careful inspection should be made of the cylin-
sand with aluminum oxide cloth or honing tool until high
der assembly throughout a complete lift and lower se-
areas are removed. Heavily scored components must
quence. Check yoke area for signs of abnormal wear,
be replaced. After all parts are inspected, wash all cyl-
damage, etc. Check rams for any signs of nicks,
inder components in a good grade solvent and dry with
scratches, surface imperfections, etc. that allow abnor-
low pressure air. Place washed components in a clean
mal leakage; improper cylinder operation can create
container until reassembly.
seal damage. Check wiper rings and cap area for com-
ponent wear and/or leakage that is abnormal.
When an excessive amount of hydraulic oil is evident
on the top of the cylinder where the ram exits from the
cap, the rod packing is probably bad and should be re-
placed. Replacement of the packing can be accom-
plished without removing the ram from the cylinder
tube or truck. Refer to Accessing Rod Packing and Rod
Packing Replacement located in this section.
M8.0-7330-002 SP 3500 Crown 1994 PF10326-2 Rev. 11/07
03 Rev. 11/07
370
CYLINDERS
Accessing Mast Cylinder Rod Pack- Accessing Free Lift Cylinder Rod
ing Packing
1. Disconnect battery and chock load wheels. 1. Using a lifting device, raise platform approximately
76 mm (3.0 in), disconnect battery and chock load
2. Remove screw, nut and lockwasher located at the
wheels.
top of the mast cylinder ram. Refer to Figure
13834-01. 2. Securely block both sides of the platform. Refer to
Platform for lifting and blocking procedures.
3. Disconnect chains secured to free lift cylinder.
4. Remove screw securing yoke to cylinder. Remove
yoke from cylinder ram and set aside.
CAUTION
Be careful not to "kink" control cables or hydraulic
hoses during removal and installation.
Screw, Nut
& Lockwasher
Figure 13834-01
3. Attach a lifting device to the top cross brace of the

2nd stage mast and raise high enough to have ac-
cess to the cylinder cap. Securely block the mast.
Refer to Control Of Hazardous Energy Lockout/Ta-
gout and Lifting Mechanism for lifting and blocking
procedures.
Crown 1994 PF10326-3 Rev. 11/07 SP 3500 M8.0-7330-003

03 Rev. 11/07
371
CYLINDERS
Rod Packing Replacement

1. Remove bleeder screw. Refer to Figure 18213.
2. Remove cylinder cap from the cylinder. Refer to
Figure 18213.
(a) Number 8 Metal Screw (Headless)

4 mm Self-Tapping
(b) Screwdriver
152 mm (6.0 in) Shaft Length (Minimum)
(a) Cylinder Tube 4 mm (0.156 in) Shaft Diameter (Maximum)
(b) Cap (c) Tape
(c) Seal (d) Weld (Grind Off Excess) to a Maximum
(d) Bleed Screw Diameter of 4 mm (0.156 in)
3. The rod packing can now be removed. To facilitate 4. Insert tools between ram and the cylinder walls,
packing removal, a pair of special tools can be 180 degrees apart, and screw into the face of the
made. Refer to Figure 18213. To make these tools, packing to be removed. Refer to Figure 18215. Af-
weld or braze a headless 4.0 mm (No. 8) metal ter the threads are sufficiently secured into the
self-tapping screw to the end of a screwdriver. The packing, pull gently on the screwdriver handles un-
screwdriver must have at least a 152 mm (6.0 in) til the packing is removed.
shank length with no larger than a 4.0 mm (0.15 in)
shank diameter. After attaching the screw to the
screwdriver, grind off excess weld to a diameter of
4.0 mm (0.15 in). Wrap the shank with electrical
tape from tip of the screw to the screwdriver han-
dle. This will prevent scratching of the cylinder tube
or ram.
(a) Cylinder Tube

(b) Seal Pulling Tool
(c) Ram
(d) Seal
Figure 18215
M8.0-7330-004 SP 3500 Crown 1994 PF10326-4 Rev. 11/07
03 Rev. 11/07
372
CYLINDERS
NOTE
Extreme care should be taken to prevent damage to
cylinder wall and ram assembly.
5. Remove the wiper ring from the cylinder cap since
the packing rod and wiper ring should always be
replaced at the same time. Thoroughly clean
where the seals seat. Any burrs, dirt or seal debris
must be removed before installing replacement
seals.
CAUTION
Close inspection of seal seating critical areas should
be made before replacement seal is installed. Your
seal failure may not have been caused by a worn seal,
but rather by burrs, nicks and dirt located on the seal (a) Cylinder Tube
seating area, causing the seal to deform and loose its (b) Sleeve
sealing ability. (c) Forging Tool
6. Lightly apply clean hydraulic oil to replacement (d) Seal

seals and seal contact areas of cylinder and instal- (e) Critical Seal Seating Area
lation tools. Install rod packing in cylinder "lip" first. (f) Collar
A sleeve should be used to protect the seal from
damage on threads and shoulders, refer to Figure Figure 18216
18216. Tools used to install hydraulic seals should
be of soft metal or suitable plastic, free of burrs and 7. Install wiper ring and assemble cap to cylinder.
sharp edges. Screwdrivers and other similar tools 8. Inspect bleed screw seal and replace if needed.
should not be used. Crown has sleeves (Poly-Pak Apply hydraulic sealant (061004-023) to bleed
Seal Tools) available for installing replacement screw threads and install seal and screw.
seals. Refer to Cylinders for correct Poly-Pak seal
tool. 9. Install yoke and connect lift chains.
10. Cycle cylinder(s) to check operation and leakage.
11. Bleed air from cylinder before placing truck back
into service.
Crown 1994 PF10326-5 Rev. 11/07 SP 3500 M8.0-7330-005

03 Rev. 11/07
373
CYLINDERS
Mast Cylinder Removal 3. Attach a lifting device to the top cross brace of the
2nd stage mast and raise mast approximately
1. Disconnect battery and chock load wheels. 1524 mm (60.0 in). Securely block mast. Refer to
2. Remove screw, nut and lockwasher located at top
Lifting Mechanism for lifting and blocking proce-
of the mast cylinder ram. Refer to Figure 13834-01.
dures.
4. Disconnect hydraulic hoses and cylinder screws at
bottom of cylinder, refer to Figure 18217. Be pre-
pared to catch hydraulic oil.
Screw, Nut
& Lockwasher
Figure 13834-01
(a) Part of Mainframe
(b) Remove Hoses and Fittings
WARNING
(c) Remove Screws
glasses, steel-toe shoes, etc. whenever performing Figure 18217
maintenance work. To avoid injury, Do Not place fin-
gers, hands, arms or feet through mast or position 5. Attach a lifting device to cylinder to secure cylinder.
them at pinch points. Remove hose guides.
Make sure lifting device is sufficiently rated to lift vari- 6. Remove cylinder from truck.
ous parts of the mast sections either individually or as
a group. Make sure that the blocking material is strong 7. Reverse the above procedures for reinstalling cyl-
enough to withstand the weight. Never work under or inder on truck.
around a truck that is not securely blocked. Refer to
Control Of Hazardous Energy Lockout/Tagout chapter
for lifting and blocking procedures.
M8.0-7330-006 SP 3500 Crown 1994 PF10326-6 Rev. 11/07
03 Rev. 11/07
374
CYLINDERS
Free Lift Cylinder Removal

1. Using a lifting device, raise platform approximately
76 mm (3.0 in). Disconnect battery and chock load
wheels.
2. Securely block both sides of the platform. Refer to
3. Disconnect chains secured to free lift cylinder. Re-
CAUTION
5. Attach a lifting device to cylinder to secure cylinder
and disconnect hydraulic hoses at bottom of cylin-
der.
6. Remove nuts and clamp securing cylinder to 3rd
stage mast. Refer to Figure 18218.
7. Remove cylinder.
(a) Yoke Mounting Screw

(b) Cylinder Mounting Screws
(c) Cylinder Mounting Screw
Figure 18218
Crown 1994 PF10326-7 Rev. 11/07 SP 3500 M8.0-7330-007

03 Rev. 11/07
375
CYLINDERS
Mast And Free Lift Cylinder Assem-

bly
Before assembling cylinder, coat all seals, ram, tube,
etc. with clean hydraulic oil. When installing ram into
cylinder tube, never allow ram to come in contact with
any sharp edges. Extreme care must be taken not to
damage seals or the surfaces they operate on. Apply
thread locking adhesive (061004-026) to velocity fuse
cap screws.
Mast And Free Lift Cylinder Installa-

tion
To install cylinder, reverse removal procedures. Apply
thread locking adhesive (061004-019) to lower cylinder
mounting screws.
After the cylinder is installed on the truck, but before the
truck is put back into operation, air must be bled from
the hydraulic system. Without a load on the forks, raise
platform approximately 150 - 305 mm (6.0 - 12.0 in) to
pressurize the cylinder. Loosen bleeder screw, located
at the top of the cylinder until all air escapes and only a
solid stream of oil continues to flow from the screw.
Tighten the screw and completely lower mast and plat-
form to relieve all pressure in cylinder. Loosen bleed
screw 2-3 revolutions. Remove oil from threads with
degreaser and dry with low pressure air. Apply hydrau-
lic sealant (061004-023) to threads and tighten screw.
Verify hydraulic oil level in reservoir and add as
needed.
M8.0-7330-008 SP 3500 Crown 1994 PF10326-8 Rev. 11/07
03 Rev. 11/07
376
PLATFORM
377
Notes:
378
PLATFORM
Platform Height Sensor
Platform Height Sensor Height Sensor Encoder Replace-

ment (ECR4)
WARNING Block truck wheels.
Wear appropriate items, such as safety glasses and Raise platform high enough to expose height sensor
steel-toe shoes whenever performing maintenance assembly (ECR4) mounted on bottom of the platform to
work. Do not place fingers, hands or arms through allow removal. Refer to Figure 17711.
mast or position them at pinch points. Disconnect battery and securely block platform. Refer
In this section you may be required to lift and block the to Control of Hazardous Energy Lockout/Tagout and
truck and mast or raise and lower different components Platform for proper procedures to securely block the
for removal and installation. Make sure lifting device platform. Refer to Figure 17711.
being lifted. Never work under or around a truck that is Disconnect height sensor (ECR4) wires from PC317 on
not properly secured. Refer to truck Data Plate for truck bottom of platform.
weight information.
mast, disconnect electrical connections and hydraulic
lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
with some additional information on other procedures
WARNING
Make sure blocking material is strong enough to with-
stand the weight. Never work under or around a truck
that is not properly blocked. Truck must be in an area
with enough clearance to safely raise the platform. Re-
fer to Control of Hazardous Energy Lockout/Tagout
and Platform for proper procedures to securely block
the platform.
(a) Raise Platform to Allow Access to Height Sensor (ECR4)

(b) Block Platform per Control of Hazardous Energy
Figure 17711
Crown 2007 PF15822-1 SP 3500 M9.0-7335-050
379
PLATFORM
Disconnect height encoder cable from bottom of main Hold the cable and allow it to slowly rewind onto the
frame. DO NOT release the cable to be quickly re- cable reel until the sleeve makes contact with the outer
tracted into height sensor as the cable could cross housing. Refer to Figure 17713-01.
thread and cause binding of height sensor. Refer to
Remove mounting screws that secure height encoder
Figure 17712.
(ECR4) assembly to platform.
Move height sensor assembly to work bench and place
face down on bench to allow access to ECR4's mount-
ing screws.
Disconnect Height Sensor

(a) Make Sure Cable Does Not Cross Thread
Cable from Mainframe
on Cable Reel
(b) ECR4 Mounting Screw
Figure 17712
(c) Install 3/8 - 16 bolt, 31.75 mm (1.25 in)
Long to Lock Cable Reel
(d) Remove Bearing Block Mounting Screw
(e) Cable Sleeve in Contact with Outer Housing
Figure 17713-01
Install a 3/8-16 bolt, 31.75 mm (1.25 in) long into exist-

ing hole in housing to lock the cable reel. Refer to Fig-
ure 17713-01.
Remove screw that mounts ECR4 to bearing block
shaft. Refer to Figure 17713-01.
Remove two mounting screws that secures ECR4
bearing block to housing. Refer to Figure 17713-01.
M9.0-7335-051 SP 3500 Crown 2007 PF15822-2
380
PLATFORM
Remove ECR4 bearing block by using the two screws Tighten ECR4 mounting screw and make sure it is
in opposite holes on the bearing block. Refer to Figure properly seated in the bearing block.
17714-01.
After ECR4 and bearing block are securely mounted on
outer housing, remove reel stop bolt.
Use Bearing Block Mounting Mount height encoder assembly on platform using ex-
Screws to Remove Encoder isting screws.
from Bearing Block
Connect cable from height encoder to bottom of mast.
Verify cable on the reel did not get cross threaded.
Reconnect height sensor harness PC317 to truck.
Remove platform blocking material.
Connect battery and lower platform.
Verify height sensor (ECR4) is functional.
WARNING
Figure 17714-01 work. Do not place fingers, hands or arms through
Remove ECR4 from bearing block. mast or position them at pinch points.
Install replacement ECR4 in bearing block with wire truck and mast or raise and lower different components
harness pointing up towards top of height encoder as- for removal and installation. Make sure lifting device
sembly. and sling are sufficiently rated to withstand the weight
NOTE not properly secured. Refer to truck Data Plate for truck
weight information.
Make sure replacement ECR4 is evenly pressed into
the bearing block.
Mount bearing block and ECR4 on housing using exist- mast, disconnect electrical connections and hydraulic
ing screws. lines. "Control of Hazardous Energy" section provides
NOTE with some additional information on other procedures
When tightening mounting screw for ECR4 the cable read and reviewed prior to mast removal, installation
reel will start to unwind. Make sure bolt has been in- and maintenance as outlined in this section.
stalled into housing prior to tightening the mounting
screw. Truck must be in area with enough clearance to safely
raise the platform. Refer to Control of Hazardous En-
ergy Lockout/Tagout and Platform for proper proce-
dures to securely block the platform.
Disconnect height sensor (ECR4) wires from PC317 on
bottom of platform.
Block truck wheels.
Crown 2007 PF15822-3 SP 3500 M9.0-7335-052
381
PLATFORM
Raise platform high enough to expose height sensor

assembly (ECR4) mounted on bottom of the platform to WARNING
allow removal. Refer to Figure 17711.
Make sure blocking material used is strong enough to
withstand the weight of the platform. Never work under
or around a truck that is not properly blocked.
Disconnect battery and securely block platform. Refer
to Control of Hazardous Energy Lockout/Tagout and
Platform for proper procedures to securely block the
platform.
Disconnect height encoder cable from bottom of main
frame. DO NOT release the cable to be quickly re-
tracted into height sensor as the cable could cross over
and cause binding of height sensor. Refer to Figure
17712.

Figure 17711

Figure 17712
M9.0-7335-053 SP 3500 Crown 2007 PF15822-4
382
PLATFORM
Hold the cable and allow it to slowly rewind onto the Remove ECR4 bearing block by using the two screws
cable reel until the sleeve makes contact with the outer in opposite holes on the bearing block. Refer to Figure
housing. Refer to Figure 17718-01. 17719-01.
assembly to platform.
ing screws.
(a) Remove Height Sensor Mounting

Bracket Screws
(b) Height Sensor Mounting Bracket
(c) Use Bearing Block Screws to Remove
Bearing Block from Housing
Figure 17719-01
Remove mounting bracket from height sensor.

Turn height sensor over to expose front cover.

on Cable Reel
(c) Remove Bearing Block Mounting Screws
(d) Cable Sleeve in Contact with Outer Housing
Figure 17718-01
Crown 2007 PF15822-5 SP 3500 M9.0-7335-054
383
PLATFORM
CAUTION WARNING
When last screw is removed in the following step, DO NOT remove spring mounted inside of cable reel.
spring tension will be released through cover rotation. Spring is reverse wound and if not kept restrained, will
unwind completely in the opposite direction. Secure
Remove screws, cover and spacer. Refer to figures
spring in cable reel to prevent spring from coming out
17720 and 17721.
of reel. Cable can be rewound on reel with spring in-
stalled inside of reel. Personal injury is possible if ex-
treme caution is not exercised when working in this
area of the height sensor.
Turn height sensor so cable reel is face down on a flat
surface.
Unwind cable from reel and leave cable lay flat so it
does not twist or kink.
Place thumbs on shaft and remove outer housing from
Remove Cover Screws cable reel.
Remove bearing from outer housing.
Figure 17720
Install replacement bearing into outer case. Make sure
bearing is evenly pressed into the outer housing.
Inspect cable reel and cable.
Replace as needed.
(a) Cover
(b) Spacer
(c) Reel
(d) Spring
(e) ARbor
Figure 17721
M9.0-7335-055 SP 3500 Crown 2007 PF15822-6
384
PLATFORM
Cable Replacement NOTE

To replace cable you will need cable 094422-002 15 m It is easier to wind cable onto reel with cable reel in
(50 ft), two sleeves 107208, swagging tool 107416 and outer housing.
chain and steel cable lubricant, 063001-009.
Make sure cable is evenly wound on reel and cable is
not cross threaded on reel. Refer to Figure 17722.
WARNING
DO NOT remove spring mounted inside of cable reel.
Spring is reverse wound and if not kept restrained, will
Remove existing cable from reel by cutting cable where
sleeve attaches cable to reel.
Install one end of replacement cable in hole on cable
reel. Refer to Figure 17722.
Attach sleeve (107208) and crimp using swagging tool
(107416). Refer to Figure 17722. (a) Wrap Clockwise
Install cable reel into outer housing. (b) Sleeve

(c) Cable (094422-002)
Install bearing block on outer housing. Make sure wires
(d) Cable Should be in Reel Grooves
are pointing up.
and Not Cross Threaded
Place height sensor in a vise.
Turn cable reel and feed cable onto reel. Refer to Fig- Figure 17722
ure 17722. Leave last groove on outside of reel empty.
Secure cable and install outer housing over cable reel.
Lubricate cable and cable reel with 063001-009.
Crown 2007 PF15822-7 SP 3500 M9.0-7335-056
385
PLATFORM
Clean and install spacer over cable reel. Refer to Fig- NOTE
ure 17723.
Sleeve needs to be placed so it does not go into height
Lubricate spacer with 063001-009. sensor during operation.
Mark one of the mounting holes on height sensor as a Connect cable from height encoder to bottom of mast.
reference point. Refer to Figure 17723.
Verify cable on reel did not get cross threaded.
Clean, lubricate (063001-009) and install cover.
Rotate cover nine complete turns clockwise to preload
spring. Using mark placed on the cover as a starting Remove platform blocking material.
point. Refer to Figure 17723. Connect battery and lower platform.
After spring has been pre-loaded, secure cover with Verify height sensor (ECR4) is functional.
existing screws. Refer to Figure 17723.
(a) Part of Mast

(b) Sleeve Should be 75 mm (3.0 in) Above Bracket
(c) 75 mm (3.0 in)
(a) Place Mark on Cover, Using Mark as Starting Point,

Rotate Cover Six Times Clockwise to Pre-load Spring Figure 17724
(b) Install Spacer
(c) Install Cover
(d) Use Existing Screws to Secure Cover
Figure 17723
Install mounting bracket onto height sensor using exist-

ing bracket and mounting hardware.
Mount height encoder assembly on platform using ex-
isting screws.
Crimp remaining sleeve (107208) approximately
75 mm (3.0 in) above bracket that secures cable to
main frame. Refer to Figure 17724.
M9.0-7335-057 SP 3500 Crown 2007 PF15822-8
386
GLOSSARY
387
Notes:
388
GLOSSARY
Glossary
Glossary on the truck such as on platform or in power unit. The

Function column then explains the function or circuit of
Components have been listed in chart form to assist that device. The Diagram column gives the page num-
the service technician in locating these components on ber of the diagram on which the component can be
the Electrical Diagrams and Parts Breakdown forms. found. The callout in parenthesis following the page
number corresponds to the grid callouts on that dia-
The chart is in columns: Component; Location; Func-
gram, locating that component. The Parts Breakdown
tion; Diagram; Parts Breakdown. The Component
column includes the parts breakdown page number on
column contains the abbreviation of the component as
which the component is located along with the index
it appears on the Diagrams in the Maintenance Sec-
number, in parenthesis, if applicable.
tion. The Location column gives the general location
BATTERY
Location Function Diagram Parts Breakdown
Battery Power Unit Battery Power Supply DIA-7535-002
Compartment DIA-7535-004
CONNECTIONS
CA101 Distribution Panel - Module Power B+ DIA-7535-006 04.3-7335-050
Platform DIA-7535-007
DIA-7535-008
CA102 Distribution Panel - Overhead Guard Light/Fan DIA-7535-006 04.3-7335-050
Platform Assemblies DIA-7535-007
DIA-7535-008
CA103 Distribution Panel - Module Power & Controls DIA-7535-006 04.3-7335-050
DIA-7535-008
CA104 Distribution Panel - Mast Cable 2 DIA-7535-006 04.3-7335-050
DIA-7535-008
CA105 Distribution Panel - CAN DIA-7535-006 04.3-7335-050
DIA-7535-008
CA106 Distribution Panel - Mast Cable 1 DIA-7535-006 04.3-7335-050
DIA-7535-008
CA107 Distribution Panel - Module & Control Power B- DIA-7535-006 04.3-7335-050
DIA-7535-008
CA201 Distribution Panel - Controls Power B+ & MMS DIA-7535-009 04.3-7335-001
Power Unit DIA-7535-010
CA202 Distribution Panel - Lift Power Panel & Brake DIA-7535-009 04.3-7335-001
Power Unit Power DIA-7535-010
CA203 Distribution Panel - Mast Cable #2 DIA-7535-009 04.3-7335-001
CA204 Distribution Panel - CAN Communication DIA-7535-009 04.3-7335-001
Crown 2008 PF17170-1 SP 3500 M10-7335-001
389
GLOSSARY
Glossary
CONNECTIONS (Continued)
CA205 Distribution Panel - Mast Cable #1 DIA-7535-009 04.3-7335-001
CA206 Distribution Panel - Battery Voltage B+ DIA-7535-009 04.3-7335-001
CA301 Platform CAN Access, DIA-7535-003
Programming, InfoLink DIA-7535-005
DIA-7535-011
DIA-7535-012
DIA-7535-013
CA302 Platform I/O DIA-7535-011
DIA-7535-012
DIA-7535-013
CA303 Vehicle Control Module Power & I/O DIA-7535-011 09.0-7535-001 (24)
(VCM) DIA-7535-012
DIA-7535-013
CA304 Vehicle Control Module Power & I/O DIA-7535-011 09.0-7535-001 (24)
(VCM) DIA-7535-012
DIA-7535-013
CA305 Platform Key Switch (KYS) DIA-7535-014 04.6-7335-001 (22)
DIA-7535-015
CA308 Platform Switches - Travel, Lift, DIA-7535-014 04.6-7534-050 (11);
Lower, Horn 04.6-7534-052 (68)
CA309 Platform Throttle & Switches - DIA-7535-014 04.6-7335-001
Guidance, Two Hand (EU), DIA-7535-015
Override
CA310 Platform Lights & Fan DIA-7535-016 04.8-7330-100
(18-21)
(18-21)
(18-21)
(18-21)
(18-21)
(18-21)
CA317 Platform Height Encoder DIA-7535-011 09.0-7535-200 (17)
DIA-7535-012
DIA-7535-013
M10.0-7535-002 SP 3500 Crown 2008 PF17170-2
390
GLOSSARY
Glossary
CA318 Platform Steer Sense DIA-7535-011 04.6-7335-003 (41)
DIA-7535-012
DIA-7535-013
CA322 Platform Gate Switches DIA-7535-014 09.0-7334-150 (4)
CA323 Platform Display Control Module DIA-7535-011 04.6-7335-003 (41)
(DCM) Steer Indicator DIA-7535-012
DIA-7535-013
CA324 Platform Switches - Travel, Lift, DIA-7535-014 04.6-7534-050 (11);
Lower, Horn 04.6-7534-052 (68)
CA325 Platform PVLF Driver DIA-7535-011
DIA-7535-013
CA326 Platform SV1 Driver DIA-7535-011
DIA-7535-013
CA327 Platform Lifting Forks Option DIA-7535-011
DIA-7535-013
CA328 Platform Lifting Forks Option DIA-7535-011
DIA-7535-013
CA329 Platform End of Mast PDS Platform Harness DIA-7535-024
Cable #4 DIA-7535-025
CA330 Platform Travel Alarm, Lifting Forks DIA-7535-011
B-
CA331 Platform EU Chain Break DIA-7535-011
DIA-7535-013
CA332 Platform Zone Select Switch DIA-7535-014 04.8-7330-100 (17)
DIA-7535-015
DIA-7535-015
DIA-7535-015
DIA-7535-015
CA401 Traction Control Module I/O DIA-7535-018 04.1-7335-001 (13)
(TCM) DIA-7535-019
CA402 Steering Control Module Communications DIA-7535-020 04.1-7335-001 (17)
DIA-7535-021
CA403 Steering Control Module I/O DIA-7535-020 04.1-7335-001 (17)
DIA-7535-021
CA406 Power Unit Current Sensor DIA-7535-020
DIA-7535-021
Crown 2008 PF17170-3 SP 3500 M10.0-8055-003
391
GLOSSARY
Glossary
CA407 Power Unit Brake DIA-7535-002 05.3-7335-001
DIA-7535-004
DIA-7535-020
DIA-7535-021
CA408 Power Unit Connector from Feedback DIA-7535-024
Splitter Block to PDS Mod- DIA-7535-025
ule
CA409 Power Unit Connector from Traction DIA-7535-024
Motor Encoder to Feed- DIA-7535-025
back Splitter Block
CA410 Power Unit Steering Feedback DIA-7535-020 04.8-7335-200 (3)
DIA-7535-021
CA411 Power Unit Traction Feedback Encoder DIA-7535-020 03.1-7335-001 (16)
DIA-7535-021
DIA-7535-024
DIA-7535-025
CA414 Power Unit Chain Slack, Chain Break DIA-7535-018
(EU) DIA-7535-019
(EU) DIA-7535-019
(EU) DIA-7535-019
(EU) DIA-7535-019
CA418 Power Unit Brake/Tow DIA-7535-009
DIA-7535-010
CA501 Overhead Guard Lights DIA-7535-016 04.9-7335-050 (2, 7,
DIA-7535-017 11);
04.9-7335-052 (54,
69, 73)
CA503 Overhead Guard Lights & Fan DIA-7535-016 04.9-7335-050 (2, 7,
DIA-7535-017 11);
04.9-7335-052 (49,
54, 69, 73)
CA601 Guidance Control Communications DIA-7535-023 04.1-7335-001 (25)
Module (Optional)
CA602 Guidance Control I/O DIA-7535-023 04.1-7335-001 (25)
Module (Optional)
Module (Optional)
Module (Optional)
M10.0-7535-004 SP 3500 Crown 2008 PF17170-4
392
GLOSSARY
Glossary
CA607 Guidance Control Mast Cable #3 DIA-7535-023 04.1-7335-001 (25)
Module (Optional)
CA608 EAC Sensor Sensor Power DIA-7535-023 10.0-7334-001
CA611 Power Unit Connector on PDS Module DIA-7535-024
to TCM, SCM and Feed- DIA-7535-025
back Splitter Block
CA612 Power Unit Connector on PDS Module DIA-7535-024
to TCM, SCM and Mast DIA-7535-025
Cable #4
CA616 Power Unit Connector on Mast Cable DIA-7535-024
#4 to Power Unit Harness DIA-7535-025
CA701 Platform Heaters, Lifting Forks, DIA-7535-026
(Freezer/Corrosion) Travel Alarm DIA-7535-027
(Optional)
CA702 Platform Heaters DIA-7535-026
(Freezer/Corrosion)
(Optional)
CA807 C/C Distribution Board Heaters & Thermostat DIA-7535-026
CA808 C/C Distribution Board Input Power DIA-7535-026
CA809 Power Unit Mast Cable #3 DIA-7535-026
(Freezer/Corrosion) DIA-7535-027
(Optional)
JC413 Power Unit Drive/Tow DIA-7535-002 04.3-7335-001
DIA-7535-004
DIA-7535-020
DIA-7535-021
PC102 Distribution Panel Lights & Fan DIA-7535-016
DIA-7535-017
PC306 Platform Customer Accessories DIA-7535-014
DIA-7535-015
PC307 Platform PC Serial Port DIA-7535-011
DIA-7535-012
DIA-7535-013
PC314 Platform Spot Lights DIA-7535-016 04.0-7535-100 (1)
Crown 2008 PF17170-5 SP 3500 M10.0-7535-005
393
Notes:
394
SCHEMATIC DIAGRAMS
395
Notes:
396
SCHEMATIC DIAGRAMS
Introduction to Diagram Usage
Introduction to Diagram Usage • The truck has been sectioned with one page cov-
ering each section. When options affect the wiring
in a section, an additional page is added which du-
Schematic plicates wiring that is identical and adds the option
wiring. In this way only one page of the truck sec-
• Power up diagram. Illustrates the circuitry involved tion is required for the applicable truck configura-
in getting the truck system to an operating mode tion.
(Can Interface, Access 1,2,3, Controller, Contac-
tor, ect.). • Wiring that is identified by color rather than number
will typically be a cable or wires with vendor com-
• Circuitry which stands alone and is separate from ponentry.
truck operation is shown in block form with the pic-
torials detailing the circuitry (e.g. light package, dis- • Page titles, listed at the beginning of the electrical
plays, wire guidance, freezer condition). diagrams, indicate the subsystem or section of
truck wiring that is covered by each page.
Pictorials
• Terminal board and connector numbering on the
pictorials are in two classes; power unit and plat-
form. Power unit TB's and CA's are even 100's
(200, 400, 600 etc.) and platform TB's and CA's are
odd 100's (100, 300, 500 etc.). On manup trucks
(SP, TS, TSP etc.), odd and even 100's will be
present on the wiring diagrams. Man-down trucks,
which don't have a platform (stand-up rider, pallet
etc.), only even 100's will be present.
• Wiring starts at a central location (e.g. distribution

board) and wiring connection points are numbered
with the lowest number odd or even. The next wir-
ing connection point from the distribution board are
then numbered with the next group of 100's and so
on for each connection point removed from the
central location.
• Terminal board and connector numbering is se-

quential on each consecutive page. In this way a
wiring address giving a connector number or termi-
nal board number will indicate which direction to
look in the diagrams for the other end of the wire.
When wiring goes to a component and not a termi-
nal board or connector, a reference terminal board
is used and is shown with a dashed line box with
the reference terminal board number in parenthe-
sis. This terminal board will not appear on the truck
and only present as a wiring directory.
• Input/Output arrows may appear at terminal

boards and connectors. These indicate whether
what the wire is carrying is incoming or outgoing.
This is helpful when tracing the origin of the signal
or voltage.
Crown 1991 PF8974-1 Rev. 6/08 SP 3500 DIA-ITD-001

02 Rev. 6/08
397
Notes:
398
SCHEMATIC DIAGRAMS
Electrical Diagrams Index

This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Title Page Number Revision
Schematic - Power Unit W/Options DIA-7535-002 01 - 6/08

Schematic - Platform W/Options DIA-7535-003 01 - 6/08
Schematic - Power Unit W/PDS Options DIA-7535-004 01 - 6/08
Schematic - Platform W/PDS Options DIA-7535-005 01 - 6/08
Schematic - Power Unit DIA-7535-006 01 - 6/08
Schematic - Platform DIA-7535-007 01 - 6/08
Platform Distribution Panel DIA-7535-008
Power Unit Distribution Panel DIA-7535-009 02 - 6/08
Power Unit Distribution Panel W/PDS DIA-7535-010 01 - 6/08
Platform Modules Access 1 & 4 DIA-7535-011 01 - 6/08
Platform Modules Access 1 & 4 Forks First Option DIA-7535-012 01 - 6/08
Platform Modules Access 1 & 4 W/PDS DIA-7535-013 01 - 6/08
Control Pod And Light Switches DIA-7535-014 01 - 6/08
Control Pod And Light Switches Forks First Option DIA-7535-015 01 - 6/08
Overhead Guard Lights/Fans DIA-7535-016 01 - 6/08
Overhead Guard Lights/Fans Forks First Option DIA-7535-017 01 - 6/08
Traction Control Module Access 3 DIA-7535-018 01 - 6/08
Traction Control Module Access 3 W/PDS DIA-7535-019 01 - 6/08
Steering Control Module Access 5 DIA-7535-020 01 - 6/08
Steering Control Module Access 5 W/PDS DIA-7535-021 01 - 6/08
Hydraulics & Optional MMS DIA-7535-022 01 - 6/08
Guidance Control Module Access 6 (Optional DIA-7535-023 01 - 6/08
PDS/FSB1 Option DIA-7535-024 02 - 6/08
PDS/FSB1 & Forks First Option DIA-7535-025 01 - 6/08
Freezer Conditioning (Optional) DIA-7535-026 01 - 6/08
Freezer Conditioning Forks First Optional DIA-7535-027 01 - 6/08
Power Cables DIA-7535-028 01 - 6/08
Wire Harnesses DIA-7535-029 01 - 6/08
Crown 2007 PF17083-1 Rev. 6/08 SP 3500 DIA-7535-001

02 Rev. 6/08
399
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/Options
142679 C EU sh 2
DIA-7535-002 SP 3500 Crown 2007 PF17083-2 Rev. 6/08
01 Rev. 6/08
400
SCHEMATIC DIAGRAMS
Schematic - Platform w/Options
142679 C EU sh 1
Crown 2007 PF17083-3 Rev. 6/08 SP 3500 DIA7535-003

01 Rev. 6/08
401
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/PDS Options
Schematic - Power Unit w/PDS Options
142678 C EU sh 2
01 Rev. 6/08
402
SCHEMATIC DIAGRAMS
Schematic - Platform w/PDS Options
Schematic - Platform w/PDS Options
142678 C EU sh 1

01 Rev. 6/08
403
SCHEMATIC DIAGRAMS
Platform Distribution Panel
142680 D EU
01 Rev. 6/08
404
SCHEMATIC DIAGRAMS
Platform Distribution Panel w/PDS
Platform Distribution Panel w/PDS
142691 C EU

01 Rev. 6/08
405
SCHEMATIC DIAGRAMS
Platform Distribution Panel Forks First Option
Platform Distribution Panel Forks First Option
142696 B EU
DIA-7535-008 SP 3500 Crown 2007 PF17083-8
406
SCHEMATIC DIAGRAMS
Power Unit Distribution Panel
142681 C EU

02 Rev. 6/08
407
SCHEMATIC DIAGRAMS
Power Unit Distribution Panel w/PDS
Power Unit Distribution Panel w/PDS
142692 B EU
01 Rev. 6/08
408
SCHEMATIC DIAGRAMS
Platform Modules Access 1 & 4
142682 C EU

01 Rev. 6/08
409
SCHEMATIC DIAGRAMS
Platform Modules Access 1 & 4 Forks First Option
Platform Modules Access 1 & 4 Forks First Option
142697 B EU
01 Rev. 6/08
410
SCHEMATIC DIAGRAMS
Platform Modules Access 1 & 4 w/PDS
Platform Modules Access 1 & 4 w/PDS
142693 C EU

01 Rev. 6/08
411
SCHEMATIC DIAGRAMS
Control Pod and Light Switches
142683 C EU
01 Rev. 6/08
412
SCHEMATIC DIAGRAMS
Control Pod and Light Switches Forks First Option
Control Pod and Light Switches Forks First Option
142698 C EU

01 Rev. 6/08
413
SCHEMATIC DIAGRAMS
Overhead Guard Lights/Fans
142687 C EU
01 Rev. 6/08
414
SCHEMATIC DIAGRAMS
Overhead Guard Lights/Fans Forks First Option
Overhead Guard Lights/Fans Forks First Option
142699 B EU

01 Rev. 6/08
415
SCHEMATIC DIAGRAMS
Traction Control Module Access 3
142684 B EU
01 Rev. 6/08
416
SCHEMATIC DIAGRAMS
Traction Control Module Access 3 w/PDS
Traction Control Module Access 3 w/PDS
142694 A EU

01 Rev. 6/08
417
SCHEMATIC DIAGRAMS
Steering Control Module Access 5
142685 B EU
01 Rev. 6/08
418
SCHEMATIC DIAGRAMS
Steering Control Module Access 5 w/PDS
Steering Control Module Access 5 w/PDS
142871 B EU

01 Rev. 6/08
419
SCHEMATIC DIAGRAMS
Hydraulics & Optional MMS
142686 A EU
01 Rev. 6/08
420
SCHEMATIC DIAGRAMS
Guidance Control Module Access 6 (Optional)
142688 A EU

01 Rev. 6/08
421
SCHEMATIC DIAGRAMS
PDS/FSB1 Option
PDS/FSB1 Option
142695 B EU
01 Rev. 6/08
422
SCHEMATIC DIAGRAMS
PDS/FSB1 & Forks First Option
PDS/FSB1 & Forks First Option
142701 A EU

01 Rev. 6/08
423
SCHEMATIC DIAGRAMS
Freezer Conditioning (Optional)
Freezer Conditioning (Optional)
142689 C EU
02 Rev. 6/08
424
SCHEMATIC DIAGRAMS
Freezer Conditioning Forks First Optional
Freezer Conditioning Forks First Optional
142700 C EU

01 Rev. 6/08
425
SCHEMATIC DIAGRAMS
Power Cables
Power Cables
142690 B EU
01 Rev. 6/08
426
SCHEMATIC DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
141028 (a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142220 (b) Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, PC408,
PC409, JC410, PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, JC611, JC612,
PC616, BNEG, BRES1, BRES2, BW-P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL. RGSR,
SV1, THS-P1, THS-P2
142670 (a) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142671 (a) Wire Guidance Harness: JC602, PC603, PC604
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2,
BW-P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
Platform
134322 (a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC307, PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331,
CA332, PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, FNS, LGS3
140170 Chain Break Harness: CA331, CHB7, CHB8
140290-001 (a) InfoLink Harness
141029 Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC307, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335,
PC501, PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
142219 (b) PDS Wire Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC307, PC308, PC317, PC318, JC322, PC322, PC323, PC325, JC326, PC327, PC328,
PC329, PC330, JC331, PC331, PC332, JC333, PC334, JC335, BRS, CDS, CHS1, CHS2,
GTS1, GTS2, HGRTS, HN1, HN2
(a) Optional
(b) Trucks w/PDS Option

01 Rev. 6/08
427
Notes:
428
HYDRAULIC SCHEMATIC
429
Notes:
430
HYDRAULIC SCHEMATIC
Single Speed Lift
Single Speed Lift
Single Speed Lift
Lift Control
To Lift
Cylinder
(a) Accumulator, precharged to 3447.4 kPa (500 psi)

(b) Lift control manifold block for Single Speed Lift
(c) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
and 16133.7 to 16306.1 kPa (2340 to 2365 psi) for TL mast
(d) Lift Pump and motor, P1 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(e) Return line filter, 10 micron nominal
(f) Reservoir capacity is approximately 13 liters (3.5 gal) for trucks with
single speed lift
(g) Suction strainer, 100 mesh
Figure 15744-01
Crown 2007 PF15666-1 Rev. 1/08 SP 3500 HYD-7335-001

01 Rev. 1/08
431
HYDRAULIC SCHEMATIC
Two Speed Lift
Two Speed Lift
Two Speed Lift
Lift Control
To Lift
Cylinder

(b) Lift control manifold block for Two Speed Lift
(c) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
(d) Lift Pump and motor, P1 & P2 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(e) Return line filter, 10 micron nominal
(f) Reservoir capacity is approximately 17 liters (4.5 gal) for trucks with
two speed lift
(g) Suction strainer, 100 mesh
Figure 15745-01
HYD-7335-002 SP 3500 Crown 2007 PF15666-2 Rev. 1/08
01 Rev. 1/08
432
HYDRAULIC SCHEMATIC
Single Speed Lift (With Lifting Fork)
Single Speed Lift (With Lifting Fork)
Single Speed Lift

(With Lifting Fork)
To Main Lift
Cylinder
To Lifting Fork
Cylinder on
Platform

(b) Lift control manifold block for One Speed Lift
(c) Bias pressure, 2068.4 kPa (300 psi)
(d) RV2 preset to 11721.1 kPa (1700 psi)
(e) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
(f) Lift Pump and motor, P1 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(g) Reservoir capacity is approximately 13 liters (3.5 gal) for trucks with
single speed lift
(h) Suction strainer, 100 mesh
(i) Return line filter, 10 micron nominal
Figure 15746-01

01 Rev. 1/08
433
HYDRAULIC SCHEMATIC
Two Speed Lift (With Lifting Fork)
Two Speed Lift (With Lifting Fork)
Two Speed Lift

(With Lifting Fork)
To Main Lift
Cylinder
To Lifting Fork
Cylinder on
Platform

(b) Lift control manifold block for Two Speed Lift
(c) Bias pressure, 2068.4 kPa (300 psi)
(d) RV2 preset to 11721.1 kPa (1700 psi)
(e) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
(f) Lift Pump and motor, P1 & P2 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(g) Reservoir capacity is approximately 17 liters (4.5 gal) for trucks with
two speed lift
(h) Suction strainer, 100 mesh
(i) Return line filter, 10 micron nominal
Figure 15747-01
HYD-7335-004 SP 3500 Crown 2007 PF15666-4 Rev. 1/08
01 Rev. 1/08
434
HYDRAULIC SCHEMATIC
Mast Cylinders
Mast Cylinders
To Power Mast
Unit Cylinders
TL Mast
Cylinders
Free Lift
Cylinder
To Power
Unit
Mast Mast
Cylinder Cylinder
TT Mast
Cylinders
Figure 15748

01 Rev. 1/08
435
Notes:
436
SP
SP 3571 &
SP 3581 Series
AC Traction
Service Manual
Crown 2010 812586-006

This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

– European Headquarter –
Moosacher Str. 52
80809 München
Germany
Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 133
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2010
CROWN Equipment Corporation
TABLE OF CONTENTS
I
Notes:
II
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PAGE SERIAL NO. CUT REV.

General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . 3
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lockout - Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Towing Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Towing by Pulling in Power Unit First Direction . . . . . . . . 11
Towing by Pushing in Forks First Direction . . . . . . . . . . . . 12
Towing by Lifting Truck and
Pulling in Power Unit First Direction . . . . . . . . . . . . . . . . . 13
Pulling in the Forks First Direction . . . . . . . . . . . . . . . . 13
Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Blocking Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . 17
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INTRODUCTION PAGE SERIAL NO. CUT REV.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operator Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Data Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LUBRICATION & ADJUSTMENT PAGE SERIAL NO. CUT REV.

Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Component Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Audible Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
HN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
HN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SP3500
III
TABLE OF CONTENTS
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ED1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ED2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FAN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FAN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Mast Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FU8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FU9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FU10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FU11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FU12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FU13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FU14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FU15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT2, 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT3, 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT4, 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT8, 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
BRK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
BW-P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
BW-P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EACA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EACA2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
EACB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
EACB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FIL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
GS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
GS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
InfoLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SP3500
IV
TABLE OF CONTENTS
ORF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ORF2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ORF3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Quick Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SB30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Shock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ACCESS 1 (DCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ACCESS 3 (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ACCESS 4 (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ACCESS 5 (SCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ACCESS 6 (GCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
K12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
K15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
RES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
RES2, RES3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
RES5, RES6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
RES7, RES8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
RES9, RES10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RES11, RES12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RES13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RES14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RES15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RES16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RES17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RES18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RES19, RES20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RES21, RES22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RES25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RES111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
BRES1, BRES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CHB4, CHS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CHB7, CHB8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CHS1, CHS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CHS3, CHS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DMS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FNS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
GTS1, GTS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
GTS5, GTS6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
GUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
HGTRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LOS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LOS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
ORS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
RAS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
RAS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
RGSR and RGSL (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 94
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
THS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
THS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
THS-P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
THS-P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ZSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CV3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
MLV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
PVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
PCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
RV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Velocity Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Caster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Caster Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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HYDRAULIC SYSTEM PAGE SERIAL NO. CUT REV.

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Low Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
High Speed Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Accumulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Manual Lower Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 117
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Lift Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Freezer Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 119
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Pump - Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Composite Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lift/Lower Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Relief Valve (RV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Precharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 135
DRIVE UNIT PAGE SERIAL NO. CUT REV.

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Drive Unit Removal and Installation . . . . . . . . . . . . . . . . . . . 144
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ELECTRICAL SYSTEM PAGE SERIAL NO. CUT REV.

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
K1 and K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Power Up Relay and Power Unit Relay . . . . . . . . . . . . . . 149
Start Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
K11 and K12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Freezer/Condition Relays . . . . . . . . . . . . . . . . . . . . . . . . 150
K15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Travel Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
ACCESS 123® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
ACCESS 1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Operator Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Steer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Model - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Timer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Trip - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
BDI - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Hours - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Odometer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . 165
Speed - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Service Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Analyzer Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
A1 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
A2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
A3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Features Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Performance Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Calibration Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Level 2 Hour Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Level 3 Hour Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Events Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Utilities Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
End Aisle Control (EAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
EAC Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Termination Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . 245
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Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Traction Request Potentiometer (POT1) . . . . . . . . . . . . 251
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Traction Request Potentiometer (POT1) . . . . . . . . . . . . 252
Actuator Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Potentiometer (POT1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Cam, Torsion Spring, Stop . . . . . . . . . . . . . . . . . . . . . . . 254
Twist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
RAS1, RAS2, LOS1, LOS2, HNS, EDS . . . . . . . . . . . . . . . . 257
Button Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Power Disconnect Button Springs . . . . . . . . . . . . . . . . . 259
Steering Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Checking the Battery Under Load . . . . . . . . . . . . . . . . . . 268
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Event Code 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Event Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Event Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Event Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Event Code 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Event Code 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Event Code 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Event Code 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Event Code 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Event Code 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
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Event Code 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Event Code 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Event Code 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Event Code 327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Event Code 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Event Code 336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Event Code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Event Code 339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Event Code 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Event Code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Event Code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Event Code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Event Code 344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Event Code 345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Event Code 346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Event Code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Event Code 349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Event Code 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Event Code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Event Code 352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Event Code 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Event Code 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Event Code 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Event Code 356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Event Code 357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Event Code 358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Event Code 359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Event Code 360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Event Code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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Event Code 362 .................................... 335

Event Code 363 .................................... 336
Event Code 365 .................................... 337
Event Code 366 .................................... 338
Event Code 367 .................................... 339
Event Code 368 .................................... 340
Event Code 369 .................................... 341
Event Code 370 .................................... 342
Event Code 371 .................................... 343
Event Code 372 .................................... 344
Event Code 373 .................................... 345
Event Code 374 .................................... 345
Event Code 375 .................................... 346
Event Code 378 .................................... 346
Event Code 379 .................................... 347
Event Code 380 .................................... 348
Event Code 381 .................................... 349
Event Code 382 .................................... 350
Event Code 383 .................................... 350
Event Code 384 .................................... 351
Event Code 385 .................................... 351
Event Code 386 .................................... 352
Event Code 387 .................................... 352
Event Code 389 .................................... 353
Event Code 390 .................................... 354
Event Code 392 .................................... 355
Event Code 393 .................................... 356
Event Code 395 .................................... 357
Event Code 396 .................................... 357
Event Code 397 .................................... 358
Event Code 398 .................................... 359
Event Code 401 .................................... 360
Event Code 405 .................................... 361
Event Code 411 .................................... 362
Event Code 413 .................................... 363
Event Code 415 .................................... 364
Event Code 416 .................................... 365
Event Code 421 .................................... 366
Event Code 422 .................................... 367
Event Code 423 .................................... 368
Event Code 424 .................................... 369
Event Code 425 .................................... 369
Event Code 426 .................................... 370
Event Code 427 .................................... 370
Event Code 429 .................................... 371
Event Code 430 .................................... 376
Event Code 431 .................................... 380
Event Code 432 .................................... 384
Event Code 433 .................................... 385
Event Code 435 .................................... 387
Event Code 440 .................................... 388
Event Code 441 .................................... 389
Event Code 442 .................................... 390
Event Code 443 .................................... 391
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Event Code 445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Event Code 446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Event Code 447 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 448 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Event Code 449 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Event Code 452 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 453 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Event Code 460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Event Code 462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Event Code 463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Event Code 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Event Code 466 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Event Code 469 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Event Code 470 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Event Code 473 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Event Code 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Event Code 504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Event Code 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Event Code 506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Event Code 511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Event Code 512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Event Code 513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Event Code 514 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Event Code 515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Event Code 521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Event Code 522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Event Code 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Event Code 526 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Event Code 527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Event Code 528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Event Code 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Event Code 530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Event Code 531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Event Code 532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Event Code 533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Event Code 534 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Event Code 535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Event Code 536 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Event Code 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Event Code 538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Event Code 539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Event Code 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Event Code 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Event Code 542 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Event Code 544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Event Code 545 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Event Code 546 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
Event Code 548 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
Event Code 549 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
Event Code 551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Event Code 552 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Event Code 553 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Event Code 554 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
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Event Code 555 .................................... 444

Event Code 556 .................................... 445
Event Code 557 .................................... 446
Event Code 558 .................................... 447
Event Code 561 .................................... 448
Event Code 562 .................................... 449
Event Code 563 .................................... 449
Event Code 564 .................................... 450
Event Code 565 .................................... 450
Event Code 566 .................................... 452
Event Code 567 .................................... 453
Event Code 568 .................................... 454
Event Code 569 .................................... 455
Event Code 570 .................................... 456
Event Code 571 .................................... 457
Event Code 572 .................................... 458
Event Code 573 .................................... 459
Event Code 574 .................................... 460
Event Code 576 .................................... 461
Event Code 581 .................................... 462
Event Code 582 .................................... 463
Event Code 585 .................................... 464
Event Code 586 .................................... 465
Event Code 587 .................................... 466
Event Code 588 .................................... 466
Event Code 589 .................................... 467
Event Code 590 .................................... 468
Event Code 591 .................................... 469
Event Code 592 .................................... 470
Event Code 593 .................................... 471
Event Code 594 .................................... 471
Event Code 595 .................................... 472
Event Code 596 .................................... 472
Event Code 597 .................................... 473
Event Code 601 .................................... 474
Event Code 603 .................................... 475
Event Code 604 .................................... 476
Event Code 605 .................................... 477
Event Code 611 .................................... 478
Event Code 612 .................................... 479
Event Code 621 .................................... 480
Event Code 628 .................................... 481
Event Code 631 .................................... 482
Event Code 632 .................................... 483
Event Code 633 .................................... 484
Event Code 636 .................................... 485
Event Code 637 .................................... 485
Event Code 638 .................................... 486
Event Code 639 .................................... 487
Event Code 652 .................................... 488
Event Code 659 .................................... 489
Event Code 660 .................................... 489
Event Code 663 .................................... 490
Event Code 664 .................................... 491
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Event Code 667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

Event Code 668 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Event Code 671 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
Event Code 672 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
BRAKE SYSTEM PAGE SERIAL NO. CUT REV.

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Braking Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Brake Force Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Torque Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Rotor and Brake Pad Replacement . . . . . . . . . . . . . . . . . 503
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
STEERING PAGE SERIAL NO. CUT REV.

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Steering Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Steering Wheel Direction Indicator . . . . . . . . . . . . . . . . . . . . 510
Steering Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Steering Motor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
LIFTING MECHANISM PAGE SERIAL NO. CUT REV.

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Shim Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
TL Mast Column Roller Removal . . . . . . . . . . . . . . . . . . . . . 517
TT Mast Column Roller Removal . . . . . . . . . . . . . . . . . . . . . 519
Shim Measurements (Tolerances) . . . . . . . . . . . . . . . . . . . . 521
Mast Testing (Assembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Top Column Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Bottom Column Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . 529
Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Chain Anchors and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 531
Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
Disconnect Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . . 531
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Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
Mounting Support And Platform Bore Measurement . . . 534
Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
CYLINDERS PAGE SERIAL NO. CUT REV.

Mast and Free Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 539
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
Accessing Mast Cylinder Rod Packing . . . . . . . . . . . . . . . . 541
Accessing Free Lift Cylinder Rod Packing . . . . . . . . . . . . . . 541
Rod Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 542
Mast Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
Free Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . 545
Mast And Free Lift Cylinder Assembly . . . . . . . . . . . . . . . . . 546
Mast And Free Lift Cylinder Installation . . . . . . . . . . . . . . . . 546
PLATFORM PAGE SERIAL NO. CUT REV.

Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
Floor Mat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
Safety Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Fork Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 551
Pallet Grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
Release Handle Adjustment . . . . . . . . . . . . . . . . . . . . . . 551
Foot Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 551
Pallet Grab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
Operator Compartment Gates . . . . . . . . . . . . . . . . . . . . . . . 553
Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
Operator Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
Shim Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Platform Removal & Shimming TL Mast . . . . . . . . . . . . . . . 556
Platform Removal & Shimming TT Mast . . . . . . . . . . . . . . . 559
Platform Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
Height Sensor Encoder Replacement (ECR4) . . . . . . . . . . . 563
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
GLOSSARY PAGE SERIAL NO. CUT REV.

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
SP3500
XV
TABLE OF CONTENTS
SCHEMATIC DIAGRAMS PAGE SERIAL NO. CUT REV.

Introduction to Diagram Usage . . . . . . . . . . . . . . . . . . . . . . . . 579
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
Electrical Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
Schematic - Power Unit w/Options . . . . . . . . . . . . . . . . . . . . . 582
Schematic - Platform w/Options . . . . . . . . . . . . . . . . . . . . . . . 583
Schematic - Power Unit w/Pallet Grab . . . . . . . . . . . . . . . . . . 584
Schematic - Platform w/Pallet Grab . . . . . . . . . . . . . . . . . . . . 585
Schematic - Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
Schematic - Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
Platform Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
Power Unit Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . 589
Platform Modules Access 1 & 4 . . . . . . . . . . . . . . . . . . . . . . . 590
Control Pod and Light Switches . . . . . . . . . . . . . . . . . . . . . . . 591
Overhead Guard Lights/Fans . . . . . . . . . . . . . . . . . . . . . . . . . 592
Overhead Guard Spotlights (Optional) . . . . . . . . . . . . . . . . . 593
Traction Control Module Access 3 . . . . . . . . . . . . . . . . . . . . . 594
Steering Control Module Access 5 . . . . . . . . . . . . . . . . . . . . . 595
Hydraulics & Optional MMS . . . . . . . . . . . . . . . . . . . . . . . . . . 596
Guidance Control Module Access 6 (Optional) . . . . . . . . . . . 597
Travel Alarm & Freezer Conditioning (Optional) . . . . . . . . . . 598
Travel Alarm & Pallet Grab . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
HYDRAULIC SCHEMATIC PAGE SERIAL NO. CUT REV.

Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
SP3500
XVI
SAFETY
1
Notes:
2
SAFETY
General Maintenance Instructions 5. Before starting to operate truck—

– Be in operating position.
WARNING – Apply brake.

– Place directional control in neutral.
TO PREVENT SERIOUS RISK OF INJURY TO
YOURSELF AND OTHERS OBSERVE THE FOL- – Before operating truck, check functions of lift
LOWING SAFETY INSTRUCTIONS systems, directional control, speed control,
steering, warning devices, brakes and any at-
Power industrial trucks may become hazardous if ade- tachments if any used.
quate maintenance is neglected. Therefore, adequate
maintenance facilities, trained personnel and proce- 6. Avoid fire hazards and have fire protection equip-
dures should be provided. ment present. Do not use an open flame to check
level, or for leakage of electrolyte and fluids or oil.
Maintenance and inspection shall be performed in con- Do not use open pans of fuel or flammable clean-
formance with the following practices: ing fluids for cleaning parts.
1. A scheduled planned maintenance, lubrication, 7. Keep shop well ventilated, clean and dry.
and inspection system should be followed.
8. Brakes, steering mechanisms, control mecha-
2. Only qualified and authorized personnel shall be nisms, lift overload devices, guards, and safety de-
permitted to maintain, repair, adjust and inspect vices shall be inspected regularly and maintained
truck. in a safe operating condition.
3. Before leaving the truck— 9. Capacity, operation and maintenance instruction
– Stop truck. plates or decals shall be maintained in legible con-
dition.
– Fully lower the load engaging means.
10. All parts of lift mechanisms shall be inspected to
– Place directional controls in neutral. maintain them in safe operating condition.
– Apply the parking brake. 11. All hydraulic systems shall be regularly inspected
– Turn off power (power disconnect). and maintained in conformance with good practice.
Cylinders, valves, and other similar parts shall be
– Remove key. checked to assure that “drift” has not developed to
– Block the wheels if truck is on an incline. the extent that it would create a hazard.
4. Before working on truck— 12. Batteries, motors, controllers, limit switches, pro-
tective devices, electrical conductors, and connec-
– Raise drive wheel free of floor or disconnect tions shall be maintained in conformance with
power sources. good practice. Special attention shall be paid to the
– Use chocks or other positive positioning de- condition of electrical insulation.
vices.
13. Trucks shall be kept in a clean condition to mini-
– Block load engaging means, inter masts, or mize fire hazards and facilitate detection of loose
chassis before working under them. or defective parts.
– Operation to check performance of truck or at- 14. Modifications and additions which affect capacity
tachments shall be conducted in an authorized and safe truck operation shall not be performed by
safe clearance area. the customer or user without manufacturers prior
written approval. Capacity, operation and mainte-
nance plates or decals shall be changed accord-
ingly.
15. Care shall be taken to assure that all replacement
parts are interchangeable with the original parts
and of equal quality to that provided in the original
equipment.
Crown 1980 PF6285-1 Rev. 10/06 SP3500 MA-04.5-001

03 Rev. 10/06
3
SAFETY
16. Be sure that any equipment added to the truck (ter-

minal, fan, clipboard, etc.) is positioned so that it
does not block your vision or interfere with safe and
efficient operation of the truck.
For further information pertaining to operating and
maintenance procedures, refer to F.E.M. safety code -
Power Industrial Truck (section 4).
For copies send to:
F.E.M.
10 Avenue Hoche
75382 Paris Cedex 08 France
MA-04.5-002 SP3500 Crown 1980 PF6285-2 Rev. 10/06
03 Rev. 10/06
4
SAFETY
Control of Hazardous Energy • Do not allow dirt, cleaning solution or other foreign
material to enter cells. Impurities in the electrolyte
Lockout/Tagout charge.
In the interest of safety and to ensure compliance with • If battery repair is planned, follow the battery man-
OSHA Regulations, (Standards - 29 CFR), control of ufacturer's instructions concerning repair practices
hazardous energy (lockout/tagout) - 1910.147, Crown and procedures.
has developed guidelines for proper energy control
when performing service and maintenance on the
truck. Before performing any service or maintenance, Battery Care
review the appropriate sections in this service manual
for additional procedures to be followed.
CAUTION
In addition, Crown recommends that all mechanics
wear appropriate protective items, such as safety Only qualified and experienced personnel should per-
glasses, work gloves, and steel-toed shoes, whenever form maintenance and repair on batteries.
performing service or maintenance work on Crown
equipment.
• Make certain the charger being used matches the
voltage is listed on the truck serial plate.
Battery
• Before disconnecting or connecting batteries to a
charger, make sure the charger is OFF. If an at-
Safety Rules tempt is made to do this while the charger is ON,
serious injury to you, the battery and charger could
• Wear protective clothing, such as, rubber apron,
result.
gloves, boots and full-face shield when performing
any maintenance on batteries. Do not allow elec- • Never use a match or lighter. Battery fumes are ex-
trolyte to come in contact with eyes, skin, clothing plosive.
or floor. If electrolyte comes in contact with eyes,
flush immediately and thoroughly with clean water. • Make certain battery used meets weight, size and
Obtain medical attention immediately. Should elec- voltage requirements of truck (refer to serial plate).
trolyte be spilled on skin, rinse promptly with clean NEVER operate truck with an undersized battery.
water and wash with soap. A baking soda solution
(one pound to one gallon of water) will neutralize Charging
acid spilled on clothing, floor or any other surface.
Apply solution until bubbling stops and rinse with
clean water. CAUTION
• Keep vent plugs firmly in place at all times except Never smoke or bring flame near the battery. Gas
when adding water or taking hydrometer readings. formed during charging is highly explosive and can
cause serious injury.
• Do not bring any type of flame, spark, etc., near the
battery. Gas formed while the battery is charging, Consult the charger manufacturer's manual covering
is highly explosive. This gas remains in the cells your charger for hints on operation and maintenance.

Crown 2009 PF17831-1 SP3500 MA-7435-100
5
SAFETY
Battery Removal
CAUTION
When removing the battery, move truck to area in-
switch or toggle switch to OFF position and remove
key. Disconnect battery and lockout or tagout truck as
described in Lockout - Tagout in this section. Never
move battery partially from truck without roller stand in
place. Lower load engaging means completely. If bat-
tery is removed with load engaging means raised, use
hoist attached to mast to provide tip over protection. Do
not allow any metallic object to come in contact with the
top of the battery cells. This may cause a short circuit
when removing, transporting the battery. Use an insu- Figure 8251
lator (such as plywood) to cover the top of the battery
before and during removal. Lockout - Tagout
Always turn key switch to OFF, remove key and apply
Battery Installation tag to steering wheel or twist grip with cable tie warning
others truck is being serviced.
CAUTION
When installing the battery, move truck to area in-
switch or toggle switch to OFF position and remove
key. Lockout or tagout truck as described in Lockout -
Tagout in this section. If battery was removed with load
engaging means raised, use hoist attached to mast to
provide tip over protection. Do not allow any metallic
object to come in contact with the top of the battery
cells. This may cause a short circuit when transporting
or installing the battery. Use an insulator (such as ply-
wood) to cover the top of the battery before and during Figure 8262
installation.
When maintenance is to be performed and the battery
will be left in the truck, disconnect battery, remove the
CAUTION main power fuses and install a commercially available
lockout device on the battery connector.
Make certain battery used meets weight, size and volt-
When maintenance is performed and the battery is re-
age requirements of truck (refer to serial plate).
moved from the truck, remove main power fuses, install
NEVER operate truck with an undersized battery.
a lockout device on the truck's battery connector if pos-
sible, or if possible install a tag with a cable tie on the
truck's battery connector so it cannot be removed eas-
ily warning that the truck is not available for operation.
MA-7435-101 SP3500 Crown 2009 PF17831-2
6
SAFETY
Brake
The brakes can be released through the use of the
Drive/Tow switch (DTS1) during a maintenance situa-
tion. When using this method to release the brakes, the
truck will not have brakes available for stopping. The
truck will not have traction control and the power steer-
ing system will not work.
WARNING
Extreme care must be taken when using the Drive/Tow
switch to release the brakes. The truck will be free-
wheeling and the brake pedal in the operator compart-
ment will have no effect on braking. Brakes will only be
applied when DTS1 is moved from the Tow to the Drive
position.

• Chock wheels or make sure truck is secured by

some means to keep it from rolling away.
Distribution Panel
• When towing the truck make sure all operators are
informed of the trucks lack of braking.
• Disconnect brake connector PC407 from JC407

and connect PC407 to JC413 on harness. Refer to
Figure 23081. Figure 23542
• Move switch DTS1 from the Drive position to the

Tow position.
• Move truck to area intended for maintenance.
• Move DTS1 from the Tow to the Drive position. Dis-

connect battery.
• Disconnect brake connector PC407 from JC413

and connect to original connection, JC407.
NOTE
If electrical power is provided to the ACCESS 123®
modules and brake and the electrical system is func-
tioning properly, the brakes can be released through
the Utilities menu (U2 Tow Mode) in Level 2 of the
ACCESS 123 system. All functions except traction are
enabled. For more information, refer to the Figure 23081
ACCESS 123 section of this service manual.
Crown 2009 PF17831-3 SP3500 MA-7435-102
7
SAFETY
Capacitance
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance which
may permit contact with the bus bars and associated
power cables, discharge the capacitors.


• Place a minimum 100 ohm, 2 watt resistor between

the positive and negative terminals of the controller
for 15 or more seconds.
Figure 16318-02
1 Battery Positive
2 Battery Negative
MA-7435-103 SP3500 Crown 2009 PF17831-4
8
SAFETY
Hydraulic
WARNING
AVOID HIGH PRESSURE FLUIDS – Escaping fluid
under pressure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting hydraulic
hand.
despite an initial normal appearance of the skin. There
may occur. Medical attention should be sought imme- Manual Lower Valve
type of injury. Figure 15658
When maintenance is to be performed on the hydraulic
system, make certain the hydraulic system is not under
pressure by:

• Completely lower load engaging means (mast) or,

if required for maintenance, block mast sections at
the appropriate height as described in Mast of this
section.

• Open power unit doors and locate the lift manifold.
• Open the manual lower valve to remove hydraulic

pressure.
Crown 2009 PF17831-5 SP3500 MA-7435-104
9
SAFETY
Accumulator
The accumulator (hydraulic system shock absorber)
contains a charge of inert gas such as dry nitrogen. Do
not tamper with the gas valve on the accumulator in an
attempt to reduce the amount of this charge. Use accu-
mulator charging equipment and procedures as de-
scribed under Accumulator in Hydraulic Maintenance.
Figure 15726-01
1 Accumulator
Figure 16830-02
1 Accumulator
2 Gas Valve
3 Hydraulic Line Connection
MA-7435-105 SP3500 Crown 2009 PF17831-6
10
SAFETY
Towing Truck • When attaching towing device to lift truck being

towed, first install eyelets in the holes provided in
Refer to the following guidelines when towing the truck: the skirt (see Figure 23079). Then attach tow strap/
chains that are both long enough to provide safe
Towing by Pulling in distance for towed truck to coast to a stop and also
Power Unit First Direction are capable of the pull force requirements.
WARNING
• Towed truck must always maintain all wheels in
contact with floor.
• Maximum travel speed while towing truck is
1.6 kph (1 mph).
• Do not make sharp turns when towing this truck.
• Floor is to be level and flat without trash or debris
in towing path.
• Towed vehicle forks should be empty and no more
than 305 mm (12.0 in) off floor.
• Excessive acceleration by towing vehicle, or drag
caused by towed vehicle (i.e., brake drag, drive
unit drag, wheel drag, etc.) will greatly increase re-
quirements to pull or push a vehicle.
Preparing Truck For Towing:
Figure 23079
• Power should be ON if steering is not inhibited and
1 Holes in Skirt for Eyelets
the operator can be on towed vehicle if steering is
not inhibited. Towing Guidelines:
• If standard brake release pedal does not function, • Maximum travel speed while towing truck is
then release brakes with brake tow switch. Refer to 1.6 kph (1 mph).
Brake in this section.
• Steering towed vehicle: If steering is operational, a
Towing Device Requirements:
second operator should be on towed vehicle to
• Gross vehicle weight of towed vehicle should not steer truck. If steering is inhibited, tow vehicle in a
exceed 4535 kg (10000 lb). Refer to data plate for straight line out of aisle with no operator on towed
gross vehicle weight; include battery weight if it is truck. Once outside of aisle, make necessary re-
in vehicle during towing. pairs to re-gain steering operation, then follow in-
structions in previous sentence.
• Towing device/vehicle must have pulling/braking
capacity greater than 3175 kg (7000 lb).
contact with floor.
• Allow sufficient distance for truck to coast to stop at

final destination.
Crown 2009 PF17831-7 SP3500 MA-7435-106
11
SAFETY
Towing by Pushing Pushing Disabled Truck:

in Forks First Direction • Using another vehicle, push against the skirt of the
NOTE: This procedure can be followed if aisle layout/ disabled vehicle in forks first direction. See Figure
position of truck in aisle does not allow for pulling truck 23112.
by power unit skirt. Once truck is outside of aisle, follow
previous procedure for pulling truck in power unit first
direction.
WARNING
contact with floor.
1.6 kph (1 mph).
in towing path.
than 305 mm (12.0 in) off floor.
• Power should be ON if steering is not inhibited and Figure 23112

the operator can be on towed vehicle if steering is
not inhibited. 1 Skirt
• If standard brake release pedal does not function,

then release brakes with brake tow switch. Refer to
Brake in this section. WARNING
Pushing Vehicle Minimum Requirements: Braking force is not applicable if brakes are to be re-
leased with brake tow switch.
• Gross vehicle weight of towed vehicle should not
Towing Guidelines:
exceed 4535 kg (10000 lb). Refer to data plate for
gross vehicle weight; include battery weight if it is • Maximum travel speed while towing truck is
in vehicle during towing. 1.6 kph (1 mph).
• Towing vehicle must have pushing/braking capac- • Steering pushed vehicle: If steering is operational,
ity greater than 3175 kg (7000 lb). a second operator should be on towed vehicle to
steer truck in a straight line to get it out of aisle.
Once outside of aisle, follow previous procedure
for towing truck by pulling in power unit first direc-
tion. If steering is inhibited, push vehicle in a
straight line out of aisle with no operator on towed
truck. Once outside of aisle, make necessary re-
pairs to re-gain steering operation, then follow pre-
vious procedure for towing truck by pulling in
power unit first direction.
• Allow sufficient distance for truck to coast to stop at

final destination.
MA-7435-107 SP3500 Crown 2009 PF17831-8
12
SAFETY

Pulling in Power Unit First Direction
WARNING
• Towed truck must always maintain two contact
points with floor.
1.6 kph (1 mph).
in towing path.
than 305 mm (12 in) off floor.
• Gross vehicle weight should not exceed 4535 kg

(10000 lb). Refer to data plate for gross vehicle Figure 23079
weight; include battery weight if it is in vehicle dur-
1 Holes in Skirt for Eyelets
ing towing.
• Avoid damaging underside of towed vehicle with Towing by Lifting Truck and
towing device (i.e., remove wire guidance sensor). Pulling in the Forks First Direction
• No operator on towed vehicle.
Lifting Vehicle Requirements: WARNING
• Truck should be capable of traveling and braking Towing by lifting truck and pulling in the forks first
when towing a truck weighing 4535 kg (10000 lb). direction is not recommended.
• Towing device should be capable of safely lifting

2720 kg (6000 lb) at skirt of towed vehicle.
Towing Guidelines:
WARNING
Do not lift towed truck higher than 51 mm (2 in) off
floor.
• No operator on towed truck.
• Lift and tow from center of power unit skirt.
• Ensure towed vehicle does not uncouple from tow-

ing vehicle and that towing point remains at center
of skirt (see Figure 23079).
Crown 2009 PF17831-9 SP3500 MA-7435-108
13
SAFETY
Lifting and Blocking 1 100 x 100 mm (4 x 4 in) Hardwood Block

2 Load Wheel
3 See Warning
4 See Warning
• No load on forks. 5 Side

NOTES:
• Hydraulic Jack Capacity: 3620 kg (8000 lb)

• Crown Part Number: 122599
• Collapsed Height Minimum: 60 mm (2.25 in)
• Raised Height Maximum: 400 mm (16 in)
• Jack Stand Capacity: 4500 kg (10000 lb)

• Commercially Available.
WARNING
Truck stability decreases dramatically if load wheels
are raised more than 60 mm (2.5 inch). Attach sling
and overhead lifting device to all cross members of the
mast to prevent truck from tipping over when raising
the side of the truck.
Do not raise platform more than 150 mm (6 in) from
floor.
Figure 14984-01
WARNING
Before raising truck, check that jack does not interfere
with wire guide sensors.
1 Set jack stand height as required. Not to exceed 400 mm
(16 in). Locate jack stands and jack on truck skirt.
2 Chock both load wheels
3 Raise platform 70 - 150 mm (3 - 6 in) from floor
4 Steer wheel
Figure 14983-01
MA-7435-109 SP3500 Crown 2009 PF17831-10
14
SAFETY
Mast
Blocking Masts
Use 100 x 100 mm (4 x 4 in) or bigger hardwood blocks
of the appropriate length for supporting the mast chan-
nels. Block both mast rails of each stage to maintain
truck stability.
Remove any carriage mounted accessories (i.e., roll
loader, etc.) before blocking masts. These accessories
add significant weight to the mast.

• Chock wheels of truck (refer to Lifting and Blocking

in this section).
• Connect battery.
Figure 16833-02
• Raise forks and position blocks under first stage
1 Clamps
mast of appropriate length. Do not block the first
stage mast when work at the main frame base is to 2 Set Under platform
be performed. Set blocks under the platform only, 3 Set under first stage
as described in the following steps.
• Using clamps, secure blocks to mast channel.
• Using the manual lowering valve, lower platform

and position appropriate length blocks under plat-
form frame in mast channels.
• Using clamps, secure blocks to mast channel or

first stage block.
• Continue to lower platform until platform frame

rests on blocks.

Crown 2009 PF17831-11 SP3500 MA-7435-110
15
Notes:
16
SAFETY
Cleaning of Material Handling Equipment
Cleaning of Material Handling operation or immediate failure could be the resultant of

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

Degreaser & Cleaner 363105-001 20 oz. Can
363105-012 (12) 20 oz. Cans
All Purpose Cleaner 363114-001 20 oz. Can
363114-012 (12) 20 oz. Cans
Glass Cleaner 363101-001 20 oz. Can
363101-012 (12) 20 oz. Cans
Waterless Hand Cleaner 363111-001 15 oz. Tube
363111-012 (12) 15 oz. Tubes
Pumiced & Smooth Hand Cleaner 363112-001 1 Gallon Jug
363112-004 (4) 1 Gallon Jugs
Wall Mounted Deluxe Soap Dispenser 363122 Used with 363112-001
Tough On Grease 063009-005 1 Gallon Jug
Crown 2000 PF11969-1 Rev. 10/06 SP3500 MA-1140-050

02 Rev. 10/06
17
Notes:
18
INTRODUCTION
19
Notes:
20
INTRODUCTION
Introduction
Introduction Service Training

This manual is intended for the service technician who Complete Service Training is available to the lift truck
is seeking information about maintenance and service technician covering all Crown Lift Trucks,
replacement parts. It contains a section on trouble ACCESS 123® systems, wire guidance, hydraulic and
shooting which will enable a qualified technician to lo- electrical systems. To obtain more information con-
cate and solve problems which may occur. cerning service training, contact your Crown Dealer or
under "Training" on www.crown.com.
Operator Instructions
Replacement Parts
This manual does not contain operation instructions.
Operator Instructions in tag or booklet form are sent When ordering replacement parts from this manual, al-
with each truck. Additional copies can be ordered if re- ways specify, along with the part number, the model
quired. These booklets are for you and your personnel and serial number of the truck. This information will fur-
to insure years of safe, trouble-free operation of your ther enable us to give correct, fast and efficient service.
Crown Lift Truck. For SP 3500 Series operator instruc-
For current part number of operator manuals, service
tions, refer to Crown publication, "Operator Manual
manuals, operator training programs, truck capacities
SP 3500 Series".
and technical specifications, contact your dealer or at
www.crown.com.
Operator Training This manual is arranged according to major sections
which covers maintenance and replacement parts. The
Crown has available a complete series of operator
sectional descriptions are as follows:
training programs, available through your local Crown
dealer. A complete listing of these and other available
programs can be found under "Training" on
www.crown.com
MAINTENANCE REPLACEMENT PARTS
SECTION DESCRIPTION SECTION DESCRIPTION

M1 Lubrication and Adjustment 1 Power Unit Parts
M2 Hydraulic 2 Hydraulic Parts
M3 Drive Unit 3 Drive Unit Parts
M4 Electrical 4 Electrical Parts
M5 Brake 5 Brake Parts
M6 Steering 6 Steering Parts
M7 Lifting Mechanism 7 Lifting Mechanism Parts
M8 Cylinders 8 Cylinder Parts
M9 Platform 9 Platform Parts
M10 Glossary 10 Labels and Decals
Crown 2010 PF17901-1 SP3500 ITD-7635-001
21
INTRODUCTION
Introduction
Data Plate
The data plate for the SP 3500 Series truck is located
on the lower right corner, mast side, of the platform and
includes a model number and truck data number. From
these two numbers, you can identify the truck model,
series, series updates, determine performance, capac-
ity and specific truck data. The following pages explain
the model & truck data numbering system.
Truck Data Plate
Figure 18273
Model Number Example

Series Update
Significant change(s) to the product
* Capacity
that would not merit a new series
1.25 = 1250 kg (2755 lb)
number (generation).
Image Generator
SP - Stockpicker SP3571-1.25
Performance
Series
71/81 Two speed raise & lower, 3.0 kw (4.0 hp) drive
Major technical and design changes motor, 11.3 kph (7 mph) maximum travel
making product a new and improved speed and 1085 maximum amp. hr. capacity
generation.
Example of the model number shown above *Actual rated capacity may vary, depending on special
(SP 3571-1.25) is a SP 3500 Series truck. It is equipment or modifications. Consult capacity plate lo-
equipped with two speed raise & lower, AC traction mo- cated on the overhead guard. Refer to Figure 23404.
tor and 1250 kg (2755 lb) capacity.
ITD-7635-002 SP3500 Crown 2010 PF17901-2
22
INTRODUCTION
Introduction
Capacity Plate
Figure 23404
Data Number
The truck data number provides you and your Crown
dealer with a wealth of information to insure the selec-
tion of proper parts for your Crown truck. You may sim-
ply provide this number to your Crown dealer, or use
the following breakdown if selecting your own part
numbers or service information from this manual.
Crown 2010 PF17901-3 SP3500 ITD-7635-003
23
INTRODUCTION
Introduction
Truck Data Number Example

Switch Panel
Drive Tires 1 = Standard
Wire Guidance CG = Center Groove 2 = Lift/Lower Limit Override
- = No Wire Guidance DS = Diagonal Siped 3 = Lift/Lower Limit Override,
W = Wire Guidance PP = Poly, Black Zone Select
40 = Poly, Cream 4 = Work Light, Dome Light, Fan
RS = Razor Siped 5 = Lift/Lower Limit Override,
NM = Poly, Non Marking Work Light, Dome Light, Fan
Straddle Width ** = Special 6 = Lift/Lower Limit Override,
1067 mm (42 in) through Zone Select, Work Light, Dome
1830 mm (72 in) in 25 mm Light, Fan
(1.0 in) increments 7 = Work Light, Dome Light,
Fan, Spotlight
8 = Lift/Lower Limit Override,
Mast Type Work Light, Dome Light, Fan,
TT = Telescopic Triple Stage Spotlight
9 = Lift/Lower Limit Override,
Zone Select, Work Light, Dome
Light, Fan, Spotlight
- TT 4995 1090 ----- - F NM 1070 9 C

Standard/Custom/Special Application
- = Standard - = Standard
C = Custom 1 = EAC
S = Special
Platform Width
Lift Height 1070 mm (42 in)
4955 mm (195 in) 1220 mm (48 in)
5335 (210 in) 1370 mm (54 in)
6095 (240 in) 1525 mm (60 in)
7010 (276 in) 1625 mm (64 in)
7470 (276 in)
7925 (312 in) Cold Conditioning
8385 (330 in) - = No Cold Conditioning/Wire Mesh Windshield
8840 (348 in) C = Corrosion Conditioning/Wire Mesh Windshield
9330 (366 in) F = Freezer Conditioning/Wire Mesh Windshield
Aisle Guide Wheel Width

Display Aisle Guide Wheel Width i.e.
292 = 292 mm
----- = No Rail Guidance
***** = Special Aisle Guide
ITD-7635-004 SP3500 Crown 2010 PF17901-4
24
25
Notes:
26
Lubrication and Adjustment Before performing maintenance to any unit, it should

be taken to an area set aside for maintenance or a sec-
To obtain maximum life of any industrial equipment, a tion where there is adequate space to perform required
well planned maintenance program (PM), performed work. This is a must to insure the safety of others and
by qualified technical personnel should be followed. In to insure that proper maintenance is performed to the
conjunction with, and an integral part of, any planned unit.
maintenance program should be daily operator input.
If desired, padded packs of this checklist (OF-3772)
Operator involvement can greatly reduce truck down
are available through your Crown dealer.
time, assist in determining planned maintenance (PM)
schedules and ultimately save money. For these rea-
sons, Crown recommends a checklist similar to the Op-
erators Daily Checklist shown below.
Figure 14990
Crown 1987 PF7886-1 Rev. 6/08 SP3500 M1.0-04.0-001

17 Rev. 6/08
27
The following is a list of lubricants and maintenance

products recommended when doing Planned Mainte-
nance on Crown Lift Trucks.

363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB(1) Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
C Oil (SAE 40)
363500-001 1 Quart
CC Engine Oil (10W30)
363500-012 (12) 1 Quart
363504-101 1 Gallon
D Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD(1) Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon
DDD Hydraulic Oil - DTE24 063001-021 1 Gallon
063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
063002-039 1 lb
I Grease (Lift Pump Coupling)
127801S 1 oz
063004-002 12 oz
J Brake Fluid - Dot 5
063004-003 1 Gallon
M1.0-04.0-002 SP3500 Crown 1987 PF7886-2 Rev. 6/08
17 Rev. 6/08
28

063002-034 14.5 oz Cartridge
K Grease (Wheel Bearing)
063002-045 (40) 14.5 oz Cartridges
L Metal Assembly Spray 063002-021 11 oz Spray
M Silicone Grease (Clear) 063002-020 5.3 oz Tube
363102-001 14 oz Can
Brake & Parts Cleaner
363102-012 (12) 14 oz Cans
363103-001 14 oz Can
N Low VOC Brake & Parts Cleaner
363103-012 (12) 14 oz Cans
363116-001 19 oz Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 19 oz Cans
363104-001 20 oz Can
O Penetrating Lubricant
363104-012 (12) 20 oz Cans
363108-001 11 oz Can
P Premium Formula Multi-Purpose Grease
363108-012 (12) 11 oz Cans
363110-001 11 oz Can
Q White Lithium Grease
363110-012 (12) 11 oz Cans
363109-001 15 oz Can
R Choke & Carburetor Cleaner
363109-012 (12) 16 oz Cans
363106-001 10 oz Can
Contact Cleaner - Non-Flammable
363106-012 (12) 10 oz Cans
S
363128-001 11 oz Can
Contact Cleaner
363128-012 (12) 11 oz Cans
T Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc
363124-001 18 oz Can
U Battery Cleaner
363124-012 (12) 18 oz Cans
363125-001 15 oz Can
V Battery Protector
363125-012 (12) 15 oz Cans
363127-001 12 oz Can
W Food Grade Machine Lubricant
363127-012 (12) 12 oz Cans
363126-001 11 oz Can
X Food Grade Silicone Spray
363126-012 (12) 11 oz Cans
363509-101 1 Gallon
Coolant
363509-106 (6) 1 Gallon
Y
363511-101 1 Gallon
Extended Life Coolant
363511-106 (6) 1 Gallon
Crown 1987 PF7886-3 Rev. 6/08 SP3500 M1.0-04.0-003

17 Rev. 6/08
29
Manufacturer
/ Distributor
A Gear Lube 80W-90 (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
Union Unoba EP No 2 Union 76 Co.
B Grease (Multi-Purpose) Retinax A(1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease (Low Temp) (2) Alvania RA(1) Shell
Helveum O(1) Burmah Castrol
BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
C Oil (SAE 40)
D Hydraulic Oil Crown Crown
DD Hydraulic Oil (Low Temp) (2) Crown Crown
DDD Hydraulic Oil - DTE24 (3) Mobil DTE 24 Mobil

E Channel Grease Factran #2 Standard Oil Co.
F Gear, Channel & Shaft Grease Molykote BR-2 Plus Dow Corning
Chain & Cable Lube Crown Crown
G
Premium Chain & Cable Lube Crown Crown
H Final Finish - Rubber & Vinyl Dressing Crown Crown
I Grease (Lift Pump Coupling) Nyogel 774F-MS NYE Lubricants
J Brake Fluid - Dot 5 Q2-1141 Silicon Brake Fluid Dow Corning
K Grease (Wheel Bearing) Unirex EP-2 Exxon
Lubriplate No. 1242(1) Fiske Bros. Refining Co.
L Metal Assembly Spray Dow Corning Dow Corning
M Silicon Grease (Clear) Dow Corning 111 Compound Dow Corning
Brake & Parts Cleaner Crown Crown
N Low VOC Brake & Parts Cleaner Crown Crown
Non-Flammable Brake & Parts Cleaner Crown Crown
(1) Denotes allowable substitutes, contact factory if unavailable.
(3) Premium antiwear hydraulic oil used in blending with low temp oil.
M1.0-04.0-004 SP3500 Crown 1987 PF7886-4 Rev. 6/08
17 Rev. 6/08
30
Manufacturer
/ Distributor
O Penetrating Lubricant Crown Crown
P Premium Formula Multi-Purpose Grease Crown Crown
Q White Lithium Grease Crown Crown
R Choke & Carburetor Cleaner Crown Crown
S Contact Cleaner Crown Crown
Electrical Connector Oxidation &
T Nye Grease NYE Lubricants
Corrosion Inhibitor
U Battery Cleaner Crown Crown
V Battery Protector Crown Crown
W Food Grade Machinery Lubricant Crown Crown
X Food Grade Silicone Spray Crown Crown
Y Extended Life Coolant
Crown 1987 PF7886-5 Rev. 6/08 SP3500 M1.0-04.0-005

17 Rev. 6/08
31
Notes:
32
Planned Maintenance
Planned Maintenance the oil companies; those listed below are typical and
any lubricant with equal specifications may be used.
(See Lubrication Identification Chart in Lubrication and
WARNING Adjustment).
On trucks equipped to operate in below freezing tem-
Wear appropriate items, such as safety glasses and peratures, low temperature hydraulic oil must be used.
work. Do not place fingers, hands or arms through
mast or position them at pinch points. Component Accessibility
truck and mast or raise and lower different components For regular maintenance, access to various truck com-
for removal and installation. Make sure lifting device ponents is accomplished by removing covers, panels
and sling are sufficiently rated to withstand the weight and/or doors. The following is a general explanation of
being lifted. Never work under or around a truck that is what cover, panel, etc. must be removed to allow for
not properly secured. Refer to truck Data Plate for truck the most efficient access when performing service and/
weight information. or maintenance to components. Refer to figures in this
It will be necessary to disconnect and remove the bat- section as an aid in locating parts that require attention.
tery from the truck, disconnect tilt cylinders from the More details are given in following sections on hydrau-
mast, disconnect electrical connections and hydraulic lics, electrical, brakes, etc.
lines. "Control of Hazardous Energy" section provides Top cover can be opened to allow access to battery
information for performing the above procedures along connector, battery cell caps, check battery condition,
with some additional information on other procedures strobe light, and additional mechanical and electrical
dealing with truck maintenance. This section should be components.
and maintenance as outlined in this section. Battery side covers can be removed to service and/or
remove battery.
General Power unit doors can be opened to allow access to the

following: drive unit, ACCESS 123® modules, power
Before performing maintenance to the truck, move unit distribution panel lift/power panel, drive motor,
truck to an area set aside for maintenance or where electric brake and related components, steer motor/en-
there is adequate space to perform required work. This coder and related components, lift pump(s) and mo-
is a must to ensure safety of others and to ensure tor(s), hydraulic reservoir, filter, strainer and related
proper maintenance is performed. components.
Located under platform are horn, pallet grab, fork pins
and associated parts.
WARNING
Console on platform, when removed, will allow access
Be sure battery connectors are disconnected and all to side-gate switches, steering command encoder, dis-
wheels are chocked before proceeding. play, platform distribution panel and associated plat-
To obtain maximum life of any industrial equipment, a form electrical wiring.
well planned maintenance program should be fol- Located on front side of platform are chain slack
lowed. The following information is intended to provide switches, pallet grab linkage and height reset
guidelines for proper lubrication intervals; this is ac- switch(es).
cording to hours of truck operation and/or a specific
number of days or months. These recommended fig- Control module must be removed to gain access to di-
ures should be used as an aid in maintaining safe and rectional and lift switches, various control switches and
efficient truck operation. Some operating conditions will linkages.
require more frequent checks and lubrication than Refer to figures and charts in this section as a guide for
listed. Applications with much dust or moisture will re- inspection and adjustment that may be necessary. This
quire modification of the schedule to fit that particular information used with a Planned Maintenance Inspec-
application. tion Report for Stock pickers available from your Crown
Only high grade lubricants and fluids should be used. dealer will be very helpful to a good maintenance pro-
Sources of these lubricants may be from almost any of gram.
Crown 2010 PF17906-1 SP3500 M1.0-7635-001
33
Planned Maintenance
Figure 23405
M1.0-7635-002 SP3500 Crown 2010 PF17906-2
34
Planned Maintenance

Type 250 hr 500 hr 1000 hr 2000 hr
L-1 Brake Pedal Guides C (1) (2)
L-2 Platform Gates C (1) (2)
L-3 Battery Cover Hinge C (1) (3)
L-4 Power Unit Door Hinges C (1) (2)
L-5 Battery Rollers B (1) (3)
L-6 Battery Restraint Threads B (1) (2)
L-7 Aisle Guide Wheels B (1) (3)
L-8 Load Wheel Axles B (1) (3)
(1) - As Required
(2) - Check
(3) - Lubricate
See Lubrication Identification Chart in Lubrication & Adjustment for Lube Type explanation and capacity.

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-1 Brake Pedal Switch (1)
I-2 Brake Pedal Mechanism (1)
I-3 Platform Gates and Switches (1)
I-4 Load Wheels (1)
I-5 Aisle Guide Wheels and Switches (1)
(1) - Inspect, Clean and/or Adjust. See Figure 23405 for component locations.
adjustment.
Crown 2010 PF17906-3 SP3500 M1.0-7635-003
35
Planned Maintenance
Figure 23406
M1.0-7635-004 SP3500 Crown 2010 PF17906-4
36
Planned Maintenance

Type 250 hr 500 hr 1000 hr 2000 hr
Mast, Channels, Column
L-9 E (1) (2)
Rollers
L-19 Mast Hoses H (1) (2)
(1) - As Required
(2) - Check

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-8 Battery Connector (1)
I-9 Battery (1)
I-10 Strobe Light/Flashing Light (1)
I-11 Lift Cylinders and Restraints (1)
I-12 Column Rollers - Mast (1)
I-13 Column Rollers - Platform (1)
I-14 Two Hand Handle Operation (1)
I-15 Forks (1)
I-16 Motor Brushes - Lift (1)
I-17 Motor Brushes - Power Steering (1)
I-18 Hydraulic Lines, Fittings, Hoses (1)
I-19 Power Unit to Mast Bolts (1)
adjustment.
Crown 2010 PF17906-5 SP3500 M1.0-7635-005
37
Planned Maintenance
Figure 23407
M1.0-7635-006 SP3500 Crown 2010 PF17906-6
38
Planned Maintenance

Type 250 hr 500 hr 1000 hr 2000 hr
L-10 Lift Chain G (1) (2)
L-11 Pallet Grab Linkage C (1) (2)
(1) - As Required
(2) - Check

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-20 Lift Chains (1)
I-21 Chain Anchors and Retainers (1)
I-22 Chain Slack Linkage (1)
I-23 Brake Friction Plates and Operation (1)
I-24 Pallet Grab Linkage and Operation (1)
I-25 Horn (1)
I-26 Height Sensor (1)
I-27 Steering Command Encoders (1)
adjustment.
Crown 2010 PF17906-7 SP3500 M1.0-7635-007
39
Planned Maintenance
Figure 23408
M1.0-7635-008 SP3500 Crown 2010 PF17906-8
40
Planned Maintenance

Type 250 hr 500 hr 1000 hr 2000 hr
L-12 Steering Gearbox Oil Level DDD (1) 1 liter (1 qt) (2) (2)
L-13 Steering Gears F (3) (4)
L-14 Hydraulic Filter (4) (2) (2)
Hydraulic Reservoir - Dual

L-15 D 17.5 liter (18.5 qt) (4) (2)
Pump
L-16 Hydraulic Strainer (2)
L-17 Drive Unit Thrust Bearing B (3) (5)
L-18 Drive Unit Fluid Level A 0.7 liter (0.75 qt) (4) (2)
(1) - Use “DDD” (see Lubrication and Adjustment) hydraulic oil in steering gearbox for both normal and
low temperature applications.
(2) - Change; for L-12 and L-14, change first time only as noted, thereafter check at 250 hr/60 day inter-
vals and change at longer interval as noted.
(3) - As Required
(4) - Check
(5) - Lubricate

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-28 Contactor Tips (1)
I-29 Steering Gears and Sprockets (1)
I-30 Chain Slack and Chain Break Switches (1)
I-31 Stop Blocks (1)
I-32 Drive Tire (1)
I-33 All Electrical Termination Points (1)
adjustment.
Crown 2010 PF17906-9 SP3500 M1.0-7635-009
41
Planned Maintenance
Figure 23409
M1.0-7635-010 SP3500 Crown 2010 PF17906-10
42
Planned Maintenance

Type 250 hr 500 hr 1000 hr 2000 hr
Control Cables and Pulleys
L-20 H (1) (2)
(Plastic)
(1) - As Required
(2) - Check

Index Component
250 hr 500 hr 1000 hr 2000 hr
I-34 Travel and Lift Controls (1)
I-35 Power Disconnect (1)
I-36 Panel Indicator Lights (1)
I-37 Panel Switches (1)
I-38 Cable Tension Devices (1)
I-39 Control Cables and Guides (1)
I-40 Mast Cushion Mechanisms (1)
Drive/Tow Switch and Power Unit Distribution

I-41 (1)
Panel
I-42 Overhead Console Lights (1)
I-43 Overhead Console Fan (1)
adjustment.
Crown 2010 PF17906-11 SP3500 M1.0-7635-011
43
Notes:
44
Componentry
Componentry • Adjustments required, if applicable.
• Wiring diagram page(s) on which the component

Introduction appears has one additional number immediately
following the wiring diagram page number. This
Components listed in this section have been alphabet- number (in parenthesis) is the grid coordinate (i.e.,
ically categorized to assist the service technician with DIA-7435-003 (B-2).
the following information for each component:
• Parts page on which the component appears has
• Component designator (i.e., ACCESS 1) that will
one additional number immediately following the
be found on the wiring diagram and parts pages. parts page number. This number (in parenthesis) is
• Description of the component. the index number of the component (i.e.,
09.0-7535-001 (8).
• Location of the component on the truck.
• Purpose of the component.
• Technical data of the component.
Crown 2010 PF17915-1 SP3500 M1.0-7635-050
45
Audible Indicators
Audible Indicators HN2

Travel Alarm (Optional)
ALM1
Location: platform side of power unit near bottom.
Location: distribution panel on platform.
Purpose: alert pedestrians of truck movement re-
Purpose: status alarm. quest.
Data: audible warning when operator performs incor- Data: can set to sound in forward or reverse direction.
rect sequence. ACCESS 1 supplies negative and K1 Receives +BV from K15 relay and BNEG from negative
supplies +BV to ALM1. View ACCESS 1 output to bus bar.
ALM1 from Analyzer, A3.1.1 menu.
Adjustment: none required.
Diagrams: DIA-7435-002 (B-3)
Diagrams: DIA-7435-003 (A-2) DIA-7435-004 (B-3)
DIA-7435-005 (A-2) DIA-7435-018 (A-2)
DIA-7435-007 (B-2) DIA-7435-019 (B-2)
DIA-7435-008 (B-2)
Parts Breakdown: 04.0-7635-001 (9)
HN1
Horn
Location: on power unit side of platform, near the bot-
tom.
Purpose: provide operator controlled audible warning.
Data: 24-48 volt. Receives +BV from HNS (K1) and
BNEG from negative bus bar.
DIA-7435-005 (B-1)
DIA-7435-007 (B-1)
DIA-7435-011 (C-4)
M1.0-7635-051 SP3500 Crown 2010 PF17915-2
46
Audible Indicators
1 Platform Distribution Panel
Figure 23425
Crown 2010 PF17915-3 SP3500 M1.0-7635-052
47
Contactors
Contactors ED2
Emergency Disconnect Traction & Steering Con-
ED1 tactor
Location: contactor panel.
Emergency Disconnect Main Contactor
Purpose: provides power to ACCESS 3, ACCESS 5,
brake, BRK coils and motor management sensors.
Purpose: provides power to M3 and M4 pump motors
Data: coil: 24 V, 15 to 19 ohms. Coil receives positive
(via P1 and P2 contactor tips) and platform accesso-
voltage from ACCESS 5 and negative from
ries.
ACCESS 3. View ACCESS 3 output to ED2 coil from
Data: coil: 24 V, 15 to 19 ohms. Coil receives +BV Analyzer, A3.2.5 menu. View ACCESS 5 output to ED2
through K1 relay tips, BNEG from negative bus bar. coil from Analyzer, A3.4.1 menu.
Adjustment: none required. Adjustment: none required.
Diagrams - Coil: DIA-7435-002 (C-2) Diagrams - Coil: DIA-7435-002 (C-2)
DIA-7435-004 (C-2) DIA-7435-004 (C-2)
DIA-7435-006 (C-2) DIA-7435-006 (C-2)
DIA-7435-016 (C-2) DIA-7435-016 (C-2)
Diagrams - Contacts: DIA-7435-002 (A-4) Diagrams - Contacts: DIA-7435-002 (A-4)
DIA-7435-004 (A-4) DIA-7435-004 (A-4)
DIA-7435-006 (A-4) DIA-7435-006 (A-4)
DIA-7435-014 (C-3) DIA-7435-014 (C-2)
DIA-7435-020 (B-1) DIA-7435-020 (A-1)
Parts Breakdown: 04.3-7635-100 (1) Parts Breakdown: 04.3-7635-100 (1)
04.4-6540-001 04.4-6540-001
P1
Pump 1 Contactor
Purpose: provide +BV to pump 1 M3 motor.
Data: coil: 24 V, 15 to 19 ohms. Coil receives +BV from
RAS1 and negative from ACCESS 3. View ACCESS 3
output to P1 coil from Analyzer, A3.2.3 menu.
Diagrams: Coil: DIA-7435-002 (B-2)
DIA-7435-004 (B-2)
DIA-7435-006 (B-2)
DIA-7435-016 (C-2)
Contacts: DIA-7435-002 (B-1)
DIA-7435-004 (B-1)
DIA-7435-006 (B-1)
DIA-7435-020 (B-2)
M1.0-7635-053 SP3500 Crown 2010 PF17915-4
48
Contactors
Figure 23426
Crown 2010 PF17915-5 SP3500 M1.0-7635-054
49
Fans
P2 Fans
Pump 2 Contactor (Optional)
FAN1
Purpose: provide +BV to pump 2 M4 motor. Operator Fan
Data: coil: 24 V, 15 to 19 ohms. Coil receives +BV from Location: overhead console.
RAS2 and negative from ACCESS 3. View ACCESS 3
Purpose: operator comfort.
output to P2 coil from Analyzer, A3.2.2 menu.
Data: 24 V. FAN1 receives +BV from FNS and BNEG
from negative bus bar.
Diagrams: Coil: DIA-7435-002 (A-2)
DIA-7435-004 (A-2)
DIA-7435-016 (C-2) Diagrams: DIA-7435-012 (B-3)
Contacts: DIA-7435-002 (B-1) Parts Breakdown: 04.9-7335-050 (54)
DIA-7435-004 (B-1)
DIA-7435-020 (B-2)
FAN2
Power Unit Fan
Location: above ACCESS 3 module.
Purpose: cool ACCESS 3 module
Data: 24 V. FAN2 receives +BV from K2 relay and
BNEG from ACCESS 3. View ACCESS 3 output to
FAN2 from Analyzer, A3.2.4 menu.
Diagrams: DIA-7435-002 (A-2)
DIA-7435-004 (A-2)
DIA-7435-006 (A-2)
DIA-7435-014 (B-2)
M1.0-7635-055 SP3500 Crown 2010 PF17915-6
50
Fans
Figure 23427
Crown 2010 PF17915-7 SP3500 M1.0-7635-056
51
Cylinders
Cylinders ECR2
Steering Feedback Encoder
Free Lift Cylinder
Location: in front of traction motor.
Location: 3rd stage mast.
Purpose: provide steer wheel position feedback to
Purpose: raise platform. ACCESS 5.
Data: not applicable. Data: 5 V and negative provided by ACCESS 5, 256
pulses per revolution. View ECR2 input from Analyzer,
A2.4.1 menu.
Diagrams: HYD-7435-002
Adjustment: must be calibrated. For calibration proce-
Parts Breakdown: 08.3-7435-001 dures, see Electrical - ACCESS 123.
Mast Cylinder DIA-7435-004 (B-3)
DIA-7435-006 (B-3)
Location: mainframe. DIA-7435-015 (C-4)
Purpose: raise mast. Parts Breakdown: 04.8-7435-200 (3)
Data: not applicable.
Adjustment: none required. ECR3
Traction Speed Encoder
Parts Breakdown: 08.1-7435-001
Location: traction motor.
Purpose: provide speed and direction input to
Encoders ACCESS 3.
Data: 12 V and negative provided by ACCESS 3, 32
ECR1 pulses per revolution. View ECR3 input from Analyzer,
A2.2.1 menu.
Steering Command Encoder Adjustment: none required.
Location: steering command assembly. Diagrams: DIA-7435-002 (B-2)
Purpose: provide steering command input to DIA-7435-004 (B-2)
ACCESS 4. DIA-7435-006 (B-2)
DIA-7435-015 (C-4)
Data: 12 V and negative provided by ACCESS 4, 32
pulses per revolution. View ECR1 input from Analyzer, Parts Breakdown: 03.1-7335-001 (16)
A2.3.2 menu.
DIA-7435-005 (A-1)
DIA-7435-007 (A-1)
DIA-7435-010 (A-4)
M1.0-7635-057 SP3500 Crown 2010 PF17915-8
52
Cylinders
1 Free Lift Cylinder

2 Mast Cylinder
Figure 23428
Crown 2010 PF17915-9 SP3500 M1.0-7635-058
53
Fuses
ECR4 Fuses
Lift Height Encoder
FU1
Location: lower portion, mast side of platform.
Purpose: provide measured height of forks. Customer Accessories Fuse
Data: 5 volts D.C., 32 pulses per revolution. Location: distribution panel in power unit.
Adjustment: none required. Purpose: protect customer accessories and associ-
ated wiring from over-current.
DIA-7435-005 (A-2) Data: 15A.
DIA-7435-007 (A-2)
DIA-7435-010 (A-2)
DIA-7435-004 (A-4)
DIA-7435-006 (A-4)
ECR5 DIA-7435-009 (B-3)
Steering Command Encoder
Location: steering command assembly. FU2
Purpose: provide steering command input to
ACCESS 4. Control Circuit Fuse
Data: 12 V and negative provided by ACCESS 4, 32 Location: distribution panel in power unit.
pulses per revolution. View ECR5 input from Analyzer,
Purpose: protect control circuitry from over-current.
A2.3.2 menu.
Data: 15A.
DIA-7435-005 (A-1) Diagrams: DIA-7435-002 (A-4)
DIA-7435-007 (A-1) DIA-7435-004 (A-4)
DIA-7435-010 (A-4) DIA-7435-006 (A-4)
DIA-7435-009 (B-3)
M1.0-7635-059 SP3500 Crown 2010 PF17915-10
54
Fuses
1 The power unit distribution panel includes

nine fuses. FU1 is the fuse closest to the
relay. Fuses are numbered right to left
and in numeric order.
Figure 23429
Crown 2010 PF17915-11 SP3500 M1.0-7635-060
55
Fuses
FU3 FU6
Options Fuse Inner Brake Coil Fuse
Location: distribution panel in power unit. Location: distribution panel in power unit.
Purpose: protect ACCESS 3, ACCESS 5 and Purpose: protect brake inner coil and associated wir-
ACCESS 6 control circuit, PVL coil, FAN2, SVL coil, ing from over-current.
power unit chain slack switches and associated wiring
Data: 15A.
from over-current.
Data: 15A.
DIA-7435-004 (A-3)
Diagrams: DIA-7435-002 (A-4) DIA-7435-006 (A-3)
DIA-7435-004 (A-4) DIA-7435-009 (B-2)
DIA-7435-006 (A-4)
DIA-7435-009 (B-3)
FU7
FU4 Customer Accessories Fuse
Location: distribution panel in power unit.
Manual Brake Fuse
Purpose: protect customer accessories and associ-
Purpose: protect travel alarm, drive/tow switch and as-
Data: 15A.
sociated wiring from over-current.
Data: 15A.
DIA-7435-004 (A-1)
DIA-7435-004 (A-4) DIA-7435-009 (B-3)
DIA-7435-006 (A-4)
DIA-7435-009 (B-3)
FU8
FU5 Spot Lights and Operator Fan Fuse
Location: lift/power panel in power unit.
Outer Brake Coil Fuse
Purpose: protect spot lights, operator fan and associ-
Purpose: protect brake outer coil and associated wir-
Data: 15A.
ing from over-current.
Data: 15A.
DIA-7435-004 (A-1)
DIA-7435-004 (A-3) DIA-7435-009 (B-3)
DIA-7435-006 (A-3)
DIA-7435-009 (B-2)
M1.0-7635-061 SP3500 Crown 2010 PF17915-12
56
Fuses
1 The power unit distribution panel includes nine fuses. FU1 is the fuse closest to the
relay. Fuses are numbered right to left and in numeric order.
Figure 23430
Crown 2010 PF17915-13 SP3500 M1.0-7635-062
57
Fuses
FU9 FU12
Dome and Work Lights Fuse Freezer/Condition Platform Fuse (Optional)
Location: power unit distribution panel. Location: freezer/condition panel on power unit.
Purpose: protect dome, work lights and associated Purpose: protect freezer condition components
wiring from over-current. equipped on platform and associated wiring from over-
current.
Data: 15A.
Data: 15A.
DIA-7435-004 (A-1) Diagrams: DIA-7435-018 (B-1)
DIA-7435-006 (A-1)
DIA-7435-009 (B-3)
FU13
FU10 Pump 1 Motor 3 Fuse
Location: contactor panel in power unit.
ACCESS 5 Fuse
Purpose: protect traction motor and associated wiring
from over-current.
Purpose: protect ACCESS 5 and associated wiring
Data: 300A.
from over-current.
Data: 50A.
DIA-7435-004 (B-1)
DIA-7435-004 (A-3) DIA-7435-020 (A-1)
DIA-7435-006 (A-3)
DIA-7435-014 (C-2)
DIA-7435-020 (A-1)
Parts Breakdown: 04.3-7635-100 (23) FU14
Pump 2 Motor 4 Fuse
FU11
Freezer/Condition Power Unit Fuse (Optional) Purpose: protect pump 2 motor 4 and associated wir-
ing from over-current.
Location: freezer/condition panel on power unit.
Data: 300A.
Purpose: protect freezer condition components
equipped on power unit and associated wiring from Adjustment: none required.
over-current.
Data: 15A. DIA-7435-004 (B-1)
DIA-7435-020 (A-1)
M1.0-7635-063 SP3500 Crown 2010 PF17915-14
58
Fuses
1 Freezer/Condition Panel
Figure 23431
Crown 2010 PF17915-15 SP3500 M1.0-7635-064
59
Lights
FU15 LGT3, 6
ACCESS 3 Fuse Dome Lights (Optional)
Location: contactor panel in power unit. Location: overhead console.
Purpose: protect ACCESS 3 and associated wiring Purpose: provide light inside operator compartment.
from over-current.
Data: 12 volt. PS2 power supply provides 12 V to LGT3
Data: 400A. and LGT6 dome lights.
Adjustment: none required. Adjustment: none available.
Diagrams: DIA-7435-002 (B-2) Diagrams: DIA-7435-012 (B-2, B-4)
DIA-7435-004 (B-2)
Parts Breakdown: 04.9-7335-050 (7, 59)
DIA-7435-006 (B-2)
DIA-7435-020 (A-1)
Parts Breakdown: 04.3-7635-100 (22) LGT4, 7
Platform Spot Lights (Optional)
Lights Location: overhead console.
Purpose: provide work area light outside operator
LGT1 compartment.
Data: 24 volt. LGS3 provides 24 V to LGT4 and LGT7
Strobe or Flashing Light
platform spot lights.
Location: power unit.
Adjustment: none available.
Purpose: visual warning of lift truck presence.
Diagrams: DIA-7435-012 (C-2, C-3)
Data: 24 volt. DIA-7435-013 (C-2, C-3)
Adjustment: none required. Parts Breakdown: 04.9-7335-050 (38, 88)
DIA-7435-004 (B-1) LGT8, 9
DIA-7435-006 (B-1)
DIA-7435-016 (C-3) Mast Mounted Spot Lights (Optional)
Parts Breakdown: 04.9-7330-001 Location: mast.
LGT2, 5 compartment.
Data: 24 volt. LGS3 provides 24 V to LGT8 and LGT9
Work Lights (Optional)
mast mounted spot lights.
Location: overhead console or mast.
Adjustment: none available.
Diagrams: LGT8, and LGT9 are not shown. For LGT8
compartment.
and LGT9 +BV connection (see PC338), refer to
Data: 12 volt. PS1 power supply provides 12 V to LGT2 DIA-7435-012 (B-2).
and LGT5 work lights.
Parts Breakdown: 04.9-7332-250
Adjustment: minimal manual directional adjustment.
Diagrams: DIA-7435-012 (C-1, C-4)
Parts Breakdown: 04.9-7335-050 (2, 71)
M1.0-7635-065 SP3500 Crown 2010 PF17915-16
60
Lights
1 Left Side
2 Right Side - Shown
Figure 23432
Crown 2010 PF17915-17 SP3500 M1.0-7635-066
61
Miscellaneous
Miscellaneous BW-P2
Pump 2 Motor M4 Brush Wear Sensor
ACCUMULATOR
Location: in M4 motor
Location: center, lower portion of power unit.
Purpose: cause an event if M4 motor brushes require
Purpose: shock absorber for lift/lower hydraulic sys- replacement.
tem.
Data: provides +BV input signal to ACCESS 3. View
Data: pre-charge 3445 kPa (500 psi). input from Analyzer, A2.2.6 menu.
Adjustment: refer to Hydraulic, Accumulator section Adjustment: none required.
of service manual.
Diagrams: DIA-7435-016
CS1
BRK
Current Sensor
Brake
Location: traction motor.
Purpose: monitors current flow in the negative cable.
Purpose: provide braking force to traction motor to Inputs signal to ACCESS 5.
stop truck and prevent movement of parked vehicle.
Data: 5 V and BNEG provided by ACCESS 5. View in-
Data: electrically released and spring applied. ED2 put to ACCESS 5 from Analyzer, A2.4.7 menu.
supplies +BV and ACCESS 5 supplies negative to
BRK1. View ACCESS 5 outputs to BRK1 from Ana-
lyzer, A3.4.2 and A3.4.3 menu. Diagrams: DIA-7435-002 (B-3)
DIA-7435-004 (B-3)
Adjustment: refer to Brake section of service manual.
DIA-7435-006 (B-3)
DIA-7435-004 (A-3)
DIA-7435-006 (A-3)
DIA-7435-015 (C-3)
Parts Breakdown: 05.3-7335-001 EACA1
End Aisle Control Sensor
BW-P1
Location: below battery compartment.
Pump 1 Motor M3 Brush Wear Sensor Purpose: sense end aisle control floor magnets. Inputs
signal to ACCESS 6.
Data: sensor receives 12 V and BNEG from
Purpose: cause an event if M3 motor brushes require
ACCESS 6. View EACA1 input to ACCESS 6 from An-
replacement.
alyzer, A2.5.3 menu.
input from Analyzer, A2.2.6 menu.
Diagrams: DIA-7435-002 (C-4)
DIA-7435-004 (C-4)
Diagrams: DIA-7435-016 DIA-7435-017 (A-1)
Parts Breakdown: 02.2-7330-050 (7) Parts Breakdown: see table of contents
M1.0-7635-067 SP3500 Crown 2010 PF17915-18
62
Miscellaneous
1 Accumulator
2 Mounted below battery compartment
Figure 23433
Crown 2010 PF17915-19 SP3500 M1.0-7635-068
63
Miscellaneous
EACA2 EACB2
End Aisle Control Sensor End Aisle Control Sensor
Location: below battery compartment. Location: below battery compartment.
Purpose: sense end aisle control floor magnets. Inputs Purpose: sense end aisle control floor magnets. Inputs
signal to ACCESS 6. signal to ACCESS 6.
Data: sensor receives 12 V and BNEG from Data: sensor receives 12 V and BNEG from
ACCESS 6. View EACA2 input to ACCESS 6 from An- ACCESS 6. View EACB2 input to ACCESS 6 from An-
alyzer, A2.5.4 menu. alyzer, A2.5.6 menu.
Adjustment: none required. Adjustment: none required.
Diagrams: DIA-7435-002 (C-4) Diagrams: DIA-7435-002 (C-4)
DIA-7435-004 (C-4) DIA-7435-004 (C-4)
DIA-7435-017 (A-2) DIA-7435-017 (A-2)
Parts Breakdown: see table of contents Parts Breakdown: see table of contents
EACB1 FIL1
End Aisle Control Sensor Flashing Light Filter
Location: below battery compartment. Location: below flashing light on support bracket.
Purpose: sense end aisle control floor magnets. Inputs Purpose: suppress voltage spikes.
signal to ACCESS 6.
Data: sensor receives 12 V and BNEG from
ACCESS 6. View EACB1 input to ACCESS 6 from An-
alyzer, A2.5.5 menu. Diagrams: DIA-7435-002 (B-2)
DIA-7435-004 (B-2)
DIA-7435-006 (B-2)
Diagrams: DIA-7435-002 (C-4) DIA-7435-016 (C-3)
DIA-7435-004 (C-4)
DIA-7435-017 (A-1)
Parts Breakdown: see table of contents
FILTER
Return
Location: near upper portion of reservoir.
Purpose: remove contaminants from hydraulic fluid.
Data: 10 micron.
M1.0-7635-069 SP3500 Crown 2010 PF17915-20
64
Miscellaneous
1 Filter
2 Mounted below battery compartment
3 EAC distribution panel
4 EACB1 is hidden, below EAC distribution panel
Figure 23434
Crown 2010 PF17915-21 SP3500 M1.0-7635-070
65
Miscellaneous
GS1 ORF1
Steer Wheel Wire Guidance Sensor Bar Orifice 1
Location: mounted to front inside portion of power unit Location: manifold block.
skirt.
Purpose: limits the maximum lowering speed when
Purpose: sense guide wire floor signal. PVL is fully actuated (maximum lower command is re-
quested by operator).
Data: four sensor coils in sensor bar. Receives 5 V and
BNEG from ACCESS 6. View GS1 input to ACCESS 6 Data: 4.6 mm (0.181 in) diameter.
from Analyzer, A2.5.1 menu.
Adjustment: calibration is required. For calibration
procedures, see Electrical - ACCESS 123.
DIA-7435-004 (A-4)
DIA-7435-017 (A-2) ORF2
Orifice 2
GS2 Location: manifold block.

Purpose: limits maximum manual lowering speed.
Load Wheel Wire Guidance Sensor Bar
Data: 2.0 mm (0.080 in) diameter.
Location: mounted to base of mainframe.
Purpose: sense guide wire floor signal.
Data: four sensor coils in sensor bar. Receives 5 V and
BNEG from ACCESS 6. View GS2 input to ACCESS 6
Adjustment: calibration is required. For calibration ORF3
procedures, see Electrical - ACCESS 123.
Orifice 3
DIA-7435-004 (A-4) Location: manifold block.
DIA-7435-017 (A-3) Purpose: slows PCL response to prevent abrupt (not
Parts Breakdown: see table of contents smooth) lowering
Data: 0.5 mm (0.020 in) diameter.
InfoLink Adjustment: none required.
InfoLink Module
Location: mounted on work assist tube on platform.
Purpose: monitors truck functions and impacts.
Data: does not apply.
DIA-7435-005 (A-4)
DIA-7435-010 (C-1)
M1.0-7635-071 SP3500 Crown 2010 PF17915-22
66
Miscellaneous
1 SP 3520 shown. GS1 and GS2 mounting location is the same

for SP 3571 and SP 3581.
2 InfoLink Module
Figure 23435
Crown 2010 PF17915-23 SP3500 M1.0-7635-072
67
Miscellaneous
POT1 Quick Disconnect

Location: manifold block.
Traction Request Potentiometer
Purpose: quick connect/disconnect of test gauge.
Location: control module.
Purpose: provide traction input to ACCESS 4.
Data: 22 K ohms, ACCESS 4 provides 5 V and nega-
tive to POT1. Maximum POT1 input signal to Diagrams: HYD-7435-001
ACCESS 4 in power unit first direction 4.6 V, neutral
2.6 V, maximum forks first direction 0.8 V. View POT1
inputs from Analyzer, A2.3.3 menu.
Adjustment: must be calibrated. For calibration proce- Reservoir
dures, see Electrical - ACCESS 123. Location: power unit behind lift pump motors.
Diagrams: DIA-7435-003 (B-1) Purpose: hydraulic oil reservoir.
DIA-7435-005 (B-1)
DIA-7435-007 (B-1) Data: 17.5 litre (18.5 qt).
DIA-7435-011 (B-2) Adjustment: none required.
Parts Breakdown: 04.6-7335-005 (42) Diagrams: HYD-7435-001
PS1
Light Power Supply SB30
Location: overhead console. Fan Suppressor Block
Purpose: provide 12 volt for work lights. Location: right overhead guard console.
Data: 24 volt D.C. input, 12 volt D.C. output. Purpose: suppress voltage spikes.
Adjustment: none required. Data: not applicable.
Diagrams: DIA-7435-012 (C-1) Adjustment: none required.
Parts Breakdown: 04.9-7335-050 (16) Diagrams: DIA-7435-012 (C-4)
PS2
Light Power Supply Shock Sensor
Location: overhead console. InfoLink Impact Sensor
Purpose: provide 12 volt for dome lights. Location: mounted on center, inside portion of power
Data: 24 volt D.C. input, 12 volt D.C. output. unit skirt.
Adjustment: none required. Purpose: provides truck impact input to InfoLink mod-
ule.
Data: +5 V from power supply in InfoLink Module.
DIA-7435-004 (A-1)
M1.0-7635-073 SP3500 Crown 2010 PF17915-24
68
Miscellaneous
1 Shock Sensor
2 Power Unit Skirt (Center)
3 Right Overhead Console
4 Left Overhead Console
5 Quick Disconnect
6 Reservoir
Figure 23436
Crown 2010 PF17915-25 SP3500 M1.0-7635-074
69
Modules
Strainer ACCESS 3 (TCM)

Location: in reservoir.
Traction (and Hydraulic) Control Module
Purpose: remove containments from oil.
Location: power unit ACCESS 123 module panel.
Data: 100 mesh.
Purpose: controls traction motor operation, lift pump
Adjustment: none required. motor operation (via pump contactor coils), lowering
solenoid valve (SVL) and power unit fan (FAN2).
Data: input from ACCESS 123 modules, traction en-
coder (ECR3), lift motor(s) brush and temperature sen-
sors and chain slack/break switches (CHS3, CHS4,
Modules CHS5, CHB4).
Adjustment: if module is replaced, complete truck cal-
ibration is recommended to prevent nuisance codes.
ACCESS 1 (DCM) Also if replacement module includes updated software,
the software in the remaining modules must be up-
Display Control Module dated so all software is compatible.
Location: platform. Diagrams: DIA-7435-002 (B-2)
Purpose: display pertinent truck information to opera- DIA-7435-004 (B-2)
tor or service technician, (SPI) steer position indicator DIA-7435-006 (B-2)
displays steering information (Optional). DIA-7435-013 (C-1)
DIA-7435-020 (B-2)
Data: information received from truck control modules
and sensors. Parts Breakdown: 04.1-7435-001 (13)

ibration is recommended to prevent nuisance codes. ACCESS 4 (VCM)
Also if replacement module includes updated software,
the software in the remaining modules must be up- Vehicle Control Module
dated so all software is compatible.
Location: platform.
Purpose: controls vehicle operations by checking for
DIA-7435-005 (B-2)
proper inputs and communicating to all other
DIA-7435-007 (B-2)
ACCESS 123 modules.
DIA-7435-010 (C-1, C-2)
Data: input from ACCESS 123 modules, steer com-
mand encoders (ECR1 and ECR5), height encoder
(ECR4), directional switches (FS, RS), lower switches
(LOS1 and LOS2), traction potentiometer (POT1),
chain slack switches (CHS1 and CHS2), gate switches
(GTS 1 and 2), height reset switch (HGTRS) and op-
tional zone select switch (ZSS).
Also if replacement module includes updated software,
dated so all software is compatible.
DIA-7435-005 (B-1)
DIA-7435-007 (B-1)
DIA-7435-010 (C-2)
M1.0-7635-075 SP3500 Crown 2010 PF17915-26
70
Modules
1 Torsion spring on lower gate arm

2 Platform wall (operator side)
3 Reservoir
4 Strainer
Figure 23437
Crown 2010 PF17915-27 SP3500 M1.0-7635-076
71
Motors
ACCESS 5 (SCM) Motors

Steering Control Module
M1
Purpose: control steer motor, brake and proportional Traction Motor (AC)
lowering valve (PVL).
Location: drive unit.
Data: input from ACCESS 123 modules, current sen-
Purpose: provide driving force for traction.
sor (CS1), steering feedback encoder (ECR2), optional
battery restraint switch (BRES1), optional rail guide Data: ACCESS 3 provides traction control via operator
switches (RGSR and RGSL). input (POT1). ACCESS 3 provides 3 phase AC volt-
age. View ACCESS 3 output to M1 from Analyzer,
A3.2.6 menu.
Also if replacement module includes updated software, Adjustment: none required.
dated so all software is compatible
DIA-7335-004 (B-2)
Diagrams: DIA-7435-002 (B-3) DIA-7335-006 (B-2)
DIA-7435-004 (B-3) DIA-7335-014 (C-1)
DIA-7435-006 (B-3) DIA-7335-020 (A-2)
DIA-7435-015 (C-1)
DIA-7435-020 (B-2)
M2
ACCESS 6 (GCM) Power Steering Motor (DC)
Location: steering gearbox.
Guidance Control Module (Optional)
Purpose: provide driving force for steering.
Data: ACCESS 5 provides steering control via steering
Purpose: controls automatic guidance system (wire
command encoder ECR1 and ECR5 and steering
guidance) and end aisle control, EAC.
feedback encoder ECR2. View ACCESS 5 output to
Data: input from ACCESS 123 modules, load wheel M2 from Analyzer, A3.4.5 menu.
and steer wheel sensor bars and EAC sensors.
DIA-7435-004 (B-2)
Also if replacement module includes updated software, DIA-7435-006 (B-2)
the software in the remaining modules must be up- DIA-7435-015 (C-2)
dated so all software is compatible. DIA-7435-020 (B-2)
Diagrams: DIA-7435-002 (B-4) Parts Breakdown: 06.2-7330-003 (0)
DIA-7435-004 (B-4)
DIA-7435-017 (C-1)
DIA-7435-020 (B-3)
M1.0-7635-077 SP3500 Crown 2010 PF17915-28
72
Motors
1 ACCESS 6 is mounted below ACCESS 5

and is not shown in photo.
Figure 23438
Crown 2010 PF17915-29 SP3500 M1.0-7635-078
73
Pumps
M3 Pumps
Lift Pump Motor
P1
Location: in front of reservoir.
Purpose: provide driving force for hydraulic pump sup- Lift Pump 1
plying hydraulic oil flow for lift.
Location: in front of reservoir above caster mounted to
Data: M3 receives +BV from P1 contactor and BNEG M3 motor.
Purpose: provide hydraulic oil flow for lift.
Data: displacement: 5.5 cc/rev (0.33 cir).
DIA-7435-004 (B-1)
DIA-7435-006 (C-1) Parts Breakdown: 02.1-07.3-002
DIA-7435-016 (C-3)
DIA-7435-020 (B-2)
HYD-7435-001
P2
Parts Breakdown: 02.2-7330-050 (0) Lift Pump 2 (Optional)
Location: in front of reservoir above caster mounted to
M4 M4 motor.
Purpose: provide hydraulic oil flow for high speed lift.
Lift Motor (Optional)
Data: displacement: 5.5 cc/rev (0.33 cir).
Location: in front of reservoir.
Purpose: provide driving force for hydraulic pump sup-
plying hydraulic oil flow for high speed lift. Parts Breakdown: 02.1-07.3-002
Data: M4 receives +BV from P2 contactor and BNEG
DIA-7435-004 (B-1)
DIA-7435-016 (C-3)
DIA-7435-020 (C-2)
HYD-7435-001
M1.0-7635-079 SP3500 Crown 2010 PF17915-30
74
Pumps
Figure 23439
Crown 2010 PF17915-31 SP3500 M1.0-7635-080
75
Relays
Relays K11
Freezer/Condition Relay (Optional)
K1
Location: freezer/condition distribution panel.
Power Up Relay Purpose: provide power to thermostat circuits.
Location: distribution panel (Platform). Data: 24 volt D.C. coil energized when THS2 closes
and THS3 is in temperature range.
Purpose: provides +BV to the platform control circuitry,
K2 coil and ED1 coil. Adjustment: none required.
Data: 24 volt D.C. coil energized upon key-switch start Diagrams - Coil and Contacts: DIA-7435-018 (B-1)
position closure.
Diagrams - Coil: DIA-7435-003 (B-3) K12
DIA-7435-005 (B-3)
DIA-7435-007 (B-3)
Freezer/Condition Relay (Optional)
DIA-7435-008 (B-2)
Location: freezer/condition distribution panel.
Diagrams - Contacts: DIA-7435-003 (B-4)
DIA-7435-005 (B-4) Purpose: provide power to heater circuits.
DIA-7435-007 (B-4)
Data: 24 volt D.C. coil energized when THS2 closes
DIA-7435-008 (B-2)
and THS3 is in temperature range.
Diagrams - Coil and Contacts: DIA-7435-018 (B-1)
K2
Module Power
Location: distribution panel (Power Unit).
Purpose: provides +BV to the power unit control cir-
cuitry.
Data: 24 volt D.C. coil energized by K1 relay.
Diagrams - Coil: DIA-7435-002 (C-3)
DIA-7435-004 (C-3)
DIA-7435-006 (C-3)
DIA-7435-009 (B-2)
Diagrams - Contacts: DIA-7435-002 (A-4)
DIA-7435-004 (A-4)
DIA-7435-006 (A-4)
DIA-7435-009 (B-3)
M1.0-7635-081 SP3500 Crown 2010 PF17915-32
76
Relays
1 Freezer/Condition Panel
Figure 23440
Crown 2010 PF17915-33 SP3500 M1.0-7635-082
77
Resistors
K15 RES2, RES3

Travel Alarm Relay (Optional) Traction Brake Resistors
Location: platform side of power unit near bottom un- Location: back of power unit distribution panel.
der travel alarm.
Purpose: reduce current to the brake coils to prevent
Purpose: provides +BV to travel alarm (HN2). overheating after momentary brake release when us-
ing the drive/tow switch DTS1 (Note: during normal op-
Data: 24 volt D.C. coil receives 24 V and negative from
eration RES2 and RES3 are not needed because
ACCESS 4. View ACCESS 4 output to K15 coil from
ACCESS 5 controls the amount of current applied to
Analyzer, A3.3.1 menu (Note: A3.3.1 menu displays
the brake).
ALM2 not K15. Although ALM2 is displayed, K15 coil is
energized by ACCESS 4. K15 tips close energizing Data: RES2 - 5 ohm, 50 watt, RES3 - 8 ohm, 50 watt
ALM2.)
Diagrams - Coil: DIA-7435-002 (B-1) DIA-7435-004 (B-3)
DIA-7435-004 (B-1) DIA-7435-006 (B-3)
DIA-7435-018 (A-1) DIA-7435-009 (B-4)
DIA-7435-019 (A-1)
Diagrams - Contacts: DIA-7435-002 (B-3)
DIA-7435-004 (B-3)
DIA-7435-018 (A-2) RES5, RES6
DIA-7435-019 (A-2)
Freezer/Condition Heater (Optional)
Location: aisle guide wheel brackets.
Purpose: RES5 applies heat to aisle guide switch
Resistors RGSR and RES6 applies heat to aisle guide switch
RGSL.
RES1 Data: 50 watt, 15 ohm.
Resistor (Optional)
Location: overhead console.
Purpose: reduce fan noise.
Data: 25 watt, 10 ohm.
RES7, RES8
Diagrams: DIA-7435-012 (B-4) Freezer/Condition Heater (Optional)
Parts Breakdown: 04.9-7335-050 (77) Location: battery-restraint-switch brackets.

Purpose: RES7 applies heat to battery restraint switch
BRES1 and RES8 applies heat to battery restraint
switch BRES2.
M1.0-7635-083 SP3500 Crown 2010 PF17915-34
78
Resistors
1 Power Unit Distribution Panel

2 Battery Restraint Switch Bracket - Left Side
3 Right Overhead Console
4 Left Aisle Guide Wheel Weldment
5 Right Side
6 Left Side - Shown
Figure 23441
Crown 2010 PF17915-35 SP3500 M1.0-7635-084
79
Resistors
RES9, RES10 RES14

Freezer/Condition Heater (Optional) Freezer/Condition Heater (Optional)
Location: main frame. Location: control module.
Purpose: RES9 applies heat to chain slack switch Purpose: applies heat to raise and lower switches
CHS3 and RES10 applies heat to chain slack switch LOS1, LOS2, RAS1 & RAS2.
CHS4.
Parts Breakdown: 07.6-7635-001 (6, 10)
RES15
RES11, RES12
Location: platform gate.
Purpose: applies heat to horn switch HNS1.
Purpose: RES11 applies heat to gate switches GTS1
and RES12 applies heat to gate switches GTS2.
Parts Breakdown: 09.0-7335-150 (4, 86)
RES16
RES13 Freezer/Condition Heater (Optional)
Freezer/Condition Heater
Purpose: applies heat to forward switch FS.
Purpose: applies heat to emergency disconnect
switch EDS. Adjustment: none required.
Data: 10 watt, 70 ohm. Diagrams: DIA-7435-018 (C-3)
Adjustment: none required. Parts Breakdown: 04.6-7335-050 (21)
M1.0-7635-085 SP3500 Crown 2010 PF17915-36
80
Resistors
1 Right Side - Shown

2 Left Side
3 Back of Control Module
Figure 23442
Crown 2010 PF17915-37 SP3500 M1.0-7635-086
81
Resistors
RES17 RES21, RES22

Freezer/Condition Heater (Optional) Freezer/Condition Heater (Optional)
Location: control module. Location: platform gate.
Purpose: applies heat to reverse switch RS. Purpose: RES21 applies heat to gate switches GTS5
and RES22 applies heat to gate switches GTS6.
Parts Breakdown: 09.0-7534-250 (13, 22)
RES18
RES25
Freezer/Corrosion Heater (Optional)
Location: below floorboard.
Location: part of HGTRS assembly.
Purpose: applies heat to brake switch BRS1.
Purpose: applies heat to height reset switch HGTRS.
Data: 24 V, 10 watt silicon rubber heater.
Parts Breakdown: 09.0-7335-100 (13 - part of HGTRS
assembly)
RES19, RES20
Freezer/Condition Heater (Optional) RES111
Location: platform (TT).
Freezer/Corrosion Heater
Purpose: RES19 applies heat to chain slack switch
Location: below two hand operation handle.
CHS1 and RES20 applies heat to chain slack switch
CHS2. Purpose: applies heat to operator presence switch
DMS1.
M1.0-7635-087 SP3500 Crown 2010 PF17915-38
82
Resistors
1 RES19 is mounted on the left side (shown) and RES20 is mounted on

the right side
2 Front of platform
3 RES25 is mounted inside HGTRS assembly (shown)
4 Left rear platform post
5 Part of control module
6 Bottom of platform
7 RES21 is mounted on the left rear platform post (shown) and RES22 is
mounted on the right rear platform post
Figure 23443
Crown 2010 PF17915-39 SP3500 M1.0-7635-088
83
Switches
Switches Data: wired normally open, held closed as chains

maintain proper tension. Supplies +BV input signal to
ACCESS 3. View CHB4, CHB5 input from Analyzer,
BRES1, BRES2 A2.2.2 menu.
Battery Restraint Switches (Optional)
Location: power unit skirt. DIA-7435-004 (A-2)
Purpose: monitor presence of battery retainer/side DIA-7435-014 (C-4)
cover and disable travel if battery retainer is not Parts Breakdown: 07.6-7635-001 (6, 10)
present.
Data: wired normally open, held closed when battery CHB7, CHB8
retainer/side cover is in place. Supplies BNEG input
signal to ACCESS 5. View BRES1 and BRES2 input
Chain Break Switches
Location: base of platform - mast side.
Purpose: prohibits lowering in the event mast chains
break.
DIA-7435-004 (B-3)
DIA-7435-015 (C-2) Data: wired normally open, held closed as chains
ACCESS 4. View CHB7, CHB8 input from Analyzer,
A2.3.19 menu.
BRS Adjustment: none required.
Brake Switch Diagrams: DIA-7435-003 (A-2)

DIA-7435-005 (A-2)
Location: platform below floorboard. DIA-7435-010 (C-4)
Purpose: allows operator to release or apply brake. Parts Breakdown: 07.6-7635-001 (6, 10)
Data: wired normally open, held closed when operator
is depressing brake pedal. Supplies BNEG input signal CHS1, CHS2
to ACCESS 5. View BRS1 input from Analyzer,
A2.4.10 menu.
Chain Slack Switches
Location: base of platform - mast side.
Purpose: prohibits lowering when mast chains be-
DIA-7435-005 (B-3)
come slack.
DIA-7435-007 (B-3)
DIA-7435-011 (C-4) Data: wired normally open, held closed as chains
maintain proper tension. Supplies BNEG input signal to
ACCESS 4. View CHS1, CHS2 input from Analyzer,
A2.3.8 menu.
CHB4, CHS5 Adjustment: none required.
Chain Break Switches Diagrams: DIA-7435-003 (B-1)

DIA-7435-005 (B-1)
Location: mainframe. DIA-7435-007 (B-1)
Purpose: prohibits lowering in the event mast chains DIA-7435-011 (C-3)
break. Parts Breakdown: 07.6-7635-001 (48)
M1.0-7635-089 SP3500 Crown 2010 PF17915-40
84
Switches
1 Right Side
2 Left Side - Shown
Figure 23444
Crown 2010 PF17915-41 SP3500 M1.0-7635-090
85
Switches
CHS3, CHS4 EDS

Chain Slack Switches Emergency Disconnect Switch
Location: top of mainframe. Location: control module.
Purpose: prohibits lowering when mast chains be- Purpose: disconnects +BV to key switch.
come slack.
Data: wired normally closed. Pressing switch button
Data: wired normally open, held closed as chains opens switch contacts.
ACCESS 3. View CHS3, CHS4 input from Analyzer,
A2.2.3 menu. Diagrams: DIA-7435-003 (B-3)
DIA-7435-005 (B-3)
DIA-7435-007 (B-4)
DIA-7435-004 (A-2)
DIA-7435-006 (A-2)
DIA-7435-014 (C-4)
Parts Breakdown: 07.6-7635-001 (6, 10) FNS1
Fan Switch
DMS1
Location: switch panel.
Operator Presence Switch Purpose: allows operator to turn on/off fan (FAN1)
mounted on overhead guard.
Location: below two hand operation handle.
Data: three position, on/off/on, rocker switch. Supplies
Purpose: wired normally open, held closed when the
+BV to FAN1.
two hand operator handle is push down. Supplies
BNEG input signal to ACCESS 1. View DMS1 input Adjustment: none required.
DIA-7435-005 (B-2)
DIA-7435-011 (B-3) FS
Parts Breakdown: 09.0-7535-009 (59) Forward Switch
DTS1
Purpose: provides forward travel request input signal
to ACCESS 4.
Drive/Tow Switch
Data: wired normally open. Rotating twist grip away
Location: power unit distribution panel.
from operator actuates switch. Supplies +BV input to
Purpose: to release brake allowing truck to be towed. ACCESS 4. View FS input from Analyzer, A2.3.7
menu.
Data: two position, on-on, lever handle switch.
DIA-7435-005 (A-2)
DIA-7435-004 (A-3)
DIA-7435-007 (A-2)
DIA-7435-006 (A-3)
DIA-7435-011 (B-2)
DIA-7435-009 (B-3)
M1.0-7635-091 SP3500 Crown 2010 PF17915-42
86
Switches
Figure 23445
Crown 2010 PF17915-43 SP3500 M1.0-7635-092
87
Switches
GTS1, GTS2 Diagrams: DIA-7435-003 (B-2)

DIA-7435-005 (B-2)
DIA-7435-011 (B-3)
Side Gate Switches
Location: platform console.
Purpose: prevents lift/lower and traction when gates
are up. HGTRS
Data: wired normally open, held closed when gates are
Height Reset Switch
down. Supplies BNEG input signal to ACCESS 4. View
GTS1 and GTS2 input from Analyzer, A2.3.9 menu. Location: on mast side of platform.
Adjustment: none required. Purpose: resets height encoder at approximately
300 mm (15 in).
DIA-7435-005 (B-2) Data: wired normally open held closed. Provides neg-
DIA-7435-007 (B-2) ative input signal to ACCESS 4. View input from Ana-
DIA-7435-011 (B-4, C-4) lyzer, A2.3.10 menu.
Parts Breakdown: 09.0-7535-150 (37, 82) Adjustment: none required.
GTS5, GTS6 DIA-7435-005 (B-2)
DIA-7435-007 (B-2)
DIA-7435-011 (C-1)
Rear Gate Switches
Location: rear post.
Purpose: prevents lift/lower and traction when gates
are up. HNS
Data: wired normally open, held closed when gates are
Horn Switch
down. Supplies BNEG input signal to ACCESS 4. View
GTS5 and GTS6 input from Analyzer, A2.3.9 menu. Location: control module.
Adjustment: none required. Purpose: allows operator to sound horn.
Diagrams: DIA-7435-003 (B-2) Data: wired normally open. Pushing horn button actu-
DIA-7435-005 (B-2) ates switch. Supplies +BV to HN1 from K1 relay.
DIA-7435-007 (B-2)
DIA-7435-005 (B-1)
GUS DIA-7435-007 (B-1)
DIA-7435-011 (B-2)
Guidance Switch (Optional) Parts Breakdown: 04.6-7335-050 (11)
Purpose: allows operator to select manual or auto-
matic steering.
Data: wired normally open. Supplies BNEG input sig-
nal to ACCESS 1. View GUS input from Analyzer,
A2.1.2 menu.
M1.0-7635-093 SP3500 Crown 2010 PF17915-44
88
Switches
1 Right Side
2 Left Side - Shown
Figure 23446
Crown 2010 PF17915-45 SP3500 M1.0-7635-094
89
Switches
KYS LGS3
Key Switch Spot Light Switch (Optional)
Location: control module. Location: switch panel.
Purpose: allows operator to power truck up and power Purpose: allows operator to turn on/off spot light.
truck down.
Data: two-position, on/off, rocker switch. Provides +BV
Data: key operated selector switch. Energizes K1 with to spot lights.
start position and maintains K1 with on position. View
keyswitch input (+BV) from Analyzer, A2.2.7 menu.
DIA-7435-005 (B-3)
DIA-7435-007 (B-3) LOS1
DIA-7435-011 (C-1)
Parts Breakdown: 04.6-7335-005 (22) Low Speed Lower Switch
LGS1 Purpose: allows operator to lower platform. Provides
low speed lower request input to ACCESS 4.
Dome Light Switch (Optional)
Data: wired normally open, held closed by partially de-
Location: switch panel. pressing the lower button. Supplies +BV input signal to
ACCESS 4. View LOS1 input from Analyzer, A2.3.12
Purpose: allows operator to turn on/off dome light.
menu.
to PS2 power supply.
DIA-7435-005 (A-2)
Diagrams: DIA-7435-012 (B-2) DIA-7435-007 (A-2)
DIA-7435-011 (B-2)
LGS2
Work Light Switch (Optional)
Location: switch panel.
Purpose: allows operator to turn on/off work light.
to PS1 power supply.
M1.0-7635-095 SP3500 Crown 2010 PF17915-46
90
Switches
Figure 23447
Crown 2010 PF17915-47 SP3500 M1.0-7635-096
91
Switches
LOS2 RAS1
High Speed Lower Switch Raise Switch (Low Speed Raise Switch on trucks
with optional high speed raise)
Purpose: allows operator to lower platform. Provides
high speed lower request input to ACCESS 4. Purpose: allows operator to raise platform.
Data: wired normally open, held closed by fully de- Data: wired normally open, held closed by depressing
pressing the lower button. Supplies +BV input to the raise button (partially on trucks with high speed
ACCESS 4. View LOS2 input from Analyzer, A2.3.13 raise). Supplies +BV to P1 coil and +BV input signal to
menu. ACCESS 4. View RAS1 input from Analyzer, A2.3.11
menu.
DIA-7435-005 (A-2) Diagrams: DIA-7435-003 (A-2)
DIA-7435-007 (A-2) DIA-7435-005 (A-2)
DIA-7435-011 (B-2) DIA-7435-011 (B-2)
ORS1 RAS2
Override Switch High Speed Raise Switch (Optional)
Location: switch panel. Location: control module.
Purpose: when raise or lower cutout programmed for Purpose: allows operator to raise platform.
override is encountered, actuating switch permits con-
Data: wired normally open, held closed by fully de-
tinuation of function.
pressing the raise button. Supplies +BV to P2 coil.
Data: momentary contact switch. Provides BNEG input
signal to ACCESS 1. View ORS1 input signal from An-
alyzer, A2.1.3 menu. Diagrams: DIA-7435-003 (A-2)
DIA-7435-005 (A-2)
DIA-7435-011 (B-2)
DIA-7435-005 (B-2)
DIA-7435-007 (B-2)
DIA-7435-011 (B-3)
M1.0-7635-097 SP3500 Crown 2010 PF17915-48
92
Switches
Figure 23448
Crown 2010 PF17915-49 SP3500 M1.0-7635-098
93
Switches
RGSR and RGSL (Optional) THS3

Rail Guide Switches Platform Thermostat (Optional)
Location: aisle guide wheel bracket mounted under Location: mounted to plate assembled to Brake
power unit. switch, BRS, located under platform floor.
Purpose: provide ability to turn on automatic steering. Purpose: turn on platform heaters.
Data: wired normally open held open. Supplies BNEG Data: wired normally closed. Contact closes at 49° C
input signal to ACCESS 5. View RGSR AND RGSL in- (120° F) and opens at 60° C (140° F).
put from Analyzer, A2.4.8 menu.
DIA-7435-004 (B-3)
DIA-7435-015 (B-2, C-2)
Parts Breakdown: 10.0-7435-001 (11) THS-P1
Pump 1 Motor M3 Thermal Switch
RS
Reverse Switch Purpose: cause an event if an M3 motor over temper-
ature condition occurs.
Purpose: provides reverse travel request input signal
to ACCESS 4.
Data: wired normally open. Rotating twist grip toward
operator actuates switch. Supplies +BV input to Diagrams: DIA-7435-016
ACCESS 4. View RS input from Analyzer, A2.3.6
Parts Breakdown: not separately available
menu.
THS-P2
DIA-7435-005 (A-2) Pump 2 Motor M4 Thermal Switch
DIA-7435-011 (B-2)
Purpose: cause an event if an M4 motor over temper-
ature condition occurs.
THS2
Power Unit Thermostat (Optional)
Location: power unit battery wall between power unit
and mast. Diagrams: DIA-7435-016
Purpose: turn on power unit heaters. Parts Breakdown: not separately available
Data: wired normally closed. Contact closes at 4° C
(40° F) and opens at 16° C (60° F).
M1.0-7635-099 SP3500 Crown 2010 PF17915-50
94
Switches
1 Right Side
2 Left Side - Shown
3 Left Aisle Guide Wheel Weldment
Figure 23449
Crown 2010 PF17915-51 SP3500 M1.0-7635-100
95
Valves
ZSS CV3
Zone Select Switch (Optional) Check Valve
Location: switch panel. Location: lift/lower manifold.
Purpose: allows selection of lift height cutouts. Purpose: prevent back flow into pump P1.
Data: three position key switch. Supplies BNEG input Data: not applicable.
signal to ACCESS 4. View switch contacts input from
Analyzer, A2.3.14 (ZSSA), A2.3.15 (ZSSB) and
A2.3.16 (ZSSC) menus. Diagrams: HYD-7435-001
Adjustment: none required. Parts Breakdown: 02.4-7435-050 (7)
DIA-7435-005 (B-2) MLV
DIA-7435-011 (B-3)
Parts Breakdown: 04.8-7335-102 (11) Manual Lowering Valve
Location: lift/lower manifold.
Valves Purpose: provide means to lower platform without
powering up truck.
CV1 Data: not applicable.

Check Valve
Purpose: prevent back flow into pump P2.
Data: not applicable. PVL
Proportional Lowering Valve
Purpose: provide proportional flow control (speed) of
lowering.
CV2
Data: 24 volt D.C. coil receives +BV from K2 relay and
negative from ACCESS 5. View ACCESS 5 output to
Check Valve
coil from Analyzer, A3.4.4 menu.
Adjustment: not applicable.
Purpose: prevent back flow into pumps P1 and P2.
Data: not applicable. DIA-7435-004 (B-3)
DIA-7435-006 (B-3)
DIA-7435-016 (C-1)
Diagrams: HYD-7435-001 HYD-7435-001
M1.0-7635-101 SP3500 Crown 2010 PF17915-52
96
Valves
Figure 23450
Crown 2010 PF17915-53 SP3500 M1.0-7635-102
97
Valves
PCL SVL
Pressure Compensator Lowering Valve Solenoid Valve Lower
Location: lift/lower manifold. Location: lift/lower manifold.
Purpose: limits the maximum rate of oil flow (speed) Purpose: provide hydraulic oil flow path for lower func-
during lowering. tion.
Data: not applicable. Data: 24 volt D.C. coil receives +BV from K2 relay and
negative from ACCESS 3. View ACCESS 3 output to
coil from Analyzer, A3.2.1 menu.
DIA-7435-004 (B-2)
RV1 DIA-7435-006 (B-2)
DIA-7435-016 (C-1)
Relief Valve HYD-7435-001
Location: lift/lower manifold. Parts Breakdown: 02.4-7435-050 (11)
Purpose: limit operating pressure for lift circuit.

Velocity Fuse
Data: set to 19200 to 19375 kPa (2785 to 2810 psi).
Location: bottom of free lift and mast cylinders.
Adjustment: refer to Hydraulic Maintenance - Lift/
Lower Manifold. Purpose: prevent lowering in the event of a hose/tube
break or significant rupture.
Parts Breakdown: 08.1-7435-001 (11, 12)
08.3-7435-001 (14, 15)
M1.0-7635-103 SP3500 Crown 2010 PF17915-54
98
Valves
1 Cut-Away View of Bottom of Free Lift and Mast Cylinder 5 Velocity Fuse
2 Bottom of Ram 6 O-ring
3 Poppet 7 Cap
4 Spring
Figure 23451
Crown 2010 PF17915-55 SP3500 M1.0-7635-104
99
Notes:
100
Caster
Caster
Caster Assembly
A dual wheel swivel caster is located at the left front
corner of the power unit. Proper maintenance to ensure
smooth trouble free operation is necessary. Lubrication
fittings are located in the thrust bearing and wheel hub
areas to allow for routine lubrication.
Caster Adjustment
CAUTION
Move truck to an area set aside for maintenance with a
level surface. Disconnect battery and chock load
wheels and drive tire. Refer to Control Of Hazardous
Energy Lockout/Tag out for procedures on lifting and
blocking the truck.
As the drive and caster wheels wears, adjustment may
be required to compensate for uneven tire wear. Une-
ven tire wear could adversely affect traction, braking,
Figure 23371
stability and/or wire guidance.
To check for uneven tire wear, position the truck on a 1 Measure from floor to power unit skirt, maximum difference
from corner to corner is ± 3.0 mm (0.12 in)
level surface. Measure the distance between the floor
and bottom of the skirt on each side of the power unit 2 Floor/Lever surface
as indicated in Figure 23371. The difference between
these two measurements should not be more than
3.0 mm (0.12 in).
Crown 2010 PF17885-1 SP3500 M1.5-7435-001
101
Caster
The skirt height can be adjusted by replacing worn tires

or by adjusting the caster assembly up or down. In-
creasing the shim thickness below the caster assembly
will adjust the caster up, thus lowering the caster side
of the skirt. Reducing the shim thickness will have the
opposite effect. A new truck from the factory will have
two 3.0 mm (0.12 in) thick shims between the plate and
caster assembly. Refer to Figure 23372.
Figure 23372
1 Shim 13 mm (0.50 in) thick

2 Shim 3 mm (0.125 in) thick
3 Plate
4 Part of power unit
M1.5-7435-002 SP3500 Crown 2010 PF17885-2
102

All Crown trucks are manufactured with class 8.8 or
on your lift truck.
Grade

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

Medium Carbon Alloy Steel

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all of its bolted
assemblies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener
is replaced that is unmarked, replace the fastener with a class 8.8.
Figure 15048
Crown 1989 PF8514-1 Rev. 11/08 SP3500 M1.9-06.6-001

02 Rev. 11/08
103
Torque Chart - Metric Hex Head Cap Screws and Nuts
Thread Diameter Tightening Torque Nm (ft lb)

& 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: Torque values called out in the maintenance section of this manual will take precedence over torque
values found on this page.
Torque Chart - Metric Hex Socket Countersink Head Screws

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 SP3500 Crown 1989 PF8514-2 Rev. 11/08
02 Rev. 11/08
104
Torque Chart - Metric Socket Head Cap Screws

M5 x 0.80 5 - 8 (4 - 6) 7 - 9 (5 - 7) 8 - 11 (6 - 8)
M6 x 1.00 9 - 12 (7 - 9) 12 - 15 (9 - 11) 15 - 18 (11 - 13)
M8 x 1.25 22 - 24 (16 - 18) 30 - 33 (22 - 24) 35 - 38 (26 - 28)
M10 x 1.50 42 - 45 (31 - 33) 58 - 64 (43 - 47) 71 - 76 (52 - 56)
M12 x 1.75 72 - 77 (53 - 57) 102 - 110 (75 - 81) 122 - 132 (90 - 97)
M14 x 2.00 115 - 125 (85 - 92) 161 - 175 (119 - 129) 194 - 210 (143 - 155)
M16 x 2.00 179 - 194 (132 - 143) 251 - 273 (185 - 201) 301 - 327 (222 - 241)
M20 x 2.50 348 - 377 (257 - 278) 489 - 530 (361 - 391) 588 - 637 (434 - 470)
M24 x 3.00 601 - 651 (443 - 480) 846 - 915 (624 - 675) 1014 - 1098 (748 - 810)
M30 x 3.50 1196 - 1296 (882 - 956) 1681 - 1822 (1240 - 1344) 2017 - 2187 (1488 - 1613)
Torque Chart - Metric Flanged Hex Head Cap Screws and Nuts

M5 x 0.80 8 - 11 (6 - 8) 9 - 12 (7 - 9)
M6 x 1.00 14 - 16 (10 - 12) 16 - 19 (12 - 14)
M8 x 1.25 31 - 34 (23 - 25) 38 - 41 (28 - 30)
M10 x 1.50 62 - 68 (46 - 50) 75 - 81 (55 - 60)
M12 x 1.75 108 - 117 (80 - 86) 130 - 141 (96 - 104)
M14 x 2.00 174 - 187 (128 - 138) 209 - 225 (154 - 166)
M16 x 2.00 273 - 294 (201 - 217) 327 - 354 (241 - 2610
M20 x 2.50
Crown 1989 PF8514-3 Rev. 11/08 SP3500 M1.9-06.6-003

02 Rev. 11/08
105
Notes:
106
Torque Values
Torque Values
All Crown Trucks are manufactured with Grade 5 or
on your lift truck.
Grade

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

Medium Carbon Alloy Steel,

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted
assemblies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is
replaced that is unmarked, replace the fastener with a Grade 5.
Figure 14916
Crown 1979 PF5067-1 Rev. 9/06 SP3500 M1.9-14.0-001

04 Rev. 9/06
107
Torque Values
Torque Chart
Bolt Grade 5 Grade 8

Diameter Dry Torque Requirement Dry Torque Requirement
in ft Ib kgm Nm ft lb kgm Nm
1/4 9±3 1.2 ± .4 12 ± 4 13 ± 4 1.8 ± .5 17.5 ± 5.5
5/16 18 ± 5 2.5 ± .7 24.5 ± 7 25 ± 5 3.5 ± .7 34 ± 7
3/8 32 ± 5 4.4 ± .7 43.5 ± 7 48 ± 10 6.6 ± 1.3 65 ± 13.5
7/16 50 ± 10 6.9 ± 1.4 67.5 ± 13.5 75 ± 10 10.4 ± 1.4 102 ± 13.5
1/2 75 ± 10 10.4 ± 1.4 101.5 ± 13.5 112 ± 15 15.5 ± 2.0 152 ± 20.5
9/16 110 ± 15 15.2 ± 2.0 149 ± 20.5 163 ± 20 22.5 ± 3.0 221 ± 27
5/8 150 ± 20 20.7 ± 2.8 203.5 ± 27 225 ± 30 31.1 ± 4.1 305 ± 41
3/4 265 ± 35 36.6 ± 4.8 359 ± 47.5 400 ± 50 55.2 ± 6.9 542 ± 68
7/8 420 ± 60 58.1 ± 8.3 569 ± 81 640 ± 80 88.3 ± 11.0 868 ± 108
1 640 ± 80 88.5 ± 11.1 868 ± 109 960 ± 115 132.5 ± 15.9 1300 ± 156
1 1/8 800 ± 100 110.6 ± 13.8 1085 ± 136
1 1/4 1000 ± 120 138 ± 16.6 1356 ± 163
1 3/8 1200 ± 150 166 ± 20.7 1630 ± 203
1 1/2 1500 ± 200 207 ± 27.7 2034 ± 271
Mounting bolt torque requirements in-
volving hydraulic valves.
5/16 13 ± 2 1.8 ± .3 17.5 ± 2.5

3/8 24 ± 2 3.3 ± .3 32.5 ± 2.5
7/16 39 ± 2 5.4 ± .3 53 ± 2.5
NOTE:Torque values called out in the maintenance section of this manual will take prece-
dence over torque values found on this page.
M1.9-14.0-002 SP3500 Crown 1979 PF5067-2 Rev. 9/06
04 Rev. 9/06
108
HYDRAULIC SYSTEM
109
Notes:
110
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic System Figure 23153 shows the hydraulic component loca-

tions in the power unit. Refer to Componentry section
Pumps, P1 & P2, supply oil flow for the lift function. for pump and valve information. Refer to Manifold sec-
tion for RV1 pressure settings.
valve, RV1. The setting for RV1 is noted on hydraulic
schematics.
1 Quick Disconnect (for Pressure Gauge

2 Lift/Lower Manifold
3 Reservoir
4 Sight Gauge
5 Filter
6 Strainer
7 Accumulator
Figure 23153
Crown 2010 PF17859-1 SP3500 M2.0-7435-001
111
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic Circuits Relief Valve Operation

The following pages contain a brief description of hy- During lift function, relief valve RV1 monitors hydraulic
draulic circuits for current standard SP 3570 and pressure protecting the hydraulic system from exces-
SP 3580 trucks. Your unit may vary. Refer to the Hy- sive pressure. Oil pressure is applied to the sensing
draulic Schematic located just after the wiring diagrams side of RV1 through the pilot line. If oil pressure ex-
in this manual for the appropriate schematic. ceeds RV1's adjustable pressure setting, pilot pressure
will overcome RV1's spring force compressing the
spring and opening the valve. Oil will bypass the lift cir-
Lift Circuit cuit, by flowing through RV1 out the manifold through
Refer to Figure 23154 on the next page for lift circuit T1, through a 10 micron filter and into the reservoir.
operation.
Low Speed Lift

When the lift button is depressed to the first detent, oil
is drawn from the hydraulic reservoir though a 100
mesh strainer by pump P1. Oil flows from P1 through
manifold port P1, unseats check valve CV1 and flows
through CV1 to relief valve RV1. Oil flows to check
valve CV2, unseats CV2 and flows through CV2, to the
quick disconnect valve, accumulator and exits the
manifold through port C1. Oil flows though the mast
hoses and enters the lift cylinders through the velocity
fuse(s) located at the the bottom of the cylinders, and
extends the cylinders. During lift, the free lift cylinder
will extend fully before the mast cylinders begin to ex-
tend.
When lift is no longer requested and P1 stops operat-
ing, pressurized oil flow will seat CV2 blocking oil within
the lift circuit; CV1 prevents oil from back flowing
through P1.
High Speed Lift

When the lift button is completely depressed, oil is
drawn from the reservoir by both pumps P2 and P1. In
addition of low speed lift operation (see above), addi-
tional oil flows from P2 through manifold port P2
through check valve CV3 and joins P1 oil flow. When
lift is no longer requested and P2 stops operating, CV2
blocks oil within the lift circuit, and CV3 prevents pres-
surized oil from back flowing through P2.
M2.0-7435-002 SP3500 Crown 2010 PF17859-2
112
HYDRAULIC SYSTEM
Hydraulic System
Accumulator Operation bladder located within the accumulator. The bladder

acts as a pillow to the pressurized oil, cushioning ap-
The accumulator is used as a shock absorber for the plied pressure within the hydraulic circuit. The typical
lift/lower hydraulic system. If the platform is stopped symptom of a bad or de-pressurized accumulator is
suddenly, the change in oil flow exerts pressure on the abrupt starting and stopping of the platform during lift or
hydraulic system. The accumulator absorbs this oil lower. To charge the accumulator, refer to the Accumu-
pressure change through the use of a gas pressurized lator section of this manual.
1 Accumulator, precharged to 3445 kPa (500 psi)

3 RV1 preset to 19200 to 19375 kPa (2785 to 2810 psi)
4 Lift Pump, P1 & P2 output: 25.4 l/m at 3445 kPa (6.7
gal/min at 500 psi), 17.8 l/m at 12410 kPa
(4.7 gal/min at 1800 psi)
Supply Flow
Pilot Pressure 5 Return line filter, 10 micron
Suction 6 Reservoir capacity is approximately 17 liters (4.5 gal)
7 Suction strainer, 100 mesh
8 Quick disconnect (for pressure gauge)
9 Velocity fuse
10 Mast cylinder
11 Free lift cylinder
Figure 23154
Crown 2010 PF17859-3 SP3500 M2.0-7435-003
113
HYDRAULIC SYSTEM
Hydraulic System
Lower Circuit Once oil exits PCL, it is directed out of the manifold
through port T1. From port T1, oil flows through the 10
When lower is selected, oil begins to exit the lift cylin- micron return line filter back to the reservoir.
ders. Oil leaving the cylinders is monitored by an inter-
nal velocity fuse in each cylinder.
Velocity fuses are hydraulic valves designed to prevent
the sudden release of hydraulic oil from a cylinder un-
der a catastrophic failure condition such as a line rup-
ture. If a mast hose or tube ruptures, hydraulic fluid will
be suddenly released out of the hydraulic cylinder(s)
due to the higher pressure of the oil in the lift cylin-
der(s). The sudden high flow exiting through the veloc-
ity fuse valve creates a pressure differential sensed at
the pilot side of the velocity fuse. If oil pressure ex-
ceeds the velocity fuse's spring force, pilot pressure
will compress the spring and close the velocity fuse.
This will block oil from exiting cylinder.
Lower
Refer to Figure 23155 on the next page for lower circuit
operation.
When the lower button is depressed, solenoid valve
SVL and proportional valve PVL coils are energized
causing SVL and PVL's spools to move to the open po-
sition permitting oil flow. If the lower button is pushed to
the first detent for low speed lower, PVL is only partially
opened permitting partial oil flow. If the lower button is
fully pushed for high speed lower, PVL is fully opened
permitting full hydraulic oil flow. SVL is fully opened
when the lower button is depressed regardless of how
much the button is depressed.
Oil exits the lift cylinders and enters the lift/lower man-
ifold block through port C1. Oil flows through the open
envelopes of SVL and PVL and through orifice ORF1.
Oil pressure is also sensed through the pilot lines act-
ing on both sides of pressure compensator valve PCL.
The pilot line opposite PCL's spring also includes
ORF1. Lower pressure at the inlet to PVL is sensed in
the pilot line to PCL opposite the PCL bias spring, and
outlet pressure from PVL is also sensed at the pilot line
connected to the PCL bias spring chamber. If flow
passes through PVL, a pressure differential is created.
If the pressure differential is higher than the spring bias
pressure it will cause PCL to respond and close propor-
tional to the differential pressure, and thus limit the flow
output through PVL & PCL. The combined pressure
drop across PVL and ORF1 results in the sensed pres-
sure differential and results in pressure compensated
flow output. ORF3 orifice provides pressure damping
to the sensed pressure to PCL to provide smooth con-
trolled response to pressure or flow changes, for
smooth motion control.
M2.0-7435-004 SP3500 Crown 2010 PF17859-4
114
HYDRAULIC SYSTEM
Hydraulic System

3 RV1 preset to 19200 to 19375 kPa (2785 to 2810 psi)
4 Lift Pump, P1 & P2 output: 25.4 l/m at 3445 kPa
(6.7 gal/min at 500 psi), 17.8 l/m at 12410 kPa
Return Flow (4.7 gal/min at 1800 psi)
6 Reservoir capacity is approximately 17 liters (4.5 gal)
9 Velocity fuse
10 Mast cylinder
Figure 23155
Crown 2010 PF17859-5 SP3500 M2.0-7435-005
115
HYDRAULIC SYSTEM
Hydraulic System
Manual Lower Circuits From port T1, oil enters the return line filter then back
to the reservoir.
The manual lowering feature is used to lower the plat-
form during truck down situations. The manual lower-
ing valve MVL is located on the lift/lower manifold.
When MVL is opened, oil trapped in the cylinders is
released. Oil enters the lift/lower manifold through port
C1. From port C1, oil flows through the manual lower-
ing valve MVL and through ORF2. ORF2 restricts flow
limiting the maximum rate of oil flow. After oil passes
through ORF2, it exits the manifold through port T1.

3 RV1 preset to 19200 to 19375 kPa (2785 to
2810 psi)
4 Lift Pump, P1 & P2 output: 25.4 l/m at 3445 kPa
Return Flow (500 psi), 17.8 l/m at 12410 kPa (1800 psi)
6 Reservoir capacity is approximately 17 liters
(4.5 gal)
9 Velocity fuse
10 Mast cylinder
Figure 23156
M2.0-7435-006 SP3500 Crown 2010 PF17859-6
116
HYDRAULIC SYSTEM
Hydraulic System
Reservoir 1. Blow air through all hoses and lines to remove

loose particles before installation. Any rubber hose
With all cylinders in the retracted position and after all with wire braid inner construction, or any steel tube
air has been bled from the hydraulic system, fill the res- lines which have been collapsed or kinked are per-
ervoir so the oil level is at the high mark on the reservoir manently damaged and must be replaced even if
sight gauge (Figure 17175). Total capacity of the hy- damage is not externally visible.
draulic system at this level should be approximately
2. Flexible hose must be replaced if it collapses in the
17 litres (4.5 gallons).
normal operating position.
3. All hoses and lines are to be clear of any surface or
edge which will cause damaging wear and cuts, or
on which they can become caught.
4. All connections are to be leak free.
5. Beaded elbows in suction ports of all pumps must
be positioned such that the suction hose retains its
full volume flow and does not collapse.
Filter
NOTE
Do not tighten the filter with a wrench. A wrench should
only be used for removing the filter.
Figure 23157
The spin on filter cartridge has been tightened by
1 Reservoir Sight Gauge Crown. When replacing the filter, apply a film of oil
063001-001 to the seal and hand tighten the filter.
Hydraulic Lines and Fittings
NOTE
Do not use hydraulic brake fluid.
WARNING
Use only a good grade of hydraulic oil such as Mobil
AVOID HIGH PRESSURE FLUIDS - Escaping fluid un- DTE 24 (Crown No. 063001-021) or equal. On trucks
der pressure can penetrate the skin causing serious in- equipped to operate in below freezing temperatures,
jury. Relieve pressure before disconnecting hydraulic Mobil Aero HFA or equal is recommended (Crown No.
lines. Tighten all connections before applying pres- 063001-006) in a 50/50 blend with standard hydraulic
sure. Keep hands and body away from pin holes which oil.
hand. Drift Test
despite an initial normal appearance of the skin. There CAUTION
may occur. Medical attention should be sought imme- Never stand or work under a suspended load.
diately by a specialist who has had experience with this All drift tests should be conducted with a capacity load
type of injury. (refer to the serial plate for the rated capacity of your
truck). Material used for the test load must be evenly
stacked within the limits of a 1200 x 1200 mm (4 x 4 ft)
square pallet and must be secured to the platform.
Crown 2010 PF17859-7 SP3500 M2.0-7435-007
117
HYDRAULIC SYSTEM
Hydraulic System
Lift Drift Test A proper mixture of freezer hydraulic oil will ensure the
best and most efficient operation of your Crown equip-
ment.
NOTE
The lift measurement is to be taken from the tip of the
fork to the floor. SP Models
Elevate the test load above staging height. After five

minutes, measure the distance the platform has drifted.
Drifting in excess of 15 mm (0.5 in) over a five minute
period is considered unacceptable.
Occasionally, a slight creep of platform may occur due
to internal leakage in the cylinder, but it can also be
caused by leakage in the manifold valves. To seat
these valves properly when this occurs, lift and lower
the platform to flush out any foreign material from the
valve seat.
A thorough check for leaks in the system should be
conducted if abnormal oil losses occur.
(a) 50/50 Mix of Low Temperature (063001-006 [50%]) and
Standard Hydraulic Oil (063001-021 [50%])
Freezer Preparation (b) Standard Hydraulic Oil (063001-021 [100%])
(c) 80/20 Mix of Lower Temperature (063001-006 [80%]) and
Standard Hydraulic Oil (063001-021 [20%])
NOTE
Trucks equipped with velocity fuses may experience Figure 18203
staging issues if an insufficient mix of low temperature
oil has been used.
If Crown trucks are operated in cooler or freezer envi-
ronments, the hydraulic fluid my require modification to
maintain the appropriate viscosity. Crown trucks may
require a mixture of low temperature hydraulic oil,
Crown P/N 063001-006 (gallons), blended with stand-
ard hydraulic oil, Crown P/N 063001-021 (gallons)
when used in a freezer or cooler. 100% low tempera-
ture oil is too thin for most cold storage operations and
therefore could shorten the life of cylinder packings and
pumps if used in higher ambient temperatures.
For truck applications operating continually in temper-
atures at or above 4° C (40° F), use 100% standard hy-
draulic oil (063001-021).
For truck applications primarily operating continuously
in a cooler environment with intermittent freezer entry,
use a 50/50 blend, 50% low temperature (063001-006)
and 50% standard hydraulic oil (063001-021).
For truck applications continuously operating in a
freezer environment, use an 80/20 blend, 80% low
temperature (063001-006) and 20% standard hydrau-
lic oil (063001-021); see Crown Service for fluid recom-
mendations.
M2.0-7435-008 SP3500 Crown 2010 PF17859-8
118
HYDRAULIC SYSTEM
VENTED RESERVOIR
with lines above fluid level ELECTRIC MOTOR
unidirectional single speed
VENTED RESERVOIR
with lines below fluid level
ELECTRIC MOTOR
unidirectional variable speed
FILTER or STRAINER
HYDRAULIC LINE HYDRAULIC PUMP

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

HYDRAULIC MOTOR
limited flow
bi-directional
LINES CROSSING
GAUGE
LINES CONNECTED pressure
QUICK DISCONNECT
(disconnected) GAUGE
temperature
PLUGGED PORT
(test port)
ACCUMULATOR
gas charged diaphragm type
FLOW METER
Figure 3559-03
Crown 1979 PF5066-1 Rev. 2/10 SP3500 M2.1-00.0-001

05 Rev. 2/10
119
HYDRAULIC SYSTEM
PRESSURE SWITCH
ACTUATOR MANUAL
CYLINDER SPRING
double acting unequal area (bias to normal
de-energized position)
CYLINDER
double acting equal area
(steer) (double end) SOLENOID
single coil or winding
CYLINDER
single acting spring returned
(rod end vented)
HYDRAULIC PILOT
OPERATED
CYLINDER
single acting ram type
SOLENOID
pilot operated
CYLINDER
single acting with cushion
SOLENOID DUAL
COMPONENT ENCLOSURE
manifold block SOLENOID PROPORTIONAL
ACTUATOR MANUAL LEVER

VALVE PILOT CHECK
(pilot to open)
Figure 3560-04
M2.1-00.0-002 SP3500 Crown 1979 PF5066-2 Rev. 2/10
05 Rev. 2/10
120
HYDRAULIC SYSTEM
ORIFICE THROTTLE
VALVE SHUTTLE
fixed
ORIFICE THROTTLE
adjustable
VALVE
SINGLE COUNTERBALANCE
FLOW CONTROL in manifold
fixed
FLOW CONTROL
fixed with reverse flow bypass FLOW DIVIDER/COMBINER
FUSE VELOCITY
BYPASS FLOW CONTROL
regulated flow
pressure compensated
VALVE RELIEF
VALVE MANUAL SHUTOFF
fixed setting
TORQUE GENERATOR
VALVE RELIEF
adjustable
STEER UNIT
hydrostatic
VALVE CHECK
Figure 3561-04
Crown 1979 PF5066-3 Rev. 2/10 SP3500 M2.1-00.0-003

05 Rev. 2/10
121
HYDRAULIC SYSTEM
VALVE
VALVE
2 way 2 position
3 way 2 position
spring bias, solenoid control
VALVE
3 way 2 position
VALVE
4 way 3 position
dual spring centered,
VALVE manual lever control
4 way 2 position
VALVE
4 way 3 position
NOTE: The type of valve

depends on the number of
spools found in the
VALVE component enclosure
2 way infinite positions (Triple spool valve
shown)
VALVE
4 way infinite positions
Figure 3562-03
M2.1-00.0-004 SP3500 Crown 1979 PF5066-4 Rev. 2/10
05 Rev. 2/10
122
HYDRAULIC SYSTEM
Pump Maintenance
Pump Maintenance
Figure 9221-01
Pump - Gear Oil Seal Removal

Overhaul the pump only in a clean, dust-free location, The oil seal (index 11) is best removed by applying
using clean tools and equipment. Dirt or grit will dam- pressure simultaneously to the pump inlet and outlet
age the highly polished machined surfaces and will re- ports. This has the effect of pressurizing the seal cavity
sult in leakage or premature failure of the pump. and forcing out the oil seal while ensuring that the pres-
sure on each side of the lobe seals (item 3 & 4) is
Before beginning the disassembly, scribe match marks
equalized so that these seals are not displaced. If the
on the body assembly, the end cover and mounting
oil seal is distorted and leaking badly, it may not be pos-
flange to insure that the pump will be reassembled
sible to build up sufficient pressure to remove it in this
properly. This pump can be assembled for either clock-
way. In this case, disassemble the pump as far as step
wise or counter-clockwise rotation as viewed from the
5 of the "DISASSEMBLY PROCEDURE" and clamp
end of the splined drive gear assembly. Arrows are
the mounting flange securely in a soft-jawed vice. The
molded in to the body assembly and the word "ROTA-
seal can then be removed with the use of a seal remov-
TION" appears on the mounting flange to aid in deter-
ing tool. Be careful not to damage the mounting flange
mining the pumps rotation. Note which direction the ar-
seal bore or the drive shafts sealing surface.
row is pointing next to the word "ROTATION" prior to
disassembly.
Crown 1982 PF5372-1 Rev. 9/06 SP3500 M2.1-10.0-001

01 Rev. 9/06
123
HYDRAULIC SYSTEM
Pump Maintenance
Oil Seal Replacement 7. Hold the pump body vertically with the mounting
flange end downward and with one hand under-
1. Make sure the seal housing in the pump mounting neath to prevent the bushings (index 5) from falling
flange is clean and free from burrs. out. Tap the side of the body with a rawhide mallet
to dislodge the lower bushings, and slide them
2. Pack the space between the lips of the seal with a
carefully out of the body. Keep the bushings as a
high melting point, mineral based grease.
pair and place them on or near the mounting
3. Seat the oil seal. flange.
– If the mounting flange has been removed: 8. Invert the body and lift out the drive (index 9) and
Start the oil seal squarely into the housing, with the idler (index 8) gears.
the garter spring facing inward and press home
9. Remove the remaining pair of bushings as de-
to the full depth of the recess.
scribed in step 7 and place on or near the end
– If the pump is assembled: cover.
Slide an "Assembly Sleeve" (available from
Crown [#93170]) over the shaft splines until it
comes in contact with the shaft shoulder. Parts Inspection
Lightly grease the sleeve. Slide the oil seal,
Wash all metal parts thoroughly with a good cleaning
with the garter spring facing inwards, over the
fluid. Inspect, in the order disassembled, for wear and
sleeve and start it squarely into the housing.
damage.
4. Press the seal into the full depth of the recess.
5. Remove the Assembly Sleeve. Body
To obtain high efficiency the design allows for the tips
Pump Disassembly of the gear teeth to wipe the walls of the body bores
when the pump is running. Pressure will force the
1. Remove the bolts which hold the pump to the lift gears against the inlet side of the bores a wear pattern
motor. will be visible in this area. If excessive wear of the
bushing inserts or gear journals occurs this wear pat-
2. Lightly mark or scribe the end cover (index 2), the
tern will deepen to form a step in the bore. Examine the
body (index 7) and the mounting flange (index 10)
body bores and if a pronounced step is felt the body
to ensure re-assembly in the correct relationship.
should be rejected. It is not advisable to fit worn bush-
Also note the direction of rotation of the pump.
ings into a new body. Check to make sure the two hol-
3. Loosen the bolts and lockwashers (index 1) and low dowels are not loose.
pull out the bolts.
4. Remove the end cover (index 2) and carefully lift Composite Bushings
out the two backing washers (index 3), the lobe Examine the bearing inserts for signs of wear and
seals (index 4) and the body "O" ring seals (index check the bushing faces adjacent to the gears for scor-
6). The body seal is a moulded rubber seal on early ing or pitting. Make sure the holes and slots in the
pumps but changed to an "O" ring on newer units bushings are not plugged. Light scored on the bush-
(Specify when ordering). ings faces can be polished out on a lapping plate.
5. Fit an "Assembly Sleeve" tool (available from
Crown [#93170]) over the splines on the drive shaft NOTE
before withdrawing the mounting flange. Lightly tap
the mounting flange clear of the two hollow dowels If new bushings are to be used in an old body, check
in the pump body and slide it squarely off of the for any burrs at the edge of the wear track. If present,
shaft. this burr must be polished out or it may hold the bush-
ing faces away from the gears and increase the internal
6. Carefully lift out the body "O" ring seal (index 6), leakage.
the two backing washers (index 3) and the lobe
seal (index 4).
M2.1-10.0-002 SP3500 Crown 1982 PF5372-2 Rev. 9/06
01 Rev. 9/06
124
HYDRAULIC SYSTEM
Pump Maintenance
Gears
Examine the gears for discoloration, caused by over-
heating. Check the shafts for scoring. Make sure the
contact marks on the teeth are evenly distributed
across each tooth surface and that none of the teeth
are chipped.
NOTE
Bushings and/or gears are matched for widths within
0.005 mm (0.0002 in) and can only be sold and re-
placed as a matched pair.
End Cover
Examine the cover to insure flatness and inspect for
scoring and pitting.
Mounting Flange
Check for damage and check the condition of the oil
seal. If the seal needs replacement refer to the "Oil
Seal Replacement" section.
Lobe
Seal
Backing Washers
Figure 9222-01
Crown 1982 PF5372-3 Rev. 9/06 SP3500 M2.1-10.0-003

01 Rev. 9/06
125
HYDRAULIC SYSTEM
Pump Maintenance
Clockwise Rotation
Flat
Bushing Lobes Bushing Lobes
Flat Bushing Flat

Lobes
Counter-Clockwise Rotation
Figure 9223-01
Pump Reassembly 3. Pack the space between the lips of the oil seal (in-
dex 11) with a high melting point, mineral based
Make sure that all pump components are perfectly grease.
clean and lubricated with the hydraulic oil to be used in
4. Pick up the body and hold it with the hollow dowels
the pump, prior to assembly.
up and with the fingers of one hand inside the
1. Prepare the bushings (index 5) for mounting flange bores of the body, ready to support the bushings.
end of the body for assembly as follows:
5. Pick up the mounting flange bushing complete with
lobe seal and backing washers, and slide them into
Place the bushings on the workbench with their
the body bores with the lobes facing outwards and
lobes up and the flats in contact. Lubricate the lobe
away from the flat at the intersection of the body
seal (index 4) with a mineral based grease and fit
bores. The bushings must be inserted squarely
it around the bushing lobes. Fit a backing washer
into the bores and must be kept square to each
(index 3) inside each lobe seal. When fitted cor-
other. Do not use force when installing the bush-
rectly, the backing washer must be level and flush
ings. If the bushings should cock in the bores, re-
with the top surface of the bushing lobes.
move them and examine for scored body walls.
2. Prepare the bushings for the cover end of the body Light scoring can be stoned out with a fine grit hand
for installation into the pump in the same manner. stone.
M2.1-10.0-004 SP3500 Crown 1982 PF5372-4 Rev. 9/06
01 Rev. 9/06
126
HYDRAULIC SYSTEM
Pump Maintenance
6. Lubricate the body seals "O" ring (index 6) with a Start Up Procedure
mineral based grease and seat it in the body.
A pump that has been re-assembled with new gears,
7. Refer to Figure 9223-01to find the position of the
bushings or body must be carefully broke-in before it is
drive gear bore for the direction of rotation you re-
subjected to full load working conditions.
quire. Lay the pump body on its side and slide the
drive gear (index 9) through the drive gear bore (as When test rig facilities are not available the following
called out in Figure 9223-01) so that the shaft pro- procedure must be carried out:
trudes out of the hollow dowel end of the body.
1. Install the pump on the application.
8. Slide the "Assembly Sleeve" (#93170) over the
2. Where the pump speed is variable set the speed to
end of the splined shaft. Hold the drive gear journal
1500 rev/min; otherwise run the pump at its normal
with one hand and slide the mounting flange (index
operating speed.
10) squarely over the shaft and onto the two hollow
dowels, flush against the body. The "Assembly 3. Run the pump at this speed for a period of 10 min-
Sleeve" provides a lead-in for the oil seal. Remove utes at minimum pressure, that is, with the hydrau-
the "Sleeve" and clamp the mounting flange in a lic system unloaded.
soft jawed vice with the pump body above the
4. If the pump operating pressure can be directly con-
flange. If the sleeve is stuck on the splines it can be
trolled, ensure that the pressure is progressively
removed by tightening a 1/4"-28 bolt into the end of
increased up to full working requirements over the
the "Assembly Sleeve".
first hour of operation. In circumstances where the
9. Check that the bushings are flush against the pressure cannot be directly controlled the same ef-
mounting flange face and that the lobe seals (index fect can be obtained by progressively increasing
4) and backing washers (index 3) have not become the work load on the machine, over the same pe-
dislodged. Check to see that the arrow on the riod of time.
body, adjacent to the word "ROTATION" is point-
5. During this period make frequent checks of the
ing in the correct pump rotation.
pump casing temperature, or the oil temperature, if
10. Mesh the idler gear (index 8) with the drive gear. If a temperature gauge is included in the system.
the original gears are being replaced on a new The temperature should not exceed that experi-
shaft, make sure that the marked side of the teeth enced under normal working conditions. If the tem-
are in contact so the bedded-in position of the teeth perature does rise excessively then it is possible
is maintained. that the pump has been assembled incorrectly and
it must be dismantled to check this. If no fault is
11. Pick up the bushings for the end cover side of the
found then further period of running-in at low pres-
pump, complete with lobe seals and backing wash-
sure, as in step 3, must be carried out.
ers and slide them over the gear journals with the
lobes facing outward and away from the flats in the
bores. Again, the bushings must be installed
squarely and without force.
12. Lubricate the body seal "O" ring (index 6) and seat
it in the body.
13. Place the end cover in position, aligning the scribe
marks made earlier.
14. Insert the bolts and lockwashers into the body and
hand tighten into the tapped holes in the mounting
flange. Apply a torque load of 4.7 to 5 kgm (34 to
36 ft lbs) to each bolt head.
15. Pour a small amount of hydraulic oil into the ports
and check the pump for freeness and direction of
rotation.
Crown 1982 PF5372-5 Rev. 9/06 SP3500 M2.1-10.0-005

01 Rev. 9/06
127
Notes:
128
HYDRAULIC SYSTEM
Lift/Lower Manifold
Lift/Lower Manifold
Relief Valve (RV1)
Operation
The lift system is protected from excessive oil pressure
by RV1. RV1 senses pressure in the lift circuit. Oil pres-
sure is applied to the sensing side of RV1 through the
pilot line. If oil pressure exceeds RV1's adjustable pres-
sure setting, pilot pressure will overcome RV1's spring
force compressing the spring and opening the valve.
Refer to Figure 23491. Oil will bypass the lift circuit by
flowing through RV1 and into the reservoir. When pres-
sure is less than RV1's pressure setting, RV1's spring
keeps RV1 closed and oil flows to the lift cylinders.
Oil flow (lift is requested)

Pilot pressure
Figure 23491
1 Pilot pressure does not exceed RV1’s spring force, valve is

closed
2 Pilot pressure exceeds RV1’s spring force, valve is open
3 Spring
4 From pump
5 To lift cylinders
6 To reservoir
Crown 2007 PF15809-1 Rev. 2/10 SP3500 M2.4-7335-001

01 Rev. 2/10
129
HYDRAULIC SYSTEM
Lift/Lower Manifold
Adjustment
To adjust RV1, refer to Figure 23159 and proceed as
follows:
1. A fully charged battery of correct voltage should be
installed in the truck before making a relief valve
(RV1) adjustment.
2. Connect a 0-35 MPa (0-5000 psi) pressure gauge
to the quick disconnect fitting.
3. Completely depress the raise button to insure both
pumps are running when the relief valve is being
set.
4. Operate the hydraulic system until the oil tempera-
ture is between 37° and 54° C (100° and 130° F).
5. Loosen the jam nut so RV1 can be adjusted. Raise
the platform until it contacts the stops. Hold the
raise button in completely so both lift pumps are
running and check indication of pressure gauge
when the relief valve opens. Turn the adjustment
screw to change the setting.
– Set the pressure to 19.20 to 19.37 MPa (2785
Figure 23159
to 2810 psi).
1 Quick Disconnect (for Pressure Gauge) 6. Tighten the jam nut when adjustment is correct.
2 Jam Nut
7. Lower the platform 150 - 300 mm (6 - 12 in) and
3 Adjustment Screw then raise the platform until it contacts the stops.
Re-check the relief valve setting and re-adjust it if
necessary.
M2.4-7335-002 SP3500 Crown 2007 PF15809-2 Rev. 2/10
01 Rev. 2/10
130
HYDRAULIC SYSTEM
Lift/Lower Manifold
Symptom Probable Cause Possible Solution

Oil leaks around Defective o-rings in cartridge Replace o-rings.
manifold. valve or port connector fittings.
Platform will not raise Relief valve stuck in the open po- Replace relief valve.
(pump[s] runs). sition.
Solenoid valves or manual valve Actuate the valve(s) and try to dislodge the de-
stuck in the open (free flow) bris. Check to see that the valve (solenoid only)
position. is not over-tightened. If neither of the above
remedies work, replace valve.
No low speed raise; high Check valve (CV1) stuck in the Actuate lift button several times to try and
speed raise works open position. dislodge debris. If that doesn’t work, replace
properly. check valve.
Platform will not raise Relief valve not adjusted correctly. Re-adjust relief valve RV1 to the proper setting
capacity load. (see the previous page).
Platform drifts down in Defective o-rings on check valves, Replace o-rings or back-up rings. Check valve
excess of the drift test solenoid valves, manual valve or capacity at o-ring sealing area for nicks or rough
specification. relief valve. surfaces.
Debris caught in check valve Actuate the valve(s) and try to dislodge the de-
seats. bris. If that doesn’t work, replace valve.
Manual valve not closed properly. Close manual valve or replace.

Platform will not lower. Solenoid coil failure. Check for proper voltage input and coil resist-
ance If OK, check valve for dirt, debris or broken
spring. Check for dirt, debris in the valve or bro-
ken valve spring.
Cylinder malfunction. Refer to Cylinders.
Electrical malfunction. Refer to the Wiring Diagrams (see Table of Con-

tents).
Crown 2007 PF15809-3 Rev. 2/10 SP3500 M2.4-7335-003

01 Rev. 2/10
131
Notes:
132
HYDRAULIC SYSTEM
Accumulator
Accumulator Precharging
The accumulator is a device in which compressed gas 1. Lower platform completely.
and oil is stored for the purpose of absorbing shock.
2. Turn key switch off, disconnect battery, chock
When the oil pressure in the line rises, incoming oil
wheels and tagout truck.
compresses the gas. As the surge of oil pressure
passes, the gas expands to its original size, forcing out 3. Open the power unit doors and locate the lift man-
oil. This reduces vibrations and shock in the system ifold. Open the manual valve (MV1) to remove oil
and reduces shock when contacting stops during lift pressure from oil side of the accumulator.
and lower.
Figure 23231
1 Accumulator
Use an inert gas, such as Nitrogen for precharging or

topping off of accumulators. Size "T" bottle dry nitro- Figure 23162
gen, 8.5m3 (300 cu ft), 17.9 MPa (2600 psi) is recom-
mended. 1 Manual Lowering Valve
4. Disconnect the hose from the accumulator, loosen

mounting clamp and remove accumulator. Refer to
WARNING Figure 23231.
Never use oxygen as a charging agent for accumula-
tors. Use only dry nitrogen as a charging agent for ac- NOTE
cumulators.
If the gas pressure in the nitrogen bottle is higher than Since this procedure disconnects an oil line, care
the maximum operating pressure of the accumulator, a should be taken to catch as much oil as possible.
gas pressure reducing valve must be used. 5. Remove dust cap from accumulator gas valve.
Crown has available a 103623-004 Accumulator 6. Use thread sealing and lubricating compound on
Charging Tool, designed for charging and testing blad- pipe threads of gage.
der and/or diaphragm type nitrogen charged accumu-
lators. 7. Attach one end of charging hose to the nitrogen
bottle and the other end to the accumulator charg-
The accumulator must be removed from the truck prior ing tool. Refer to Figure 15728. Procedure is simi-
to testing or charging. lar when using only charging hose with or without
other accessories.
Crown 2010 PF17862-1 SP3500 M2.6-7435-001
133
HYDRAULIC SYSTEM
Accumulator
8. Back gas chuck stem all the way out before attach- Do not reduce accumulator precharge by depressing
ing assembly to accumulator gas valve. valve core (high pressure may rupture rubber valve
seat).
12. If desired precharge pressure is exceeded, make
Bleeder Valve
sure nitrogen bottle valve is closed, then open
bleeder valve slightly, but only momentarily, to re-
duce pressure.
Bottle Valve 13. Once desired accumulator charge has been

achieved, remove Accumulator charging tool.
14. With the use of sealing spray or soapy water,
Gage check accumulator for leaks.
15. Replace dust cap on accumulator and install on
Accumulator truck.
16. Reconnect battery.
17. To bleed air from the accumulator, the empty forks
should be raised to sufficiently pressurize the lift
cylinders.
Nitrogen
NOTE
Since this procedure disconnects the oil line, care
should be taken to catch as much oil as possible.
18. Slowly loosen the hose connection at the accumu-
lator until all air-oil mixture is released and a steady
Figure 15728 stream of oil is evident.
9. Use wrench to tighten gas chuck swivel nut onto
accumulator gas valve. Close bleeder valve.
WARNING
10. Use gas chuck stem to loosen gas valve in accu-
mulator. AVOID HIGH PRESSURE FLUIDS-Escaping fluid un-
11. Slowly open nitrogen bottle valve to fill accumula- jury. Relieve pressure before disconnecting hydraulic
tor. Once the pointer on the gage starts to deflect lines. Tighten all connections before applying pres-
unscrew the gas chuck stem one full turn. The sure. Keep hands and body away from pin holes which
charge should be over a 2 to 4 minute period to eject fluids under high pressure. Use a piece of card-
assure a proper charge and to prevent damage to board or paper to search for leaks. Do not use your
accumulator. Shut off when gage indicates proper hand.
charge. Use the gas chuck stem to tighten gas Any fluid injected into the skin under high pressure
valve in accumulator to 11 Nm (8 ft lb). The pre- should be considered as a serious medical emergency
charge pressure setting is 3445 kPa (500 psi). despite an initial normal appearance of the skin. There
may occur. Medical attention should be sought imme-
CAUTION diately by a specialist who has experience with this
type of injury.
Do not loop or twist hose as it will stiffen when gas
pressure is released from nitrogen bottle. 19. Tighten connector.
Never loosen swivel nut attached to gas valve in accu-
20. Remove wheel chocks and tagout. Return the
mulator without first backing gas chuck stem out all the
truck to service.
way.
M2.6-7435-002 SP3500 Crown 2010 PF17862-2
134
HYDRAULIC SYSTEM
Hydraulic Troubleshooting lems that occur. The ability to identify problems and
proceed in solving the problem grows with experience.
The following Troubleshooting Chart contains general The following chart contains symptom, probable cause
information necessary to effectively solve the more and remedy. The information is general in nature and a
common hydraulic problems. Know the system to the remedy may simply refer you to a maintenance section
best of your ability. Understand the components and that has more complete troubleshooting. Use the
their function within the system. Develop a systematic chart(s) carefully and completely. Do not overlook the
pattern to locate and solve the various hydraulic prob- simplest reason(s) for a hydraulic problem.
Hydraulic Troubleshooting Chart

Hydraulic oil foaming Introduction of air into the pump Check reservoir oil level.
Check for proper oil viscosity.
Check plumbing.
Water in oil Check reservoir and replace oil.
Hydraulic oil overheating * Oil too thin * Change to proper viscosity oil.
Oil contaminated Change filters and replace oil with clean oil.
Introduction of air into pump Check plumbing.
Oil level low Fill reservoir to proper level.
Platform will not raise Mast assembly binding Inspect mast for damage or misalignment.
Lift motor or pump not operating Refer to pump troubleshooting.
Manual lowering valve open Close manual valve. Refer to Componentry
section.
Relief valve setting incorrect Reset relief valve. Refer to Lift/Lower Manifold
section.
Relief valve open Check for more than capacity load. Check relief
valve for dirt, debris or broken spring.
Platform will not lower Velocity fuse actuated Check for severe oil leak.
Raise slightly to reset velocity fuse.
Chain slack switch actuated Platform/Forks resting on obstruction.
Raise slightly to eliminate chain slack.
Solenoid valve(s) malfunction Check for proper voltage input and coil resist-
ance. If OK, check valve for dirt, debris or bro-
ken spring.
ment, etc.
*Be sure the truck has been performing its normal duty cycle at this time. Trucks equipped to operate in
freezer require a thinner weight oil.
Crown 2010 PF17889-1 SP3500 M2.9-7335-001
135
HYDRAULIC SYSTEM

Lowers too slow Debris in valve(s) Cycle through lift/lower to free possible debris.
Accumulator malfunction Check accumulator operation.
ment, etc.
Lowers too fast Debris in valve(s) Cycle through lift/lower to free possible debris.
External oil leak Check plumbing for leak(s).
Accumulator malfunction Refer to accumulator maintenance section
M2.6.
No hi-speed raise Pump P2 malfunction Check pump operation. Check pump and mo-
tor spline.
RAS2 switch malfunction in con- Refer to componentry section M1.0.
trol module
No hi-speed lower LOS2 switch malfunction in con- Refer to componentry section M1.0.
trol module
Proportional solenoid valve PVL Check for proper voltage input and coil resist-
malfunction ance. If OK, check valve for dirt, debris or bro-
ken spring. If resistance is OK. Check for dirt,
debris in the valve or broken valve spring.
No cushion during raise or Accumulator malfunction Charge accumulator properly. Refer to section
lower M2.6.
Damaged cushion springs or Inspect for damage.
bumpers
Will not lift capacity load Relief valve not adjusted properly Adjust relief valve. Refer to Lift/Lower Manifold
section M2.4.
Mast binding Inspect mast for damage, misalignment, etc.
Hydraulic component(s) malfunc- Refer to hydraulic pump M2.1 & cylinders M8.0.
tion
Platform drifts down Debris in valve(s) Cycle through lift/lower to free possible debris.
(in excess of drift test)
Lift cylinder packings leaking Refer to cylinder information section M8.0.
Accumulator loses charge Accumulator valve leaking, Repair/replace accumulator. Refer to accumu-
cracked, deformed, or a hole has lator maintenance section M2.6.
developed in the internal bladder,
etc.
Abnormal hydraulic oil us- External leak Check plumbing, cylinder, other hydraulic com-
age ponents.
M2.9-7335-002 SP3500 Crown 2010 PF17889-2
136
HYDRAULIC SYSTEM

Lift pump & motor over- Relief valve setting too high Reset relief valve. Refer to hydraulic mainte-
heating * nance section M2.4.
Battery is discharged Check battery under load. Check battery volt-
age (from ACCESS 1, Level 2, scroll to A2.4.3
Battery). If battery discharge is too deep, adjust
performance menu P9 BDI setting.
Exceeding capacity load Check load weight.
Worn or damaged pump & motor Inspect pump & motor. Repair or replace.
Fluid level low Inspect fluid level. Fill system to proper level.
Refer to section M2.0.
Failure of platform to raise Lift chains not adjusted properly Adjust chains.
and lower smoothly
Mast and/or platform binding Inspect mast & platform for damage, wear, etc.
Hydraulic component malfunction Inspect pump, motor, valve, cylinder, etc. for
damage, leaks, wear, etc.
Accumulator malfunction Refer to section M2.6.
Air trapped in cylinder Bleed.
* Be sure the truck has been performing its normal duty cycle at this time.
Crown 2010 PF17889-3 SP3500 M2.9-7335-003
137
Notes:
138
DRIVE UNIT
139
Notes:
140
DRIVE UNIT
Drive Unit
Drive Unit 5. Use suitable press tooling for press to contact hub
circumference and remove existing tire from hub.
6. Discard existing tire.
CAUTION
7. Check the OD leading edge chamfer of the hub to
Disconnect battery and chock load wheels before per- verify it is free of burrs or gouges.
forming any maintenance procedure. 8. Check the circumference of the hub for heavy gall-
ing, replace if necessary.
Drive Tire Replacement 9. Verify the base band of the tire has not been previ-
ously pressed.
CAUTION 10. Place new tire on press, centered below ram.

11. Lightly lubricate inside top 75 mm (3 in) of tire band
Replacement of original equipment tires with other
with light oil.
than those recommended by Crown may result in de-
creased operating performance, traction and stability. 12. Place hub directly over tire with leading edge
Refer to the table of contents for appropriate parts chamfer inserted into tire band. Refer to Figure
pages. 23283.
When replacing the drive tire, make sure the composi-
tion and size are such that maneuverability and braking
requirements are maintained. Refer to truck data plate
for tire information.
The drive tire is a press-on type. To press the old tire
off of the hub and press the new tire on:
1. Disconnect battery and chock wheels. Lockout/Ta-
gout the truck as described in Lockout/Tagout in
the Control of Hazardous Energy section of the
manual.
CAUTION
Make sure the lifting device and blocking material are
sufficiently rated and strong enough to withstand the
weight of the truck. Never work under or around a truck
that is not properly blocked and secure.
2. Raise and block the power unit so the drive tire is
off of the floor. Refer to Control of Hazardous En-
ergy, Lifting and Blocking for correct procedures. Figure 23283
3. Remove eight lug bolts and remove drive tire from 1 Ram
the truck. Be careful not to damage the threaded
2 Hub
studs when removing the tire.
3 Tire
4 Steel Plate Work Surface
CAUTION
13. Center hub and tire below ram plate, which should
Extreme pressure is used to press tires, always exer- be a minimum 205 mm (8.00 in) diameter.
cise caution and assure that only trained personnel are
allowed to operate a hydraulic press.
4. Place existing tire assembly on hydraulic press di-
rectly below ram.
Crown 2010 PF17876-1 SP3500 M3.0-7435-001
141
DRIVE UNIT
Drive Unit
14. Several checks should be made during the press

operation:
– Monitor hub tire alignment closely during first
75 mm (3 in) of insertion, misalignment can
damage the tire band.
– Monitor press force during process, low force
may indicate a worn out hub.
– Always press the hub into the tire for proper in-
stallation.
– Press until hub face is flush with tire band.
15. Inspect hub (2) and remove any paint that may be
present on tapered lug seats (3) or on inner hub
face (1) that contacts truck axle. Refer to Figure
23281.
Figure 23282
17. Remove blocks, lower power unit, connect battery,

remove wheel chocks and tagout.
Figure 23281
16. Finger tighten lug bolts. Then, according to the se-

quence shown in Figure 23282, torque bolts to 135
- 150 Nm (100 - 110 ft lb).
M3.0-7435-002 SP3500 Crown 2010 PF17876-2
142
DRIVE UNIT
Drive Unit
Drive Unit Lubrication Oil Pump Disassembly

The drive unit has a capacity of approximately 710 ml
(Refer to Figures 16867-01 and 17179-01)
(1.5 pints) of 80/90W gear oil. Refer to Lubrication &
Adjustment chapter for correct lubricant part number. 1. Disconnect battery and chock wheels. Lockout/Ta-
Remove drain plug (2) to completely drain unit. Apply gout truck as described in Control of Hazardous
hydraulic sealer (part number 061004-023) to drain Energy section.
plug and replace. To fill, remove fill plug (1). Add gear
oil until present at oil level check plug. Refer to Figure
17178-01.
Figure 16867-01
1 Oil Pump Housing 8 Spring

2 O-Ring 9 Piston
3 O-Ring 10 Bearing Cup
4 Ball 11 Bearing Cone
Figure 17178-01 5 Spring 12 Axle

6 Special Plug 13 Cam
1 Fill and Oil Level Check Plug 7 Ball 14 Drive Unit Housing
2 Drain Plug
2. Remove drain plug (2); drain oil from drive unit. Re-
fer to Figure 17178-01.
Crown 2010 PF17876-3 SP3500 M3.0-7435-003
143
DRIVE UNIT
Drive Unit
Oil Pump Assembly

(Refer to Figures 16867-01 and 17179-01)
Inspect all component parts and drive unit casting for
dirt and burrs before assembly.
1. Place ball (4) and spring (5) into oil pump housing
(1).
2. Place ball (7), spring (8) and special pipe plug into
piston (9). Lubricate piston with oil to aid in smooth
action and install piston into oil pump housing in-
stalled in drive unit housing.
3. Install o-rings (2) and (3) onto pump body.
4. Oil pump body and port thoroughly and screw
pump assembly into casting until seated.
(1.5 pints) of gear oil. Refer to Lubrication and Ad-
justment chapter for lubricant information.
6. To check oil pump output, remove plug (15) and
observe oil flow from port.
Drive Unit Removal and Installation

1. Disconnect battery and chock wheels. Lockout/Ta-
gout truck as described in Control of Hazardous
Energy section.
2. Open power unit doors.
Figure 17179-01
25 Tubing is Installed Through Cored Hole in Casting

NOTE
3. Remove oil pump housing (1) from drive unit and Make note of all electrical connections removed.
move to a clean work area for further disassembly. 3. Disconnect all electrical wiring to drive motor and
4. Check o-rings (2) and (3) for damage and replace electric brake. Remove four bolts that secure drive
if necessary. motor and electric brake to drive unit and remove
completely.
5. Remove piston (9), spring (8) and ball (7) from oil
pump housing.
6. Remove special pipe plug (6), spring (5) and ball
(4) from oil pump housing.
7. Thoroughly clean housing and all parts.
M3.0-7435-004 SP3500 Crown 2010 PF17876-4
144
DRIVE UNIT
Drive Unit
6. Remove four bolts and two dowel pins that fasten

drive unit to power unit. When reattaching drive
unit with these bolts, apply a small amount of
thread locking adhesive (061004-009) and tighten
to 340 - 370 Nm (250 - 275 ft lb).
7. Stabilize drive unit and raise and block power unit
until drive unit will clear power unit.
8. Move drive unit to a clean work area for further dis-
assembly.
9. Reverse steps 1 through 7 to install drive unit. Align
marks on drive unit and pivot stud. Refer to Figure
23285. This ensures steered wheel is in straight
ahead position.
1 Brake 1 Pivot Stud

2 Drive Motor 2 Alignment Marks
3 Drive Unit Mounting Bolts 3 Drive Unit
4 Drive Unit Dowel Pins
4. Raise and block power unit. Remove drain plug in and replace drain plug. Fill drive unit with gear oil.
bottom of drive unit and allow gear oil to drain. Refer to Lubrication and Adjustment chapter for lu-
5. Remove drive tire. Refer to Drive Tire Replace- bricant information.
ment when assembling drive tire.
Crown 2010 PF17876-5 SP3500 M3.0-7435-005
145
Notes:
146
ELECTRICAL SYSTEM
147
Notes:
148
ELECTRICAL SYSTEM
Relays
Relays NOTE
ED1 provides +BV to the platform accessories, M3 and
K1 and K2 M4 via P1 and P2 contactor tips. ED2 provides +BV to
ACCESS 3, ACCESS 5 and the BRK1 coils. Using
separate relays and contactors for the different func-
Power Up Relay and Power Unit Relay tions allows traction, steering and hydraulics to be dis-
K1 is mounted on the platform distribution panel and abled while keeping the modules powered up when the
provides +BV to the platform control circuitry, K2 coil operator leaves the platform.
and ED1 coil. K2 is mounted on the power unit distribu-
tion panel and provides +BV to the power unit control Start Up Circuit
circuitry.
The following is a step-by-step explanation of how the
start up circuit works. Refer to Figure 23337.
Figure 23337
1. While the key switch is in the OFF position, before 5. When the key switch is turned to the IGN position,
keying the truck ON, K1 is open and does not con- current flows through the K1 contacts. The current
duct. flowing through the K1 contacts keeps the K1 coil
energized via CR2, maintaining the state of K1.
2. When the key switch is turned to the START posi-
tion, the K1 coil is energized through CR1, which 6. The current through the K1 contacts now flows to
causes the K1 contacts to close. the ED1 coil and the K2 coil.
3. No current will be supplied to the K1 contacts until 7. The ED1 coil and the K2 coil are fully energized
the key switch is turned to the IGN position. after about 10 milliseconds. The K2 contacts close
and supply +BV to ACCESS 3, ACCESS 5,
4. While the key switch is in the START position, an
ACCESS 6 and other functions through FU3. The
initial inrush of current flows through TR1 and be-
ED1 contacts close and supply +BV to M3, M4 and
gins to pre-charge ACCESS 1 and ACCESS 4 (lo-
other functions. CR11 ensures that after the K2
cated on the platform), the ED1 coil, the K2 coil,
contacts close, the K1 contacts no longer provide
ACCESS 3, ACCESS 5 and ACCESS 6 (located in
+BV to ACCESS 3, ACCESS 5 and ACCESS 6
the power unit) through FU3.
(the pre-charge current is off) and that the K2 con-
tacts no longer provide +BV to the K1 coil.
Crown 2010 PF17877-1 SP3500 M4.0-7435-001
149
ELECTRICAL SYSTEM
Relays
8. The start up circuit remains energized until the key K11 and K12
switch is turned to the OFF position, or until EDS is
opened.
Freezer/Condition Relays
9. +BV is then cut off to K1 and the K1 coil is de-en-
ergized. CR11 prevents current from the K2 con- K11 and K12 are mounted on the freezer/condition dis-
tacts from re-energizing the K1 coil. CR3 forms a tribution panel. The freezer/condition distribution panel
path for the regenerative current that keeps flowing is mounted on the bottom of the power unit controller
through the K1 coil after its voltage has been re- panel beneath ACCESS 5 and ACCESS 6. When
moved. CR3 is necessary to prevent the K1 coil THS2, which is mounted on the power unit battery wall,
from generating a high voltage that could damage registers less than 4° C (40° F), it closes. Since the
itself or other components. temperature is less than 49° C (120° F), THS3, which
is mounted below the platform, also closes and K11
10. With K1 OFF, +BV to the ED1 coil and the K2 coil and K12 energizes. When THS3 registers more than
is cut off and the truck powers down. 60° C (140° F), it opens and removes the current path
from the K11 and K12 coils, resetting the relay contacts
and opening the current path to the heaters. As the
temperature drops to less than 49° C (120° F), the
THS3 contact closes again. Since the K11A contact is
open and the temperature is more than 4° C (40° F),
keeping THS2 open, K11 and K12 do not energize until
the temperature drops to less than 4° C (40° F), closing
THS2. Refer to Figure 23338.
Figure 23338
K15
Travel Alarm Relay

K15 is mounted on the platform side of the power unit
and provides +BV to HN2. Refer to Figure 23338.
M4.0-7435-002 SP3500 Crown 2010 PF17877-2
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ELECTRICAL SYSTEM
Electrical System
Electrical System circuit in which it is used. Each wire is assigned a three

or four digit number. The first one or two numbers iden-
The following is an explanation of terms and symbols tify the color of the lead. The last two numerals number
which are standard on Crown wiring diagrams. the lead from one thru ninety-nine. Exceptions to this
can be component leads supplied by vendors. Each
wire is identified by a number on a wiring pictorial (refer
Wiring Color Codes to section DIA).
Wires are limited to the colors shown in the chart be-
low. The color of the wire is based on the function of the
Wiring Color Codes Chart
Number Color Function

0** Black Traction Inputs/Outputs
1** Brown Analog Inputs
2** Red Battery Positive
3** Orange Non-Battery Positive
4** Yellow Status Inputs/Outputs
5** Green Battery Negative
6** Blue Isolated Negative
7** Violet Load Position Inputs/Outputs
8** Gray Indicators and Warning Devices
9** White Miscellaneous
29** Red Stripe/White Positive that has gone thru a switch
59** Green Stripe/White Negative that has gone thru a switch or resistor
Power Cables
Except WP trucks, power cables are designated using Power Cables Abbreviations Chart
one of the following abbreviations, followed by a dash
number. Abbreviation Part Numbers
PC#1 084571
PC#2 084570
PC#4 084569
PC#6 084568
PC#10 090963
PC#1/0 084572
PC#2/0 084573
PC#3/0 086749
An example of such a cable is PC # 1/0 - 10. The part

number for this cable is 084572-010.
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ELECTRICAL SYSTEM
Electrical System
Component Abbreviations and Designators

Component Abbreviations and Designators
REC Rectifier
Components
RES Resistor
1AD 1A Bypass Driver
SB Suppressor Block
ALM Alarm
SSC Safety Switch Card
ATD Anti Tie Down Module
SV Hydraulic Solenoid
BATT Battery
SVA Solenoid Valve - Accessory
BDI Battery Disch. Interrupt
SVL Solenoid Valve - Lower
BRK Brake
SVP Solenoid Valve - Pilot
CA Connector Assembly
SVR Solenoid Valve - Reach
CAP Capacitor
SVS Solenoid Valve - Sideshift
DB Diode Block
SVT Solenoid Valve - Tilt
DFR Defrost
TB Terminal Board
DMC Dual Motor Card
TD Time Delay
DR Driver Module
TDR Time Delay Relay
ECN Encoder
TMM Truck Management Module
FAN Fan
TP Test Point
FIL Filter
TT Hour Meter (Truck Time)
FLS Flasher
V Discharge or Volt Meter
FU Fuse
XC Socket for PC Board
HF Hash Filter
Contactor and Relays
HN Horn
A Speed Contactor
HR Heater
B Speed Contactor
HSC High Speed Card
C Speed Contactor
JC Fixed Part of Ca
D Dual Contactor
LGT Light
ED Emerg. Disc. Contactor
M Motor
F Forward Contactor
MCR Motor Control
FA Forward Contactor A
PC Movable Part of Ca
FB Forward Contactor B
PCVA "Pressure Compensated Valve, Acc."
FW Field Weakening
PCVH "Pressure Compensated Valve, Hoist"
K Relay
PMTD Pulse Monitor Trip Driver
P Pump Contactor
POT Potentiometer
R Reverse Contactor
PS Power Supply
RA Reverse Contactor A
PS Pressure Switch
RB Reverse Contactor B
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ELECTRICAL SYSTEM
Electrical System
Component Abbreviations and Designators Component Abbreviations and Designators
RGB Regen. Braking Contactor DTS Drive Tow Switch

S Power Steering Contactor ECS Elevation Control Switch
1A Bypass Contactor EDS Emergency Disconnect Switch
Switches EIS Extend In Switch
1AS Traction Bypass Switch EMS Emergency Switch
ACC Accessory Switch ENS Entry Switch
ACS Accelerator Switch EOS Extend Out Switch
AHS Aux. Height Switch ERLS Emergency Raise/Lower Switch
AS Switch For A Contactor ERS Erase Switch
AxA Aux. Sw. on A Contactor EXS Extend Switch
AxB Aux. Sw. on B Contactor FHS Fork Home Switch
AxC Aux. Sw. on C Contactor FKS Fork Switch
AxF Aux. Sw. on Fwd. Contactor FLMCS Forward Left Motor Cover Sw
AxR Aux. Sw. on Rev. Contactor FLS Fork Left Switch/Free Lift Switch
AXS Aux. Function Switch FNS Fan Switch
BFS Brake Fluid Switch FRMCS Forward Right Motor Cover Sw
BLS Battery Latched Switch FRS Fork Right Switch
BMS Brake Monitor Switch FS Forward Switch
BPS Brake Pressure Switch FTS Foot Guard Switch
BRES Battery Restraint Switch GCSL Gate Closed Switch Left
BRS Brake Switch GCSR Gate Closed Switch Right
BS Switch For B Contactor GOSL Gate Open Switch Left
CHS Chain Switch GOSR Gate Open Switch Right
CHSL Chain Switch Left GTS Gate Switch
CHSR Chain Switch Right GUS Guidance Switch
CLS Clamp Switch HCS Height Cable Switch
CS Switch For C Contactor HGTS Height Switch
CTS Cable Tension Switch HNS Horn Switch
DIS Direction Switch HSS High Speed Switch
DMS Dead Man Switch HTS Heater Switch
DMSL Dead Man Switch Left HTSXX Height Switch (XX Inches)
DMSR Dead Man Switch Right KORS Key Override Switch
DPS Display Switch KYS Key Switch
DRS Door Switch LCS Lower Cutout Switch
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ELECTRICAL SYSTEM
Electrical System
Component Abbreviations and Designators Component Abbreviations and Designators
LGS Light Switch SWH Operator Activated Switch

LMS Limit Switch TBS Tilt Back Switch
LOS Lower Switch TDS Tilt Down Switch
LTS Loadtray Switch TES Test Switch
MFS Multi-funciton Switch THS Thermal Switch
MVS Multi-voltage Switch TLS Traverse Left Switch
NUS Null Switch TLT Tilt Switch
ORS Override Switch TRS Traverse Right Switch
PLS Pivot Left Switch TUS Tilt Up Switch
PORS Presence Overide Switch TVS Traverse Switch
PRS Pivot Right Switch ZSS Zone Select Switch
PS Pressure Switch Terms
PTS Pivot Switch ASM Assembly
PUS Pump Switch CTRL Control
QPS Quick Pick Switch CTRLR Controller
RAS Raise Switch DESIG LIST Designation List
RES Reach Extended Switch DIST PNL Distribution Panel
RGS Rail Guide Switch DSPL Display
RGSL Rail Guidance Switch Left F/C Freezer Conditioning
RGSR Rail Guidance Switch Right HCM Hydraulic Control Module
RIS Reach In Switch HDL Handle
RLMCS Rear Left Motor Cover Switch HYD Hydraulic
ROS Reach Out Switch OHG Overhead Guard
RRMCS Rear Right Motor Cover Switch PCB Printed Circuit Board
RS Reverse Switch PICT Pictorial
RSS Sheet Retainer Switch PKT Packet
SAS Safety Switch PL Platform
SCS Sideshift Center Switch PWR Power
SES Seat Switch PWR SPLY Power Supply
SLS Sideshift Left Switch SCHEM Schematic
SQS Sequence Switch TCM Traction Control Module
SRS Sideshift Right Switch TMM Truck Management Module
SSS Sideshift Switch TRAC Traction
STS Power Steer Switch
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ELECTRICAL SYSTEM
Electrical System
Switches Momentary or Maintained Contact
Switch symbols convey: • Momentary contact is a shaded triangle.
1. Type of switch.
2. Number of terminals.
3. Momentary or maintained contact. Figure 8119-01
4. How the switch is held and wired. or
5. How the switch is activated.

6. Application.
Figure 8120-01
Type of Switch
• Maintained is an open circle (an open circle also
• With common denotes the common terminal).
Figure 8115-01 Figure 8115-01
or or
Figure 8117-01
Figure 8116-01
How the Switch is Held and Wired
• Without common To determine how the switch is held and wired, look
closely at the contact symbols. An open circle denotes
a maintained contact so therefore it is the normally
closed terminal. A shaded triangle denotes a momen-
Figure 8117-01 tary contact, therefore it is the normally open terminal.
or Switches having more than one maintained contact do
not have a normally open or normally closed terminal,
although they may have a common. Symbols for these
switches include the markings present on the actual
switch.
Figure 8118-01
Example:
Number of Terminals
• All terminals are shown even if not wired.
Figure 8121-01
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ELECTRICAL SYSTEM
Electrical System
Examples (All Momentary)
With Common (Transfer) Without Common (Double Break)

Wired normally
open, held open
Wired normally
open, held closed Figure 8122
Figure 8123
Wired normally
closed, held open
Wired normally
closed, held closed Figure 8124 Figure 8125
How the Switch is Activated

If it is necesary to include how the switch is mechani-
cally actuated, a note will be added to the drawing (ex-
ample: operator, lever or truck actuated, etc.)
Application
Switch application is conveyed through the abbrevia-
tion (example: HTS = Height Switch 120 in., DTS =
Drive/Tow Switch).
Notes:
• In a schematic, the condition of a circuit is defined

using a note (example: vehicle shown fully low-
ered with no operator on vehicle).
• Positive action switches are marked with the fol-

lowing symbol:
8126-02
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ELECTRICAL SYSTEM
Electrical System
Switch Symbols (Mechanically activated switches)
No. of Momentary Fully Maintained

Actuation Description
Terminals w/common w/o common w/common w/o common
Figure 8100-01
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ELECTRICAL SYSTEM
Electrical System
Switch Symbols (Mechanically activated switches)

Continued
No. of Momentary Fully Maintained

Actuation Description Terminals w/common w/o common w/common w/o common
Figure 8101-02
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ELECTRICAL SYSTEM
Electrical System
Specialty Switches
Pressure Switch
Figure 8127
Reed Switch
Figure 8128
Temperature Switch
Figure 8129
Brake Fluid Switch
Figure 8130
Three Position Key Switch
Start
Off
Figure 8131-01
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ELECTRICAL SYSTEM
Electrical System
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 Nonpolarized
Return Termination
Capacitor
Female/ Polarized
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
Figure 8132-02
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ELECTRICAL SYSTEM
Electrical System
Other Electrical Symbols
Transistor DC/DC
Dual
PNP Converter
Suppressor
Power Supply
Darlington Battery
NPN Dual
Contactor Suppressor
Normally
Darlington Open
PNP
Contactor Filter Block
Normally
N-FET With
Closed
Diode Clamp
Coil OR Gate
P-FET With
Diode Clamp Coil NOR Gate
Suppression
Motor Field, Fuse - Band Schmitt NAND
Series Shows Positive
Feed
Motor Field,
Shunt Tach Sensor Schmitt
Buffer
Series Motor, Hour Meter
DC Schmitt
Inverter
Lamp
Shunt Motor,
DC Amp/Comp
Horn
Permanent AND Gate

Magnet Encoder
Motor
NAND Gate
Suppressor
Separately
Excited Motor, DC X-OR Gate
Suppressor
Motor, AC X-NOR Gate
Suppressor
Transformer Integrated
Circuit
Figure 8133-02
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Notes:
162
ELECTRICAL SYSTEM
ACCESS 123®
ACCESS 123®
1 Display Screen
2 Navigation Keys (Up Arrow, Down Arrow, Left Arrow, Right Arrow) Used to Scroll
through Menus
3 Enter or Return Key Used to Navigate in and out of Menus and to Accept Inputs
4 Wire Guidance Display (Optional)
5 Performance Level Indicators
6 Battery Discharge Indicator
Figure 17869-02
ACCESS 1 Display Operator Level 1

ACCESS 1 display messages and menus can be ac- The operator level is accessed by turning the key
cessed from three levels of authorization: switch ON. The operator may choose from the follow-
ing options (provided a higher priority message is not
1. Operator Level
active):
2. Service Level - Level 2
• Message (for example BDI = 70%)
3. Service Level - Level 3
Typical navigation button usage: up and down arrows
• Hour
will scroll through menu choices, right arrow will enter • Events
a menu and left arrow will exit the current menu. The
enter or return button is used to select a function or • Service
choice.
• Performance
The following messages will be displayed in order of
priority (if enabled), regardless of operator selection:
1. PM Due
2. User Code
3. Static Return to OFF (SRO) or Advise Message
4. Operator selected message
If any message is more than eight characters it will be
scrolled across the display from right to left.
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ELECTRICAL SYSTEM
ACCESS 123®
After power up, the display will always show SP 3500 Steer - Message Mode
regardless of which menu was selected prior to power-
ing down the truck. To change the message displayed This menu allows the operator to display the approxi-
after power up, enter the Message Mode and select mate steer tire position on the eight character display.
one of the other choices. A more detailed Message If the truck is operating in other message modes, the
Mode explanation follows. approximate steer tire position will be displayed on the
eight character display whenever the operator is de-
pressing the brake pedal and will remain until the truck
CAUTION is traveling at a slow speed. Once the truck begins
travel, the steer indicator will go away to allow the dis-
When replacing or updating software for the playing of the other messages. If the operator would
ACCESS 123 modules, settings and calibrations for prefer to have the steer indicator present at all travel
those modules should be verified to ensure correct speeds, then the operator would select Steer as the
truck operation. message mode. To select this message, key up the
truck. Press the right arrow button to enter the Mes-
After truck power up, SP 3500 will be the message dis-
sage Mode. Use the up or down arrows to scroll to
played until a different message mode menu is se-
Steer. Press the enter or return button. The display will
lected.
exit the Message Mode and show (Steer ^).
Message Mode Model - Message Mode

To enter the Message Mode, key up truck. With a Mes- This menu allows the operator to display the generic
sage (for example BDI = 70%) present on the display, truck model. It is intended to be used in locations where
press the right arrow to enter this menu. Press the up the operator has no need for the other message mode
or down arrows to scroll through menu choices: choices. To select this message, key ON the truck.
Press the right arrow button to enter the Message
1. Steer
Mode. Use the up or down arrows to scroll to Model.
2. Model Press the enter or return button. The display will exit
the Message Mode and show (SP 3500).
3. Timer
4. Trip Timer - Message Mode
5. BDI
This menu allows the operator to display a stopwatch.
6. Hours To select this message, key up the truck. Press the
right arrow, use up or down arrows to display Timer.
7. Odometer
Press the right arrow to enter the Timer menu. Use the
8. Speed up or down arrows to scroll through choices:
NOTE
• Stop
Message Mode is controlled by the Features menu • Start

(F26). F26 allows one of the message choices (in
which case you would not be able to scroll through any
• Reset
choices) or ALL.
Timer - Start
Press the enter or return button. The display will exit
the Message Mode and display;
Stopwatch (00:00:00), which will be incrementing.
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ELECTRICAL SYSTEM
ACCESS 123®
Timer - Stop Hours - Message Mode

Use the up or down arrows to display Stopwatch. Press This menu allows the operator to display accumulated
the right arrow to enter the Message Mode. Use the up runtime hours. To select this message, key ON the
or down arrows to display Timer. Press the right arrow truck. Press the right arrow. Use the up or down ar-
to enter the Timer menu. Use the up or down arrows to rows, scroll to Hours. Press the enter or return button.
display Stop, press the enter or return button. The dis- The display will exit the Message Mode and show H1
play will exit the Message Mode and show the Stop- or H2 = XX). H1 or H2 hours can be shown depending
watch stopped, with whatever amount time accumu- on which hour meter is selected in Features menu F28
lated (example, 01:01:32). Hour Meter. See Hour for an explanation of hour me-
ters.
Timer - Reset
Use the up or down arrows to display the Stopwatch. Odometer - Message Mode
Press the right arrow to enter the Message Mode. Use
Press the right arrow. Use the up or down arrows to
the up or down arrows to display Timer. Press the right
scroll to Odometer. Press the enter or return button.
arrow to enter Timer menu. Use the up or down arrows
The display will exit the Message Mode and show the
to display Reset. Press the enter or return button. The
distance the truck has traveled, in miles (mi=XX) or kil-
display will exit the Message Mode. The Stopwatch will
ometers (km=XX).
be zeroed, and not counting (00:00:00).
Speed - Message Mode

Trip - Message Mode
This menu allows the operator to display the travel
This menu allows the operator to display the distance
speed. Press the right arrow button to enter the Mes-
traveled in either direction since the last reset. To select
sage Mode. Use the up or down arrows to scroll to
this message, key ON the truck. Press the right arrow
Speed. Press the enter or return button. The display
to enter the Message Mode. Use the up or down ar-
will exit the Message Mode and show the travel speed
rows to scroll to Trip. Press the enter or return button
in miles per hour (X.X mph) or kilometer per hour
and the display will exit the Message Mode. The dis-
(X.X kph).
play will show ft=00000 or m=00000.
Trip - Reset
Press the right arrow to enter Message Mode. Use the
up or down arrows to display Trip. Press the right arrow
to display Reset. Press the enter or return button. The
display will exit Message Mode and display distance
traveled reset ft=00000 or m=00000.
BDI - Message Mode

This menu allows the operator to display the battery
percent of remaining charge. To select this message,
key up the truck. Press the right arrow to enter the Mes-
sage Mode. Use the up or down arrows to scroll to BDI.
Press the enter or return button. The display will exit
the Message Mode and show (BDI = XX%).
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ELECTRICAL SYSTEM
ACCESS 123®
Hour Service Levels

This menu allows the operator to view one of twelve This menu enters maintenance levels 2 and 3. A pass-
different hour meter readings. word is required to enter maintenance levels. Contact
your local Crown dealer to obtain this password.
• H1 (key on, truck being used)
• H2 (key on, truck being used plus delay) NOTE

Once maintenance Levels 2 or 3 are entered the truck
• H3 (odometer)
must be turned OFF then back ON to exit the Service
• H4 (lift motor on time) menu.
• H5 (platform on time) Level 2

• H6 (traction motor on time) To enter Level 2, power up the truck. Press the down
arrow until Service is displayed. Press the right arrow,
• H7 (steer motor on time) Level 2 will be displayed. Press the right arrow and four
blank boxes will be displayed. Use the up/down arrows
• H8 (ACCESS 1 on time) to enter the first digit of the password. Press the right
arrow to move to the next digit, continue until the final
• H9 (ACCESS 3 on time) digit is entered. Press the enter/return button to accept
the password.
• H10 (ACCESS 4 on time)
After the password is accepted, the following menus
• H11 (ACCESS 5 on time) can be displayed:
• H12 (ACCESS 6 on time) • Analyzer (A1, A2 and A3 submenus)

To enter this menu, key ON the truck. Press the down • Features
arrow to display Hour. Press the right arrow, H1 will be
displayed. Use the up or down arrows to view different • Performance
hour meter readings. To stop the message from scroll-
ing press the right arrow at the desired hour meter. To • Calibration
exit Hour menu press the left arrow until Hour is dis-
played. • Hour
• Events
Events
• Utilities
This menu allows the operator to view stored event
codes (up to 16). To enter this menu, key ON the truck. An explanation of these menus is located after the
Press the down arrow until Events is displayed. Press menu charts in this section of the service manual.
the right arrow, Last will briefly be displayed. The last
event code stored will then be displayed (EV=XXX).
Use the up or down arrows to scroll through stored
event codes (Last to Last-15). Press the left arrow but-
ton to return to the main menu at Events.
NOTE
Event codes can not be cleared from the Operator level
menu.
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ELECTRICAL SYSTEM
ACCESS 123®
Level 3 Performance
The truck is not operational in Level 3. To enter this This menu allows the operator to choose one of three
level, with your foot off the brake pedal power up the performance modes to operate the truck in only if Op-
truck. Press the down arrow until Service is displayed. erator Performance is enabled in the Features menu
Press the right arrow and Level 2 will be displayed. (F20).
Press the down arrow and Level 3 will be displayed.
Enter the password using the same password and pro- • P1 (maximum achievable performance level)
cedures as entered in Level 2.
• P2 (reduced performance from maximum, similar
The difference between level 3 and level 2 are:
to previous model)
• The Analyzer A3 Outputs submenu is not available
• P3 (used where operational conditions require low-
in level 3 (only level 2).
est truck performance)
• The Analyzer A4 Test Outputs submenu is availa- To enter Performance menu, key ON the truck. Use the
ble in level 3 (not in level 2). up or down arrows to scroll to Performance. Press the
right arrow P1, P2 or P3 will be displayed. Use the up
• The Calibration menu is not available in level 3 or down arrows to display a different performance
(only level 2). level. Once the desired level is displayed, press the en-
ter or return button to select. Press the left arrow button
• Hour meters can be viewed in both level 2 and
to return to the main menu at Performance.
level 3. However, meters can only be changed in
level 3.
NOTE
An explanation of these menus is located after the
menu charts in this section of the service manual. The factory standard settings for the P1 performance
level are set to achieve maximum performance. The
factory standard settings for P2 are slower, and the fac-
tory standard settings for P3 are the slowest. However,
by customizing the settings, any performance level,
P1, P2, or P3, can be higher, lower, or the same as any
other performance level. For example, the P1 settings
could be customized to be slower than or equal to the
P3 standard settings. For more information, refer to the
Performance menu explanations that follow the menu
charts in this section of the service manual.
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ELECTRICAL SYSTEM
ACCESS 123®
Operator Level 1 - User Code and Message Mode Menus

Message Mode Menus

Allows the operator to select what is displayed in mes-
sage mode if no higher priority items are active. Also
allows the operator to control the trip meter and timer.
Only the appropriate menus will be made visible based
on features menu F26 Message Mode setting.
SP 3500 is displayed until an item from the menu is
chosen.
Message Mode Priority

1 PM Due (if H13 PM Timer menu is not set to “NONE”)
2 User Code (if F21 User Codes menu is enabled))
3 SRO 2/Advise Message
4 Operator Selected Message
1 User Codes are displayed only if F21 User Codes menu is enabled.
2 SRO means Static Return to Off. This message alerts the operator that an improper operator se-
quence was performed and the traction twist grip must be returned to neutral before travel will be
permitted. For example, the brake pedal must be depressed and the brake released before the
twist grip is rotated. If the brake pedal is depressed after twisting the grip. A message will be dis-
played alerting the operator the twist grip must be returned to neutral.
Figure 17902-02
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ELECTRICAL SYSTEM
ACCESS 123®
Operator Level 1 - Hour Menus

Figure 17903-02
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ELECTRICAL SYSTEM
ACCESS 123®
Operator Level 1 - Event, Service and Performance Menus
1 The performance menu is only visible when features menu F20 User Performance is enabled.
Figure 17904-02
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ELECTRICAL SYSTEM
ACCESS 123®
continued from page -033 Service Level 2 and 3 - Analyzer Menus
1 A3 Outputs are available in Level 2 only continued on page -015

2 A4 Test Outputs are available in Level 3 only
Figure 17905-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Analyzer Menus

ACCESS 1 Inputs
continued 0 = switch open

from page 1 = switch closed
-009 0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
ACCESS 3 Inputs
continued PUF = Positive
from page FF = Negative
-009 PUF = Positive
0 = switch open FF = Negative
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
approx. 10.3 Volts = New Brushes
approx. 1.0 Volts = Replace Brushes
Approximately Battery Volts
ACCESS 4 Inputs
continued Fork Height
from page
-009
Lifting = Increasing
Lower = Decreasing
CCW = Increasing
CW = Decreasing
Max FF = approx 0.8 V
Neutral = approx 2.6 V
Max PUF = approx4.6 V
Max FF = approx 16%
0 = switch open Neutral = approx 50%
1 = switch closed Max PUF = approx 92%
0 = switch open
1 = switch closed
1 Not displayed on North American Models
0 = switch open 2
1 = switch closed Displayed when F14 Wire guidance is Enabled
3 Only displayed on selected models
0 = switch open 4 Displayed when F24 MMS is Enabled
1 = switch closed 5 Displayed when F6 is set to TT Mast
0 = switch open
1 = switch closed
Figure 17907-02
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ELECTRICAL SYSTEM
ACCESS 123®
continued from page -010 Service Level 2 and 3 - Analyzer Menus

ACCESS 4 Inputs Continued
0 = switch open
1 Displayed only when
1 = switch closed
0 = switch open F25 is set to Yes
1 = switch closed
0 = switch open F17 is enabled
3 Displayed only on se-
1 = switch closed
lected models
0 = switch open
4 After self test, but before
1 = switch closed
0 = switch open releasing the brake, this
1 = switch closed menu will display a value
less than battery volts.
0 = switch open This menu is only accu-
1 = switch closed rate if the ED2 contactor
0 = switch open tips are closed. ED2 does
1 = switch closed not close until the brake
0 = switch open pedal is cycled for the first
1 = switch closed time after self test.
0 = switch open
1 = switch closed F18 is set to Yes
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
ACCESS 5 Inputs
CCW = decrease
continued
CW = Increase
from page
-009 Battery Volts
Battery Volts
Brake Applied = Battery Volts
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
Factory Use Only
Figure 17909-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Analyzer Menus
ACCESS 6 Inputs
continued
from page
-009
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
1 Displayed only when F14 is enabled. Must toggle GUS switch after
power up to work properly.
2 Displayed only when F16 is set to North Sensing or South Sensing.
3 The value for all four coils will be displayed. Eight numbers will appear.
The first pair of numbers is for the 1st coil, second pair for the second coil,
third pair is for the third coil and the fourth pair is for the fourth coil.
4 A3 Outputs are available in Level 2 only.
ACCESS 1 Outputs
0% = alarm does not sound
continued
100% = alarm sounds
from page
-009
Figure 17910-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 - Analyzer Menus
ACCESS 3 Outputs
0% = lower not selected
continued approx. 65%=lower selected
from page
-009 0% = lower not selected
approx. 800ma=lower selected
0% = high speed raise not selected
approx. 100%=hi spd raise selected
0% = high speed raise not selected

approx. 1030ma=hi spd raise selected
0% = raise not selected
approx. 100%=raise selected
0% = raise not selected
approx. 1030ma=raise selected
0% = fan is not operating
approx. 100%=fan is operating
0% = always
0ma = always
approx. 0 to 270 amps
approx. 145°C begins over temp
ACCESS 4 Outputs
continued 0% = alarm does not sound
from page 100% = alarm sounds
-009
1 Displayed only on trucks equipped with two lift pumps.

2 Displayed only when F19 is set to Forward, Reverse or Both.
3 Displayed only on selected models.
4 Displayed only when F17 is set to Enable.
Figure 17911-02
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ELECTRICAL SYSTEM
ACCESS 123®
ACCESS 5 Outputs
continued 100% = always

from page 0%=brake applied and/or travel is
-009 not selected.
25%=platform fully lowered, brake
released and travel is selected.
0amps=brake applied and/or travel
not selected.
1.4 amps=platform fully lowered,
brake released and travel is selected.
approx. 4 ohms = always
0%=brake applied and/or travel is not

selected.
20%=platform fully lowered, brake re-
leased and travel is selected.
0amps=brake applied and/or travel
not selected.
3.2 amps=platform fully lowered,
brake released and travel is selected.
approx. 1.6 ohms = always
0%=lower not selected

50%=low speed lower is selected and
not in soft stop slow down on trucks
equipped with high speed lower.
100%=high speed lower is selected
and not in soft stop slow down on trucks
100%=lower is selected and not in soft
stop slow down on trucks equipped with
single speed lower.
40ma=lower not selected
400ma=low speed lower is selected
750ma=high speed lower is selected
750ma=lower is selected and not in soft
stop slow down on trucks equipped with
single speed lower.
0 to 90%
Figure 17912-02
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ELECTRICAL SYSTEM
ACCESS 123®

ACCESS 1 Test Outputs
continued from
page -009

continued from
page -009
ACCESS 4 Test Inputs
continued from 1 Displayed only on trucks with high speed lift.

2
page -009 Displayed only if F19 is set to Forward, Reverse or Only.
3 Displayed only on selected models.
4 Displayed only if F17 is disabled.

continued from
page -009
Figure 17913-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Features Menus
Figure 17915-02
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ELECTRICAL SYSTEM
ACCESS 123®

North America Europe
N. America Europe
N. America Europe
N. America Europe
N. America Europe
N. America Europe
Australia
Australia
Australia
Australia
1 Refer to truck data plate for Truck Model.
Figure 17916-03
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ELECTRICAL SYSTEM
ACCESS 123®
1 F15.2 only displayed if Sense & Slow or Sense & Stop

continued on page -019 are selected.
2 F19.2 is not available if F19.1 is set to OFF
Figure 17917-03
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ELECTRICAL SYSTEM
ACCESS 123®

1F23.1 should be set to enable for trucks with

an optional Electric Pallet Clamp
Figure 17919-02
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ELECTRICAL SYSTEM
ACCESS 123®
1 F27 is only displayed if F14 is set to disabled.
Figure 17920-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Performance Menus

Figure 17922-02
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ELECTRICAL SYSTEM
ACCESS 123®
Maximum Allowable Speed dependant on truck model.
continued from
page -021
continued from
page -021
continued from
page -021
continued from
page -021
continued from
page -021
continued from
page -021
Figure 17923-03
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ELECTRICAL SYSTEM
ACCESS 123®
Figure 17924-03
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ELECTRICAL SYSTEM
ACCESS 123®
continued on
page -025
1 If P12.1.5 Stop Using Brake mode is selected, this submenu will not be available.
2 If P12.1.2 Slowdown with Auto Resume mode is selected, this submenu will not be available.
3 If P12.1.3 Slowdown with Auto Stop mode is not selected, this submenu will not be available.
4 If features menu F16 EAC submenu is set to None, P12 EAC Setup submenu will not be available.
Figure 17925-03
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ELECTRICAL SYSTEM
ACCESS 123®
continued on page -021 1 If F17 is set to disable, P13 PDS Setup submenu will not be available.
2 P14.3 is only available on European SP 3512-1.0 and SP 3522-1.0
trucks
Figure 17926-03
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 - Calibration Menus
approx.
approx.
approx.
Steps
automatically
from menu
to menu
continued on
page -030
continued on
page -027
1 To prevent nuisance event codes, as a general rule, if any ACCESS 123 module is replaced, Crown recommends performing all calibra-
tions.
2 Perform C1 calibration after replacing POT1, FS, RS or any ACCESS 123 module. You must save after completing C1 Handle calibration.
3 Perform C2 calibration after replacing PVL or any ACCESS 123 module. You must save after completing C2 Valves calibration.
4 Raise platform above 380 mm (15 in) but below staging.
5 Press and hold the lower button.
6 Momentary message.
Figure 17927-03
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ELECTRICAL SYSTEM
ACCESS 123®
continued on
page -028
1 Perform C3 calibration after replacing any ACCESS 123 module. You must save after completing calibration. Refer to Calibration
menu explanations near the end of this section for more information and proper procedures.
2 Submenu is only displayed if F25 is enabled.
3 PCT = Positive (Raise) Cutout With Override.
4 PST = Positive (Raise) Stop With No Override.
5 NCT = Negative (Lower) Cutout With Override.
Figure 17928-03
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ELECTRICAL SYSTEM
ACCESS 123®
1 Perform C4 calibration after replacing or adjusting

ECR2 or any ACCESS 123 module. Prior to calibration
rotate the steering tiller so that the alignment marks lo-
cated on the drive unit and drive unit mounting bracket
form a straight line.
2 A continuous alarm should sound if the encoder is at
index.
3 Prior to C5 Wire Guidance Calibration, refer to Cali-
bration menu explanations included near the end of this
section. Read and follow pre-calibration checks and cal-
ibration procedures.
Figure 17929-03
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ELECTRICAL SYSTEM
ACCESS 123®
1 Do not use X-Offset to center the truck over the guide wire. If an offset is needed to center the truck
over the guide wire, the truck likely has an issue that affects wire guidance and the issue should be
corrected. When entering C5.2 X-Offset, the x-offset value is set to zero in both directions. You must
save after completing x-offset calibration.
2 Travel on wire at least 12.2 m (40ft). Travel distance must be continuous in each direction. If the direc-
tion changes before traveling 12.2 m (40 ft) then the percent complete resets to zero.
Figure 17930-04
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Hour Menus
continued on
1 Level 2: View Only / Level 3: Increase Only
page -032
2 Level 2 and Level 3: View Only
Figure 17931-03
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Hour Menus
Figure 17932-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Event Menus
continued on
page -033
Figure 17933-02
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ELECTRICAL SYSTEM
ACCESS 123®
Service Level 2 and 3 - Utilities Menus
continued on
page -009
1 To deactivate tow mode, turn the key switch to OFF and then power up the truck.
Figure 18035-02
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ELECTRICAL SYSTEM
ACCESS 123®
Analyzer A1.1 Full Speed Hydraulics = ______

If the truck is equipped with full speed hydraulics and
The Analyzer menu is a troubleshooting tool that allows
the full speed hydraulics function is working properly,
the technician to check the status of various circuits,
the display should show the function is Enabled. If the
check component inputs and outputs and test/driven
function is not working, the display will show Disabled,
component outputs.
indicating the circuit requires troubleshooting. Note
The Analyzer submenus are: that even though full speed hydraulics is disabled, low
speed raise and lower may still be enabled.
• A1 Status
• A2 Inputs NOTE
The full speed hydraulics circuit is the full speed lift and
• A3 Outputs (Level 2 Only)
lower circuit. On trucks equipped with dual lift pumps,
• A4 Test Outputs (Level 3 Only) during full speed lift, the raise button is pressed fully
actuating both raise switches, RAS1 and RAS2. Both
M3 and M4 pump motors are energized causing lift
Analyzer Access pumps P1 and P2 to rotate providing full speed raise.
1. Power up the truck. From Service Level 2 or Level During full speed lower, the lower button is pressed
3, press the right arrow to enter the Service sub- fully actuating lower switches, LOS1 and LOS2. The
menus. proportional lower valve, PVL is energized with 16 volts
fully opening PVL.
2. Use the up and down arrows to navigate to the An-
alyzer menu. A1.2 Lower = ______
3. Press the right arrow to enter the Analyzer menu. During lower, the lower button is pressed approxi-
Use the up and down arrows to scroll through the mately half way actuating only lower switch LOS1. The
submenus. lower proportional valve is energized with approxi-
mately 8 battery volts opening the valve approximately
half way. If lower is Enabled the function is working. If
A1 Status lower is Disabled the function is not working.
A1 Status allows technicians to view the status of mon-
A1.3 Raise = ______
itored truck systems. This information can be used to
troubleshoot service conditions by identifying common During raise, the raise button is pressed approximately
circuits for enabled or disabled functions. The A1 Sta- half way on trucks with dual lift pumps or fully de-
tus menu includes multiple submenus. pressed on trucks with a single lift pump actuating raise
switch RAS1. M3 pump motor is energized causing lift
• For all A1 Status submenus, the display will scroll pump P1 to rotate. If raise is Enabled the function is
right to left indicating the function is either Enabled working. If raise is Disabled the function is not working.
or Disabled.
A1.4 Full Traction = ______
• To stop the display from scrolling, press the right The display indicates if Full Traction is Enabled or Dis-
arrow and the display will show Enabled or Disa- abled.
bled only.
A1.5 Limp Traction = ______
• If you press the right arrow to display Enabled or
When a truck is in an aisle and has a service condition,
Disabled only, then press the left arrow and then
limp travel allows you to move the truck to a mainte-
the down arrow to scroll to the next submenu.
nance area at a reduced travel speed. Travel is not per-
• If you don't press the left arrow and just allow the mitted with some service conditions and in these
text to scroll, then press the down arrow to scroll to cases, limp travel will be disabled. The display indi-
the next submenu. cates if the function is Enabled or Disabled.
A1.6 Steering = ______
The display indicates if Power Steering is Enabled or
Disabled.
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A1.7 ED = ______ A2.1.1 DMS1 = ______

The display indicates if Emergency Disconnect is Ena-
bled or Disabled. NOTE
A1.8 Module = ______ This switch is not used on North American SP 3500
trucks. If Features menu F3 is set to North America,
A1.8 Module is the last A1 Status menu and will always this menu will not be displayed. DMS1 is an operator
read Enabled. This menu is reserved for future use. presence switch located above and to the left of the
• Press the left arrow until you return to A1 Status steering tiller. When in guidance mode, an operator
must press this switch to operate the truck.
menu and then press the down arrow to navigate
to the A2 Inputs • To check input, press the right arrow and actuate
DMS1. Display should indicate 0 when the switch
A2 Inputs is open and 1 when closed. Press the left to return
to A2.1.1 DMS1 submenu.
The SP 3500 truck has up to 5 ACCESS 123® mod-
ules. Each module receives input signals from electri- • Press the down arrow to scroll to the next A2.1
cal components like switches, sensors and encoders. submenu.
A2 Inputs allows the technician to check to see if these
signals are received by the module. The A2 Input A2.1.2 GUS1 = ______
menus are sorted by ACCESS 123 module. Refer to
the A2 Input Submenus chart. NOTE
GUS1 switch is used only on trucks equipped with op-
A2 Inputs Submenus tional wire guidance. This menu only appears if the F14
Wire Guidance features menu is enabled.
Sub- GUS1 is the guidance switch that allows the operator
Module Function
menu to select manual or automatic steering. This switch is
A2.1 ACCESS 1 Display located on the console switch panel.
A2.2 ACCESS 3 Traction • To check input, press the right arrow and actuate
A2.3 ACCESS 4 Vehicle * GUS1. Display should indicate 0 when the switch
is open and 1 when closed.
A2.4 ACCESS 5 Steering
Wire Guidance &
• Press the left arrow to return to A2.1.2 GUS1 sub-
A2.5 ACCESS 6 menu.
End Aisle Control
* ACCESS 4 receives all platform inputs except the

• Press the down arrow to scroll to the next A2.1
submenu.
guidance switch and override switch inputs.
A2.1.3 ORS1 = ______
• Press the right arrow to scroll to the first A2 Input
submenu. Optional switch, ORS1 allows the operator to override
a raise cutout. This switch is located on the console
A2.1 ACCESS 1 Inputs switch panel.
• Press the right arrow to navigate to the first A2.1 • To check input, press the right arrow and actuate
submenu. ORS1. Display should indicate 0 when the switch
• Press the left to return to A2.1.3 ORS1 submenu.
• A2.1.3 ORS1 is the last A2.1 ACCESS 1 Inputs

submenu. Press the left arrow to navigate back to
A2.1 ACCESS 1 Inputs then press the down arrow
to scroll to the A2.2 submenu.
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A2.2 ACCESS 3 Inputs • Press the left arrow and then the down arrow to
• Press the right arrow to navigate to the first A2.2 scroll to the next submenu.
ACCESS 3 inputs submenu. A2.2.3 CHS3/CHS4 = ______
A2.2.1 ECR3 = ______ CHS3 and CHS4 are mast chain slack switches and
are located near the mainframe chain anchors. In the
ECR3 is the traction encoder and is located in the trac-
event the chains become slack (i.e., the platform is low-
tion motor. It inputs traction speed and direction.
ered on an object), lower will be prohibited.
• To check input, press the right arrow.
• To check input, press the right arrow. The display
A2.2.1.1 Speed = ______ should indicate 1 when the switches are closed
(normal operation) and 0 when open.
• To check input, press the right arrow. The speed for
ECR3 will be displayed in rpms. Positive numbers • Press the left arrow and then the down arrow to
should be displayed when traveling in the power scroll to the next submenu
unit first direction and negative numbers should be
A2.2.4 THS-P1 = ______
displayed in the forks first direction. When traveling
the numbers should increase and decrease THS-P1 is a thermal switch located in pump motor M3.
smoothly and not fluctuate in large increments. If In the event of an over temperature condition, this ther-
they fluctuate, the encoder probably needs to be mal switch will open, M3 will quit operating and an
replaced. event will be logged.
• Press the left arrow and then the down arrow to • To check input, press the right arrow. The display
scroll to the next submenu. should indicate 1 when the switch is closed and 0
when open.
A2.2.1.2 Cnt = ______
• To check input, press the right arrow. In this menu, NOTE

the input for ECR3 will be displayed in count (num-
Pump motor thermal switches are an option. Features
bers). The numbers should decrease when
menu, F24 MMS must be enabled for submenus
traveling in the power unit first direction and in-
A2.2.4 and A2.2.5 to be displayed.
crease in the forks first direction. When traveling
the numbers should increase and decrease • Press the left arrow and then the down arrow to
smoothly and not fluctuate in large increments. If scroll to the next submenu.
they fluctuate, the encoder probably needs to be
replaced. A2.2.5 THS-P2 = ______
• Press the left arrow and then the down arrow to THS-P2 is a thermal switch located in pump motor M4.
In the event of an over temperature condition, this ther-
scroll to the next submenu.
mal switch will open, M4 will quit operating and an
A2.2.2 CHB4/CHB5 = ______ event will be logged.
NOTE • To check input, press the right arrow. The display

should indicate 1 when the switch is closed and 0
CHB4 and CHB5 are platform chain break switches are when open.
not equipped on North American trucks. This menu will
not be displayed on North American trucks. • Press the left arrow and then the down arrow to
The switches are located near the top mainframe chain
anchors and will disable all hydraulic functions in the
event of a mast lift chain break.

should indicate 1 when the switches are closed
and 0 when open.
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ACCESS 123®
A2.2.6 BW-P1/P2 = ______ • Press the left arrow and then the down arrow to
BW-P1/P2 are brush wear sensors located in pump scroll to the next submenu.
motors M3 and M4. A2.3.1.2 Speed = ______
• To check input, press the right arrow. The brush The speed for ECR4 will be displayed in ips (inches per
wear value displayed on motors with new brushes second) or cmps (centimeters per second) dependent
should be approximately 10.3 volts. When the on how features menu, F2 Unit of Measure is set.
value reaches 1.0 volts for pump 1 motor (M3), the
brushes require replacement. When the value • To check input, press the right arrow. Positive num-
reaches 1.0 to 4.0 volts for pump 2 motor (M4), the bers should be displayed. When lifting and lower-
brushes require replacement. ing, the numbers should increase and decrease
smoothly and not fluctuate in large increments. If
NOTE they fluctuate, the encoder probably needs to be
replaced.
Brush wear sensors are an option. Features menu, F24
MMS must be enabled for submenu A2.2.6 to be dis- • Press the left arrow and then the down arrow to
played. scroll to the next submenu.
A2.3.1.3 Cnt = ______
• Press the left arrow and then the down arrow to
scroll to the next submenu. In this menu, the data input for ECR4 will be displayed
in count (numbers).
A2.2.7 Key Switch = ______
• To check input, press the right arrow. Volts at the

• To check input, press the right arrow. The numbers
should increase when lifting and decrease when
key switch will be displayed.
lowering. When lifting/lowering the numbers
• A2.2.7 Key Switch is the last A2.2 ACCESS 3 In- should increase and decrease smoothly and not
puts submenu. Press the left arrow until you navi- fluctuate in large increments. If they fluctuate, the
gate back to A2.2 ACCESS 3 Inputs then press the encoder probably needs to be replaced.
down arrow to scroll to the A2.3 submenu. • Press the left arrow and then the down arrow to
A2.3 ACCESS 4 Inputs scroll to the next submenu.
Press the right arrow to navigate to the first A2.3 A2.3.2 ECR1/ECR5 = ______
ACCESS 4 inputs submenu.
ECR1 and ECR5 are operator steering command en-
A2.3.1 ECR4 = ______ coders and are part of the steering command assembly
(includes tiller) mounted on the platform.
ECR4 is the height encoder and is mounted on the
height sensor. It inputs lift/lower speed and direction • To check input, press the right arrow. The data
when above free lift. numbers for both encoders should be approxi-
mately the same. The numbers should decrease
• Press the right arrow to scroll to the first A2.3.1
when turning clockwise and increase when turning
ECR4 submenu.
counterclockwise. If the numbers fluctuate, the en-
A2.3.1.1 Height = ______ coder probably needs to be replaced.
The height for ECR4 will be displayed in inches or cm • Press the left arrow until you navigate to A2.3.1
(centimeters) dependent on how Features menu, F2 ECR4 submenu and then the down arrow to scroll
Unit of Measure is set. to the next submenu.
• To check input, press the right arrow. The height A2.3.3 POT1
displayed is the approximate fork height measured
POT 1 is the traction request potentiometer that pro-
from the top of the forks. When lifting and lowering,
vides input to ACCESS 4.
the numbers should increase and decrease
smoothly and not fluctuate in large increments. If • Press the right arrow to navigate to the first A2.3.3
they fluctuate, the encoder probably needs to be POT1 inputs submenu.
replaced.
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A2.3.3.1 Raw = ______ • To check input, press the right arrow and actuate
Voltage input for POT1 is shown in this menu. RAS3 and RAS4 by raising the lifting forks. The
display should indicate 0 when the switches are
• To check input, press the right arrow. While rotating open and 1 when closed.
the twist grip, the voltage displayed should be ap-
proximately: • Press the left arrow and then the down arrow to
– 0.8 volts in the maximum forks first direction.
A2.3.5 LOS3/LOS4 = ______
– 2.6 volts in neutral position.
– 4.6 volts in the maximum power unit first direc- NOTE
tion.
These switches are not used on North American
As you rotate the twist grip, the numbers should in- SP 3500 trucks so this menu will not be displayed on
crease and decrease smoothly and not fluctuate in North American trucks.
large increments. If they fluctuate, the potentiometer
probably needs to be replaced. These switches are located on trucks equipped with lift-
ing forks and are located just below the lifting forks con-
• Press the left arrow and then the down arrow to sole.
• To check input, press the right arrow and actuate
A2.3.3.2 Scaled = ______ LOS3 and LOS4 by lowering the lifting forks. The
The percent of voltage range (5 volts) for POT1 is display should indicate 0 when the switches are
shown in this menu. open and 1 when closed.
• To check input, press the right arrow. While rotating • Press the left arrow and then the down arrow to
the twist grip, the percent of voltage displayed scroll to the next submenu.
should be approximately: A2.3.6 RS = ______
– 16% in the maximum forks first direction. RS is the reverse switch and is located in the traction
– 50% in neutral position. twist grip assembly.
– 92% in the maximum power unit first direction. • To check input, press the right arrow and actuate
RS by rotating the twist grip in the forks first direc-
As you rotate the twist grip, the numbers should in-
tion. The display should indicate 0 when the switch
crease and decrease smoothly and not jump in large
increments. If they jump, the potentiometer probably
needs to be replaced. • Press the left arrow and then the down arrow to
• Press the left arrow until you navigate to A2.3.3 scroll to the next submenu.
POT1 submenu and then the down arrow to scroll A2.3.7 FS = ______
to the next submenu.
FS is the forward switch and is located in the traction
A2.3.4 RAS3/RAS4 = ______ twist grip assembly.
NOTE • To check input, press the right arrow and actuate

FS by rotating the twist grip in the power unit first
These switches are not used on North American direction. The display should indicate 0 when the
SP 3500 trucks so this menu will not be displayed on switch is open and 1 when closed.
North American trucks.
These switches are located on trucks equipped with lift- scroll to the next submenu
ing forks and are located in the lifting forks console.
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ELECTRICAL SYSTEM
ACCESS 123®
A2.3.8 CHS1/CHS2 = ______ • Press the left arrow and then the down arrow to
CHS1 and CHS2 are platform chain slack switches and scroll to the next submenu.
are located near the platform chain anchors on trucks A2.3.12 LOS1 = ______
with TT masts. In the event the chains become slack
(i.e. the platform is lowered on an object), lower will be LOS1 is the platform lower switch and is located in the
prohibited. control console assembly.
• To check input, press the right arrow. The display • To check input, press the right arrow and actuate
should indicate 1 when the switches are closed LOS1 by lowering the platform. The display should
(normal operation) and 0 when open. indicate 0 when the switch is open and 1 when
closed.
NOTE • Press the left arrow and then the down arrow to
Features menu, F6 Mast Type must be set to TT for scroll to the next submenu.
submenu A2.3.8 to be displayed. A2.3.13 LOS2 = ______
• Press the left arrow and then the down arrow to LOS2 is the platform high speed lower switch and is
scroll to the next submenu. located in the control console assembly.
A2.3.9 GTS1/GTS2 = ______ • To check input, press the right arrow and actuate
GTS1 and GTS2 are side gate switches and are lo- LOS2 by pressing the platform lower button fully for
cated on the platform and are actuated by the top, hor- high speed lower. Display should indicate 0 when
izontal arms of the gates. GTS1 is on the left side gate the switch is open and 1 when closed.
and GTS2 is on the right side gate.
• To check input, press the right arrow. To check in- scroll to the next submenu.
put, actuate GTS1 and GTS2 by raising and lower- A2.3.14 ZSS A = ______
ing the side gates. The display should indicate 0
when the switches are open and 1 when closed. ZSS is the zone select switch. This switch is an op-
tional key switch located on the console and operators
• Press the left arrow and then the down arrow to or management can select key position/zone, A, B or
scroll to the next submenu. C. A raise cutout with or without an override is estab-
lished for each zone. Once a zone is selected, the key
A2.3.10 HGTRS = ______
can be removed so only authorized personnel may
HGTRS is a height reset switch and is located on the change the position of the zone select switch.
platform. This switch is actuated by a bar welded on the
third stage mast. NOTE
• To check input, press the right arrow and actuate Features menu, F25 Zone Switch must be set to Yes
HGTRS by raising the platform so the mast begins for submenu A2.3.14 to be displayed.
to stage. The display should indicate 0 when the
ZSS A is position A on the zone select switch.
switch is open and 1 when closed.

• To check input, press the right arrow and select po-
sition A. The display should indicate 1 when posi-
tion A is selected and 0 when not selected.
A2.3.11 RAS1 = ______
RAS1 is the platform raise switch and is located in the scroll to the next submenu.
control console assembly.
• To check input, press the right arrow and actuate

RAS1 by raising the platform. The display should
indicate 0 when the switch is open and 1 when
closed.
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A2.3.15 ZSS B = ______ • To check input, press the right arrow and rotate the
ZSS B is position B on the zone select switch. steering tiller. The numbers should decrease when
turning counterclockwise and increase when turn-
• To check input, press the right arrow and select po- ing clockwise. If the numbers fluctuate, the en-
sition B. The display should indicate 1 when posi- coder probably needs to be replaced.
tion B is selected and 0 when not selected.
• Press the left arrow and then the down arrow to scroll to the next submenu.
A2.4.3 BATTERY = ______
A2.3.16 ZSS C = ______
• To check input, press the right arrow. The battery
ZSS C is position C on the zone select switch. voltage will be displayed.
• To check input, press the right arrow and select po- • Press the left arrow and then the down arrow to
sition C. The display should indicate 1 when posi- scroll to the next submenu.
tion C is selected and 0 when not selected.
A2.4.4 Steering = ______
scroll to the next submenu. • To check input, press the right arrow. The battery
input voltage to the steer module, ACCESS 5, will
A2.3.19 CHB7/CHB8 = ______ be displayed in this menu.
NOTE • Press the left arrow and then the down arrow to
scroll to the next submenu
These switches are not used on North American
SP 3500 trucks so this menu will not be displayed on A2.4.5 BRK Inner = ______
North American trucks.
NOTE
CHB7 and CHB8 are located beneath the top main-
frame chain anchors and will disable all hydraulic func- When energized, two coils, an inner and outer coil, re-
tions in the event of a platform lift chain break. lease a 3 step traction brake. The inner and outer coils
can be energized and de-energized separately to pro-
vide 3 different levels of brake force.
should indicate 1 when the switches are closed
and 0 when open. • To check input, press the right arrow and cycle the
brake. The display should show battery volts.
• A2.3.19 CHB7/CHB8 is the last A2.3 ACCESS 4
Inputs submenu. Press the left arrow until you nav-
igate back to A2.3 ACCESS 4 Inputs then press
NOTE
the down arrow to scroll to the A2.4 submenu. After self test, but before releasing the brake, this menu
A2.4 ACCESS 5 Inputs will display a value less than battery volts. A2.4.5 menu
is only accurate if the ED2 contactor tips are closed.
• Press the right arrow to navigate to the first A2.4 ED2 does not close until the brake pedal is cycled for
ACCESS 5 inputs submenu. the first time after self test.
A2.4.1 ECR2 = ______ • Press the left arrow and then the down arrow to
ECR2 is the steering feedback encoder and is mounted scroll to the next submenu.
on the drive unit and traction motor mounting plate near A2.4.6 BRK Outer = ______
the traction motor. It provides speed and direction feed-
back to ACCESS 5. • To check input, press the right arrow. This menu
should display battery volts.

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A2.4.7 CS1 = ______ A2.4.11 Brake Test Speed = ______

CS1 monitors current through BDI to determine battery This menu is for factory use only.
status. CS1 is the current sensor and is mounted on
the contactor panel just behind the traction motor. CS1 • A2.4.11 Brake Test Speed is the last A2.4
inputs current value to ACCESS 5 for BDI. ACCESS 5 Inputs menu. Press the left arrow until
you navigate back to A2.4 ACCESS 5 Inputs then
• To check input, press the right arrow. Press the left press the down arrow to scroll to the A2.5 sub-
arrow and then the down arrow to scroll to the next menu.
submenu.
A2.5 ACCESS 6 Inputs
A2.4.8 RGSR/RGSL = ______
• Press the right arrow to navigate to the first A2.5
RGSR and RGSL are rail guidance switches and are ACCESS 6 inputs submenu.
mounted on the aisle guide wheel brackets under the
power unit. RGSR is on the right side of the power unit
and RGSL is on the left side. These switches should
NOTE
actuate when entering and exiting a rail guided aisle. GS1 and GS2 (see explanation in next NOTE) are
used on trucks equipped with wire guidance only. Fea-
tures menu, F14 Wire Guidance must be enabled for
should indicate 0 when the switches are open and A2.5.1 and A2.5.2 submenus to be displayed.
1 when closed.
• Press the left arrow and then the down arrow to NOTE
scroll to the next submenu. A wire guided truck has two sensor bar assemblies
A2.4.9 BRES1/BRES2 = ______ (GS1 and GS2); one mounted to the bottom of the main
frame (GS2) and the other mounted to the power unit
BRES1/BRES2 are battery retainer switches and are directly in front of the drive tire (GS1). Each sensor bar
mounted on the power unit skirt in front of the battery contains four coils. The following GS1 and GS2 menus
compartment. BRES1 is on the right side and BRES2 allow you to view the Raw and Scaled input values
is on the left side. These switches should actuate when from the coils inside both sensor bars. The Raw value
the battery side covers are removed and installed. is the amount of signal (millivolts) that each coil senses
• To check input, press the right arrow. The display from the guide wire path. During wire guidance calibra-
tion, the ACCESS 123 system computes a factor to
should indicate 0 when the switches are open and
multiply the Raw value by and creates the Scaled
1 when closed.
value. The purpose of the Scaled value is to balance
out the inputs from all four coils of each bar. No two
NOTE coils are manufactured exactly the same so the Scaled
The battery retainer switches are an option. Features values compensate for the manufacturing process al-
menu, F18 Battery Retainer SW must be set to Yes for lowing the coils to sense equal signal ensuring proper
submenu A2.4.9 to be displayed. wire guide tracking.
A2.5.1 GS1
scroll to the next submenu. GS1 is the steer wheel sensor bar.
A2.4.10 BRS1 = ______ • To navigate to the first A2.5.1 GS1 submenu, press
BRS1 is the brake pedal switch located below the plat- the right arrow.
form. This switch should actuate when pressing and re-
leasing the brake pedal.

should indicate 0 when the switch is open and 1
when closed.

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A2.5.1.1 Raw = ______ A2.5.1.2 Scaled = ______

This menu allows you to check the Raw value of all four This menu allows you to check the Scaled value of all
GS1 coils. four GS1 coils.
• To check input, press the right arrow. Eight digits • To check input, press the right arrow. Eight digits
should appear showing the Raw values of the should appear showing the Scaled values of the
coils. Reading from left to right, the first pair of coils. Reading from left to right, the first pair of
numbers are for the first coil, second pair of num- numbers are for the first coil, second pair of num-
bers are for the second coil, the third pair of numbers are for the second coil, the third pair of num-
bers are for the third coil and the fourth pair of numbers are for the third coil and the fourth pair of num-
bers are for the fourth coil. bers are for the fourth coil.
Move the truck at slowest speed possible and at Move truck at slowest speed possible and at the
the shallowest angle possible (5 degrees or less) shallowest angle possible (5 degrees or less) over
over an active guide wire. The peak Raw values of an active guide wire. When each coil is directly
the 2 inner coils should be within a 15 count spread over the guide wire, the Scaled value should be
between the highest and lowest. The Raw values above 95%. If it is not, the wire guidance system
should also be between 70 and 80%. If Raw value should be recalibrated.
is over 90% when coil is directly over the wire
check the line driver output with a Crown Field • Press the left arrow and then the down arrow to
Strength Meter (refer to Figure 23049). The aver- scroll to the next submenu.
age field strength should be between 168 and 190 A2.5.2 GS2
for a 6.25 KHz system or 100 and 118 for a 5.2 KHz
system. Also, check the sensor bar for the correct GS2 is the load wheel sensor bar. The procedures for
height adjustment. For height adjustment specifi- checking input are the same as GS1.
cation, refer to section M4.3 in this service manual.
NOTE
EAC is an end aisle control option. Features menu, F16
End Aisle Control must be set to North Sensing or
South Sensing for A2.5.3, A2.5.4, A2.5.5 and A2.5.6
submenus to be displayed.
NOTE
On trucks equipped with EAC, a sensor bar which in-
cludes four sensors is mounted under the power unit
battery box. The purpose of these sensors is to detect
magnets buried in the warehouse floor near the end of
an aisle and send a signal to ACCESS 6 to slow or stop
the truck. Refer to Figure 23034. A1 and B1 are active
Figure 23049
sensors when traveling in the forks first direction. A2
1 Guide Wire and B2 are active sensors when traveling in the forks
trailing direction.
2 112953 Field Strength Meter

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• Press the left arrow until you return to A2 Inputs

menu and then press the down arrow to navigate
to the A3 Outputs menu.
A3 Outputs
NOTE
A3 Output menus are available in Level 3 only.
The ACCESS 123® modules send output signals to
electrical components like alarms, solenoid valves and
contactor coils. The output signals for four of these
modules can be viewed from the display. The A3 Out-
put submenus are shown in the chart below.
Figure 23034
1 EAC Sensors Forks First Direction A3 Outputs Submenus

2 EAC Sensors Forks Trailing Direction
Sub-
Module Function
A2.5.3 EACA1 = ______ menu
EACA1 is the A1 sensor for optional end aisle control. A3.1 ACCESS 1 Display
• To check input, press the right arrow and travel in A3.2 ACCESS 3 Traction
the forks first direction over an EAC floor magnet. A3.3 ACCESS 4 Vehicle
The display should indicate 0 until the sensor is
over the magnet. When the sensor is over the mag- A3.4 ACCESS 5 Steering
net, the display should show 1. After the sensor
A3.1 ACCESS 1 Outputs
moves past the magnet, the display should change
to 0. • Press the right arrow to navigate to the first A3.1
• Press the left arrow and then the down arrow to ACCESS 1 outputs submenu.
scroll to the next submenu. A3.1.1 ALM1 = ______
A2.5.4 EACA2 = ______ ALM1 is an alarm located on the platform distribution
panel.
EACA2 is the A2 sensor for optional end aisle control.
The procedures for checking input are the same as • To check output and with the platform fully lowered,
EACA1 except travel in the forks trailing direction. raise a side gate and push the lower button. The
• Press the left arrow and then the down arrow to alarm should sound and the display should show
100%.
A2.5.5 EACB1 = ______ • A3.1.1 ALM1 is the only A3.1 ACCESS 1 Outputs
submenu. Press the left arrow to return to A3.1
EACB1 is the B1 sensor for optional end aisle control. ACCESS 1 menu and then press the down arrow
The procedures for checking input are the same as to scroll to the A3.2 menu.
EACA1.
A3.2 ACCESS 3 Outputs
• Press the down arrow to scroll to the next sub-
menu. • Press the right arrow to navigate to the first A3.2
ACCESS 3 outputs submenu.
A2.5.6 EACB2 = ______
EACB2 is the B2 sensor for optional end aisle control.
The procedures for checking input are the same as
EACA1 except travel in the forks trailing direction.
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A3.2.1 SVL A3.2.2.2 Current = ______

SVL is the lowering solenoid valve and is located on • To check output, press the right arrow. When high
the lift/lower manifold. It opens during lower providing speed raise is selected, approximately 1030 milli-
a path for oil to flow from the lift cylinders to the reser- amps should be displayed.
voir.
• Press the left arrow twice and then the down arrow
• To navigate to the first A3.2.1 SVL submenu, press
to scroll to the next submenu.
the right arrow.
A3.2.3 P1 = ______
A3.2.1.1 DC = ____%
P1 is the pump 1 contactor coil. Pump 1 contactor is
• To check output, press the right arrow. When lower located on the contactor panel just behind the traction
is not selected, 0% of DC battery volts should be motor. When P1 coil is energized, P1 contacts close
displayed. When lower is selected, approximately providing voltage to the M3 low speed lift motor.
65% of battery volts should be displayed.
• To navigate to the first A3.2.3 P1 submenu, press
• Press the left and then the down arrow to scroll to the right arrow.
the next submenu.
A3.2.3.1 DC = ____%
A3.2.1.2 Current = ______
• To check output, press the right arrow. When low
• To check output, press the right arrow. When lower speed raise is selected, approximately 100% of DC
is not selected, 0 milliamps should be displayed. battery volts should be displayed.
When lower is selected, approximately 800 milli-
amps should be displayed. • Press the left and then the down arrow to scroll to
the next submenu.
• Press the left arrow twice and then the down arrow
A3.2.3.2 Current = ______
A3.2.2 P2 = ______ • To check output, press the right arrow. When low
speed raise is selected, approximately 1030 milli-
NOTE amps should be displayed.
This submenu will only be displayed on trucks • Press the left arrow twice and then the down arrow
equipped with dual lift pumps. to scroll to the next submenu.
P2 is the pump 2 contactor coil. Pump 2 contactor is A3.2.4 FAN2 = ____%

located on the contactor panel just behind the traction FAN2 is a fan that helps to cool the ACCESS 123®
motor. When P2 coil is energized, P2 contacts close modules and is located above ACCESS 3 in the power
providing voltage to the M4 two speed lift motor. unit. The fan turns on when the ACCESS 123® mod-
ules mounting plate temperature is at or above 45°C
• To navigate to the first A3.2.2 P2 submenu, press
(113°F).
the right arrow.
A3.2.2.1 DC = ____% • To check output, press the right arrow. When the
fan is not running, 0% of battery volts should be
• To check output, press the right arrow. When high displayed. When the fan is running, 100% of bat-
speed raise is selected, approximately 100% of DC tery volts should be displayed.
battery volts should be displayed.
• Press the left and then the down arrow to scroll to
• Press the left and then the down arrow to scroll to the next submenu.
the next submenu.
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A3.2.5 ED2 A3.3 ACCESS 4 Outputs

ED2 is the #2 Emergency Disconnect contactor coil • Press the right arrow to navigate to the first A3.3
and is located on the contactor panel just behind the ACCESS 4 outputs submenu.
traction motor. ED2 coil receives battery negative from
ACCESS 3 and positive battery from ACCESS 5 (ED2 A3.3.1 ALM2 = ______
submenu is in ACCESS 3 and ACCESS 5 submenus).
When the coil is energized, ED2 contacts close provid- NOTE
ing battery positive to ACCESS 3 and ACCESS 5
power circuit. This submenu will only be displayed if the truck is
equipped with ALM2 and features menu, F19 is ena-
• To navigate to the first A3.2.5 ED2 submenu, press bled.
the right arrow. ALM2 is an optional travel alarm and is mounted be-
A3.2.5.1 DC = ____% tween the power unit and the platform on the power
unit wall. The alarm can be set to sound when traveling
• To check output, press the right arrow. 0% of DC forward, reverse or both directions.
battery volts should be displayed at all times be-
cause ACCESS 3 supplies battery negative to ED2 • To check output, press the right arrow. When the
coil. alarm sounds, the display should indicate 100%.
• Press the left and then the down arrow to scroll to • Press the left twice and then the down arrow to
the next submenu. scroll to the next A3.4 menu.
A3.2.5.2 Current = ______ A3.4 ACCESS 5 Outputs
• To check output, press the right arrow. Approxi- • Press the right arrow to navigate to the first A3.4
mately 0 milliamps should be displayed at all times ACCESS 5 outputs submenu.
because ACCESS 3 supplies battery negative to A3.4.1 ED2 = ______
ED2 coil.
ED2 is the #2 Emergency Disconnect contactor coil
• Press the left arrow twice and then the down arrow and is located on the contactor panel just behind the
to scroll to the next submenu. traction motor. ED2 coil receives battery negative from
ACCESS 3 and battery positive from ACCESS 5 (ED2
A3.2.6 M1
submenu is in ACCESS 3 and ACCESS 5 submenus).
M1 is the traction motor and is mounted to the drive unit When the coil is energized, ED2 contacts close provid-
mounting plate. ing battery positive to ACCESS 3 and ACCESS 5
power circuit.
• To navigate to the first A3.2.6 M1 submenu, press
the right arrow. • To check output, press the right arrow. 100%
should be displayed at all times because
A3.2.6.1 Current = ______
ACCESS 5 supplies battery positive to ED2 coil.
• To check output, press the right arrow and travel.
The current range is approximately 0 to 270 amps.
the next submenu.
• Press the left and then the down arrow to scroll to A3.4.2 Brake 0+/0-
the next submenu.
Brake 0+/0- is the output signal for the outer brake coil.
A3.2.6.2 Temperature = ______ The brake has two coils, an inner an outer coil. The
coils can be energized separately or at the same time
• To check output, press the right arrow. Over tem-
depending on the required brake force. The brake is
perature begins at 145°C (293°F). energized when the operator is in the operating posi-
• A3.2.6 M1 is the last A3.2 ACCESS 3 Outputs sub- tion (brake pedal depressed) and travel is selected.
menu. Press the left arrow until you return to A3.2 • To navigate to the first A3.4.2 Brake 0+/0- sub-
ACCESS 3 menu. Press the down arrow to scroll menu, press the right arrow.
to the next A3.3 menu.
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A3.4.2.1 DC = ____% A3.4.3.2 Current = ______
• To check output, press the right arrow. When the • To check output, press the right arrow. When the
brake pedal is not depressed and/or travel is not brake pedal is not depressed and/or travel is not
selected, 0% of DC battery volts should be dis- selected 0 amps should be displayed. Fully lower
played. Fully lower the platform and travel, approx- the platform and travel; approximately 3.2 amps
imately 25% of DC battery volts should be dis- should be displayed.
played.
the next submenu.
A3.4.3.3 Ohm = ______
A3.4.2.2 Current = ______
• To check output, press the right arrow. With the
• To check output, press the right arrow. When the brake applied or released, approximately 1.6 ohms
brake pedal is not depressed and/or travel is not should be displayed.
selected 0 amps should be displayed. Fully lower
the platform and travel; approximately 1.4 amps • Press the left arrow twice and then the down arrow
should be displayed. to scroll to the next submenu.
• Press the left and then the down arrow to scroll to A3.4.4 PVL
the next submenu. PVL is the proportional solenoid valve for lowering and
is located on the lift/lower manifold. It opens in propor-
A3.4.2.3 Ohm = ______
tion to the applied voltage during lower providing a path
• To check output, press the right arrow. With the for oil to flow from the lift cylinders to the reservoir.
brake applied or released, approximately 4 ohms • To navigate to the first A3.4.4 PVL submenu, press
should be displayed.
the right arrow.
• Press the left arrow twice and then the down arrow A3.4.4.1 DC = ____%
• To check output, press the right arrow. When lower
A3.4.3 Brake I+/I
is not selected, 0% of DC battery volts should be
Brake I+/I- is the output signal for the inner brake coil. displayed.
Trucks With High Speed Lower:
• To navigate to the first A3.4.3 Brake I+/I- submenu, When low speed lower is selected and the truck is
press the right arrow. not in soft stop slowdown, approximately 50% of
A3.4.3.1 DC = ____% DC battery volts should be displayed. When high
speed lower is selected, approximately 100% of
• To check output, press the right arrow. When the DC battery volts should be displayed.
brake pedal is not depressed and/or travel is not Trucks With Single Speed Lower:
selected, 0% of DC battery volts should be dis- When lower is selected and the truck is not in soft
played. Fully lower the platform and travel, approx- stop slowdown, approximately 100% of DC battery
imately 20% of DC battery volts should be dis- volts should be displayed.
played.
the next submenu.
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A3.4.4.2 Current = ______ NOTE

• To check output, press the right arrow. When lower A4 is available in Level 3 service mode only. It's not
is not selected, approximately 41 milliamps should available in Level 2. For more information and to ac-
be displayed. cess Level 3, refer to Level 3 near the beginning of this
Trucks With High Speed Lower: section.
When low speed lower is selected and the truck is
not in soft stop slowdown, approximately 400 milli- NOTE
amps should be displayed. When high speed lower
is selected, approximately 750 milliamps should be During a test, all test output submenus will display a
displayed. message Push Return to Cancel. To cancel the test,
Trucks With Single Speed Lower: you can either push the return arrow or wait approxi-
When lower is selected and the truck is not in soft mately 5 seconds and the test will time out.
stop slowdown, approximately 750 milliamps
should be displayed. • Press the right arrow to enter the submenus. Use
the up and down arrows to navigate to the desired
• Press the left arrow twice and then the down arrow submenu.
to scroll to the next submenu. A4.1 ACCESS 1 Test Outputs
A3.4.5 M2 DC = ____%
• To check output, press the right arrow. M2 is the ACCESS 1 submenu.
power steering motor. When turning, up to 90% of A4.1.1 ALM1
DC battery volts should be displayed.
ALM1 is an alarm located on the platform distribution
• This is the last A3 Outputs menu and the last Level panel.
2 Analyzer menu. Press the left arrow to return to
A3.4.5 M2 DC submenu. Press the left arrow to re- • To test output, push the return arrow. The alarm
turn to A3.4 ACCESS 5 submenu. Press the left ar- should sound.
row to return to A3 Outputs menu. Press the left
arrow to return to Analyzer menu • Press the down arrow to scroll to the next sub-
menu.
A4 Test Outputs
A4.1.2 Lamps
When troubleshooting, A4 Test Outputs can be used to
check to see if the ACCESS 123® module output volt- The A4.1.2 Lamps submenu pertains to the lamps on
age is being supplied to the components without oper- the display.
ating the truck. A4 Test Output menus are shown be-
low.
• To test output, push the return arrow. All the lamps
on the display should light.
A4 Test Outputs Submenus

• A4.1.2 Lamps is the last A4.1 ACCESS 1 Test Out-
puts submenus. Press the left arrow until you re-
turn to A4.1 ACCESS 1 submenu.
Sub-
Module Function
menu • Press the down arrow to scroll to A4.2 submenu.
A4.1 ACCESS 1 Display
A4.2 ACCESS 3 Traction
A4.3 ACCESS 4 Vehicle
A4.4 ACCESS 5 Steering
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A4.2 ACCESS 3 Test Outputs A4.2.3 P1

P1 is the pump 1 contactor coil. Pump 1 contactor is
NOTE located on the contactor panel just behind the traction
Before connecting and disconnecting a DVOM from motor. When P1 coil is energized, P1 contacts close
components, be sure to turn the key switch off, discon- providing voltage to the M3 low speed lift motor.
nect the battery and discharge the capacitance volt- • To test output, connect both DVOM leads to P1 coil
age. To properly discharge capacitance voltage,
terminals. Step on the brake pedal, depress the
refer to the Control of Hazardous Energy section in this raise button and press the return arrow. The
manual. DVOM should display approximately 10 volts.
NOTE • Press the down arrow to scroll to the next sub-

menu.
Don't disconnect the terminal leads from components
A4.2.4 FAN2
and connect them to the DVOM leads when testing out-
put. The leads must remain connected to the compo- FAN2 is a fan that helps to cool the ACCESS 123®
nent to complete the circuit. modules and is located above ACCESS 3 in the power
unit.
ACCESS 3 test outputs submenu. • To test output, connect both DVOM leads to FAN2
terminals. Press the return arrow. The DVOM
A4.2.1 SVL
should display approximately 24 volts.
SVL is the lowering solenoid valve and is located on
the lift/lower manifold. It opens during lower providing • Press the down arrow to scroll to the next sub-
a path for oil to flow from the lift cylinders to the reser- menu.
voir. A4.2.5 ED2
• To test output, connect both DVOM leads to SVL ED2 is the #2 Emergency Disconnect contactor coil.
terminals. Press the return arrow. The DVOM The #2 emergency disconnect contactor is located on
should display approximately 24 volts. the contactor panel just behind the traction motor. ED2
coil receives battery negative from ACCESS 3 and
• Press the down arrow to scroll to the next sub- positive battery from ACCESS 5.
menu.
• Press the right arrow to navigate to the first A4.2.5
A4.2.2 P2
ED2 submenu.
NOTE A4.2.5.1 Low Side

Low Side is the negative signal supplied by
This submenu will only be displayed on trucks
ACCESS 3.
equipped with dual speed lift.
P2 is the pump 2 contactor coil. Pump 2 contactor is • To test output, connect DVOM positive lead to a
located on the contactor panel just behind the traction good battery positive reference. Connect the neg-
motor. When P2 coil is energized, P2 contacts close ative DVOM lead to ED2 coil terminal. Press the
providing voltage to the M4 high speed lift motor. return arrow. The DVOM should display approxi-
mately 24 volts.
To test output, connect both DVOM leads to P2 coil ter-
minals. Step on the brake pedal, fully depress the raise • Press the down arrow to scroll to the next sub-
button and press the return arrow. The DVOM should menu.
display approximately 10 volts.

menu.
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A4.2.5.2 Both A4.3 ACCESS 4 Test Outputs

Both means the negative signal supplied by • Press the right arrow to navigate to the first A4.3
ACCESS 3 and positive signal supplied by ACCESS 5. ACCESS 4 test outputs submenu.
• To test output, connect both DVOM leads to ED2 A4.3.1 ALM2
coil terminals. Press the return arrow. The DVOM
ALM2 is an optional travel alarm and is mounted be-
tween the power unit and the platform on the power
• Press the left arrow to scroll back to A4.2.5 ED2 unit wall.
submenu. Then press the down arrow to scroll to
the next submenu. NOTE
A4.2.6 M1-U This submenu will only be displayed if the features
menu, F19 is enabled.
M1-U is the traction motor U terminal signal.
• To test output, connect DVOM positive lead to a

• To test output, connect both DVOM leads to ALM2
terminals. Press the return arrow. The DVOM
good battery positive reference such as the battery
positive terminal on ACCESS 3. Connect the neg-
ative DVOM lead to M1-U terminal. Press the re- • Press the left arrow until you return to A4.3
turn arrow. The DVOM should display approxi- ACCESS 4 submenu. Press the down arrow to
mately 12 volts. scroll to A4.4 submenu.
• Press the down arrow to scroll to the next sub- A4.4 ACCESS 5 Test Outputs
menu.
A4.2.7 M1-V ACCESS 5 test outputs submenu.
M1-V is the traction motor V terminal signal. A4.4.1 ED2
• To test output, connect DVOM positive lead to a ED2 is the #2 Emergency Disconnect contactor coil.
good battery positive reference such as the battery The #2 emergency disconnect contactor is located on
positive terminal on ACCESS 3. Connect the neg- the contactor panel just behind the traction motor. ED2
ative DVOM lead to M1-V terminal. Press the re- coil receives battery negative from ACCESS 3 and
turn arrow. The DVOM should display approxi- positive battery from ACCESS 5.
mately 12 volts.
• Press the down arrow to scroll to the next sub- ED2 submenu.
menu.
A4.4.1.1 High Side
A4.2.8 M1-W
High Side is the positive signal supplied by ACCESS 5.
M1-W is the traction motor W terminal signal.
• To test output, connect DVOM negative lead to a
• To test output, connect DVOM positive lead to a good battery negative reference. Connect the pos-
good battery positive reference such as the battery itive DVOM lead to ED2 coil terminal. Press the re-
positive terminal on ACCESS 3. Connect the neg- turn arrow. The DVOM should display approxi-
ative DVOM lead to M1-W terminal. Press the re- mately 24 volts.
turn arrow. The DVOM should display approxi-
mately 12 volts. • Press the down arrow to scroll to the next sub-
menu.
• A4.2.8 M1-W is the last A4.2 ACCESS 3 Test Out-
puts submenus. Press the left arrow until you re-
turn to A4.2 ACCESS 3 submenu. Press the down
arrow to scroll to A4.3 submenu.
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A4.4.1.2 Both A4.4.5.1 Clockwise

Both is the positive and negative signal supplied by • To test output, connect both DVOM leads to M2 ter-
ACCESS 5 and 3. minals. Press the return arrow. The DVOM should
• To test output, connect both DVOM leads to ED2 display approximately 7 volts.
coil. Press the return arrow. The DVOM should dis- • Press the down arrow to scroll to the next sub-
play approximately 24 volts. menu.
• Press the left and then the down arrow to scroll to A4.4.5.2 CCwise
the next submenu.
• To test output, connect both DVOM leads to M2 ter-
A4.4.2 BRK Outer minals. Press the return arrow. The DVOM should
A4.4.2 BRK Outer is the submenu for the outer brake display approximately 7 volts.
coil.
• To test output, connect DVOM positive lead to

brake connector CA407 pin 1 (wire 2968). Connect
the negative DVOM lead to brake connector
CA407 pin 4 (wire 5929). Press the return arrow.
The DVOM should display approximately 3 volts.

menu.
A4.4.3 BRK Inner
A4.4.3 BRK Inner is the submenu for the outer brake
coil.
• To test output, connect DVOM positive lead to

brake connector CA407 pin 2 (wire 2969). Connect
the negative DVOM lead to brake connector
CA407 pin 3 (wire 5928). Press the return arrow.
The DVOM should display approximately 1.5 volts.

menu.
A4.4.4 PVL
PVL is the proportional solenoid valve for lowering and
is located on the lift/lower manifold. It opens in propor-
tion to applied voltage during lower providing a path for
oil to flow from the lift cylinders to the reservoir.
• To test output, connect both DVOM leads to PVL

coil terminals. Press the return arrow. The DVOM

menu.
A4.4.5 M2
M2 is the power steering motor.

M2 submenu.
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Features F11 Max Load Weight = ___; This feature prompts you
to enter the maximum capacity load, which is indicated
The feature menu is shown on the following pages. The on the truck's Capacity Data Plate. If more than one
first level of the menu shows the different areas of capacity is listed, then enter the heaviest weight listed
setup for the truck. on the Capacity Data Plate. Factory setting is 1360 kg
(3000 lb) range dependant on truck model.
Features Access F14 Wire Guidance = ___; This feature adjusts wire
guidance setting. Factory setting is disabled.
After powering up the truck, navigate to the SERVICE
menu by pressing the down arrow button. At the SERV- F15 Manual Wire Sense = ___; This feature adjusts
ICE menu, press the right arrow to enter LEVEL 2. manual wire sense setting. Factory setting is disabled.
Press the right arrow again to enter the Access pass- F16 End Aisle Control = ___; This feature adjusts end
word. Use the up or down arrow buttons to change aisle control to no EAC, north sensing or south sens-
number, press right arrow to move to the next number. ing. Factory setting is No EAC.
Once all numbers in the Access code have been en-
tered press the enter or return button. Using the down F17 PDS = ___; This feature adjusts PDS setting. Fac-
arrow, navigate to the FEATURES menu and then tory setting is Disable.
press the right arrow. The message displayed will be F18 Battery Retainer Switch = ___; This feature ad-
F1 Language =. justs battery retainer alarm setting. Factory setting is
If changes have been made in the sub menus, pressing No.
the left arrow at the first level menu will prompt Save? F19 Travel Alarm = ___; This feature sets the alarm
N in the settings. Use the up and down arrows to select when traveling. Factory setting is Off.
Save? Y then press enter or return to save settings.
F20 User Performance = ___; This feature deter-
F1 Language = ___; This feature displays the desired mines whether the operator has the ability to select dif-
language for ACCESS 1 display messages. Factory ferent truck performance levels. If enabled and F21 is
setting is English. Press down to scroll through 11 total disabled, any operator can select any performance
choices. level (P1, P2, P3). If disabled, the operator can not
F2 Unit of Measure = ___; This feature determines the change truck performance modes. Press the right ar-
units of measure displayed (English or Metric). Factory row, use the up and down arrows to change. Press en-
setting is English. Press down arrow to continue. ter or return. Press the down arrow to continue. Factory
setting is Disabled.
F3 Region = ___; This feature displays desired region.
Range includes North America, Europe and Australia. F21 User Codes = ____ Use this feature to enter up to
Factory setting is North America. 25 operator codes (4 digits each) which can be applied
to various performance levels. To modify, press the
F5 Truck Model = ___; This feature is must be se- right arrow. Use the up and down arrows to enable or
lected at setup. disable. Press the right arrow to continue. Factory set-
F6 Mast Type = ___; This feature displays two mast ting is Disabled.
types: TT or TL. Factory setting is TT. Note: If F21 is enabled, operators can not change per-
F7 Collapsed Height = ___; This feature displays formance levels regardless of F20 setting. Truck will be
truck collapsed height. Factory setting is 2718 mm limited to the performance level assigned to the Oper-
(107 in). ator Code.
F8 Lift Height = ___; This feature prompts you to enter F23 Options = ____; This feature enables or disables
the truck lift height as shown on the truck data plate. truck options listed in the F23 submenus.
Factory setting is 6096 mm (240 in). F24 Motor Monitor System (MMS) = ___; This feature
F10 Truck Weight = ___; This feature prompts you to adjusts MMS setting. Factory setting is Disabled.
enter the truck weight as equipped with maximum bat- F25 Zone Switch = ___; This feature adjusts zone
tery, which is indicated on the truck's Capacity Data switch setting. Factory setting is No.
Plate. Factory setting is 3825 kg (8500 lb).
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F26 Message Mode = ___; This feature changes infor-

mation displayed during operation. Press the right ar-
row, use the up and down arrows to change.
Select from: BDI (battery percent of charge), Hours
(hour meter reading), Odometer (total distance truck
has traveled in miles), Trip (total distance truck has
traveled since last reset), Timer (stopwatch) or All (al-
lows operator to determine message using display but-
tons). Press enter or return. Menu will return to F26.
Press the down arrow to continue. Factory setting is
None.
F27 Truck Operation = ___; This feature adjusts set-
ting. Set to enabled or disabled. Only available if F14
setting is disabled. Factory setting depends on F14 set-
ting.
F28 Hour Meter Mode = ___; This feature determines
the hour meter that will be displayed during operation.
To change the displayed hour meter, press the right ar-
row, use the up and down arrows to change between
H1 and H2 (see hour meter description to determine
monitored system item). Press the enter or return but-
ton. Menu will return to F28, press the down arrow to
continue. Factory setting is Access 1.
F29 Reset Switch (HGTRS) Height = ___; This fea-
ture resets the height encoders. Factory setting is
381 mm (15 in).
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Performance Access NOTE

The performance menu explanations are shown on the P1, P2, and P3 are the three performance levels that
following pages. The explanations don't explain how to may be selected when in level 1 as long as F20 User
navigate through the menus and submenus or how to Performance submenu is enabled (if F20 User Per-
change the selection. To navigate through and/or formance submenu is disabled, the operator will then
change a menu selection, refer to the Service Level 2 be locked in at the P1 settings). Each of these perform-
and 3 - Performance Menus charts in this section of the ance levels can be programmed for different travel
service manual. The charts show the buttons that must speeds and travel acceleration rates. This allows these
be pushed to navigate through and change the menus. settings to be customized somewhat to an operator's
level of experience or warehouse congestion. The fac-
The performance menu can be accessed within Level
tory standard settings for the P1 performance level are
2 and Level 3 of the ACCESS 123® system. However,
set to achieve maximum performance. The factory
to access the performance menu, your foot must be off
standard settings for P2 are slower, and the factory
the brake pedal and the brake applied. After you select
standard settings for P3 are the slowest. However, by
the performance menu, lift, lower and travel are disa-
customizing the settings, any performance level, P1,
bled. Once you exit the performance menu, you must
P2, or P3, can be higher, lower, or the same as any
recycle the key switch for lift, lower and travel to be en-
other performance level. For example, the P1 settings
abled.
could be customized to be slower than or equal to the
After you change a performance setting, you must P3 standard settings.
press the enter button to keep the setting. After all P2 and P3 menu explanations are not included in this
changes are made and to save the settings, you must section since they are adjusted in the same manner as
press the left button until the display asks you Save? N. P1.
Change the N to a Y and press the enter button to save
P1.1 Travel Acc = ___
all changes. If you turn off the key switch without saving
the settings, the settings will revert to the previous set- The travel acceleration setting is an adjustment of how
tings. quickly the truck will accelerate from idle to top travel
speed. The setting can be changed from 1 to 9, with 1
Power up the truck, keep your foot off the brake pedal,
taking the longest to accelerate and 9 taking the least.
and navigate to the SERVICE menu by pressing the
The factory settings are P1 = 9, P2 = 7 and P3 = 5.
down arrow button. At the SERVICE menu, enter
LEVEL 2 or 3. Press the right arrow again to enter the P1.2 Travel Speeds
Access password. Use the up or down arrow buttons to
As the name implies this is where truck travel speeds
change number, press the right arrow to move to the
are set. The two adjustments within this submenu are
next number. Once all numbers in the Access code
Free Ranging and Guided.
have been entered press the enter or return button. Us-
ing the down arrow navigate to the PERFORMANCE
menu, and then press the right arrow. The message NOTE
displayed will be P1 Setup. If the F2 submenu is set to English, all speeds will be
shown in mph. If the F2 submenu is set to Metric, the
speeds will be shown in kph.
P1.2.1 Free Range
Free Ranging is the term used to describe operating a
SP 3500 with manual steering active (truck is not in
Wire or Rail guidance mode). The three adjustments
within this submenu are Speed Curve, Max FF and
Max PUF.
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P1.2.1.1 Speed Curve = ___ P5 Coast = ___

This setting adjusts when (how soon) truck travel will The P5 Coast adjustment affects the coasting effort of
begin speed reduction as the platform is raised during the truck when, with the truck traveling, the operator
free range travel. A setting of 1 means the truck will returns the twist grip to neutral and remains standing
begin to slow down sooner (at lower elevation) and a on the brake pedal. Regenerative motor current is also
setting of 9 means the truck will begin to slow down used for this function. The higher the setting, the lower
later (at higher elevation). Factory settings are P1 = 9, the amount of regenerative energy applied to the trac-
P2 = 7, P3 = 5. tion motor and the further the truck will travel or coast
when the twist grip is returned to neutral. The lower the
P1.2.1.2 Max FF = ___ (Reverse Travel)
setting, the higher the amount of regenerative energy
This setting adjusts the maximum travel speed in the applied to the traction motor and the quicker the truck
forks first (FF) direction. The range is 1.0 to 10.5 kph will coast to a stop when the twist is returned to neutral.
(1.0 to 7.0 mph) dependent on truck model. Factory The range of adjustment for Coast is 1 to 9. The factory
settings for P1, P2 and P3 are dependent on truck setting is 9.
model.
P6 Braking
P1.2.1.3 Max PUF = ___ (Forward Travel)
The P6 Braking submenu adjusts the truck's braking
This setting adjusts the maximum travel speed in the effort. Truck braking is accomplished through the trac-
power unit first (PUF) direction. The range is 1.0 to 12.1 tion motor brake in combination with regenerative mo-
kph (1.0 to 7.5 mph) dependent on truck model. Fac- tor current. On the SP 3500, braking is adjusted sepa-
tory settings for P1, P2 and P3 are dependent on truck rately for the forks first and power unit first directions of
model. travel.
P1.2.2 Guided P6.1 FF Braking = ___ (Reverse Travel)
This submenu is the same as P1.2.1 except the set- This setting adjusts the braking effort in the forks first
tings are for when the guidance switch is set to auto. (FF) direction. Range of adjustment is 1 to 9 with 1 pro-
viding the least amount of braking effort and 9 the
P1.2.2.1 Speed Curve = ___
most. The factory setting is 7. Before adjusting and so
This submenu is the same as P1.2.1.1 except the set- brake effort is properly adjusted, refer to the Brake sec-
tings are for when the guidance switch is set to auto. tion of this service manual and read and follow the
Brake Force Adjustment information.
P1.2.2.2 Max FF = ___ (Reverse Travel)
P6.2 PUF Braking = ___ (Forward Travel)
This submenu is the same as P1.2.1.2 except the set-
tings are for when the guidance switch is set to auto. This submenu is the same as P6.1 except the settings
are for the power unit first direction.
P1.2.2.3 Max PUF = ___ (Forward Travel)
P7 Free Range Speeds
This submenu is the same as P1.2.1.3 except the set-
tings are for when the guidance switch is set to auto. The P7 submenu is used to enter speed versus height
limits when operating the truck with manual steering
P4 Plug = ___
active. The two adjustments within this submenu are
The P4 Plug submenu adjusts plugging force. During the platform heights when truck speed is limited to
plugging, the control system will use regenerative mo- 1.6 kph (1.0 mph) and 0 kph (0 mph).
tor current to slow the rotation of the drive motor. The
P7.1 1 Mph Height = ___
range of adjustment is 1 to 9. A setting of 9 will provide
the shortest plugging distance and a setting of 1 the P7.1 is the first speed, height limit. The speed of the
longest. However, the plugging distance is proportional truck will be limited to 1.6 kph (1.0 mph) when the plat-
to how far the twist grip is rotated. The longest plugging form reaches the height set in this submenu. The range
distance will occur when the twist grip is rotated slightly of adjustment is 0 to 1524 cm (0 to 600 in). The factory
and near the neutral position and the P4 setting is set setting is 1524 cm (600 in).
to 1. The shortest plugging distance is achieved when
the twist grip is rotated fully and the P4 setting is set to
9. The factory setting is 9.
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P7.2 0 Mph Height = ___ P8.2 0 Mph Height = ___

P7.2 is the second speed height limit. The speed of the This submenu is the same as P7.2 except the settings
truck will be limited to 0 kph (0 mph) when the platform are for when the guidance switch is set to auto.
reaches the height set in this submenu. When this
P8.3 Acquire Speeds = ___
height is reached and travel is requested, the display
will show the message Reduce Lift Height. The range P8.3 sets the travel speed when trucks equipped with
of adjustment is 0 to 1524 cm (0 to 600 in). The factory wire guidance are acquiring the wire. The adjustment
setting is 1524 cm (600 in). range is 1.5 kph (1.5 mph) to 4.0 kph (2.5 mph). Fac-
tory setting is 4.0 kph (2.5 mph).
NOTE P9 BDI = ___
If P7.2 is set to a lower height than P7.1, the height set Changing this value affects the lift lockout level which
for P7.2 will take precedence and the truck will not be disables the lift circuit when the battery is 80% dis-
able to use the 1.6 kph (1.0 mph) speed, height limit charged. The range of adjustment for P9 is 1 to 9. De-
(P7.1) setting. creasing the P9 setting will reduce the volts-per-cell
P8 Guided Speeds monitor, allowing the battery to go into deeper dis-
charge prior to lift lockout. Increasing the P9 setting will
This submenu is the same as P7 except the settings increase the volts-per-cell monitor, disabling the lift
are for when the guidance switch is set to auto. function earlier in the discharge cycle (refer to Figure
P8.1 1 Mph Height = ___ 22572 below). Setting P9 to a level that will permit bat-
tery discharge that is too deep may cause Event Codes
This submenu is the same as P7.1 except the settings relating to low battery voltage to occur. The factory set-
are for when the guidance switch is set to auto. ting is 5.
BDI Discharge Reading

P9 set to 1
P9 set to 5
P9 set to 9
Voltage
Lift
Lockout
Percentage of Charge
Figure 22572
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• Slowdown with Auto Resume - Refer to Figure

Chart 1C 22574. When the truck travels and senses the floor
Percent P9 set to 1 P9 set to 5 P9 set to 9
magnets, Slowdown with Auto Resume mode will
cause the truck to slow down to the speed set in
100.0% 25.44 25.44 25.44 P12.2.1 and P12.3.1 Slowdown Speed submenus.
20.0% 23.33 23.71 24.10 After traveling the distance set in P12.2.3 and
P12.3.3 Resume Distance submenus, normal
travel speed is permitted. This mode is useful in
NOTE warehouses with an intersection.
P10 and P11 menus are reserved for options that may
be added in the future.
P12 EAC Setup
NOTE
When traveling in auto guided steering mode, the End
Aisle Control (EAC) system reminds the operator an
intersection or the end of the aisle is approaching. This
system incorporates magnets in the floor and sensors
on the truck. For more information concerning the EAC
system, refer to End Aisle Control section in this serv-
ice manual.
If F16 EAC submenu is set to none, the P12 EAC
Setup submenu will not be available.
P12 EAC Setup submenu is used to setup how the
truck will react when the EAC system senses the mag-
nets near the end of an aisle or intersection.
P12.1 Mode = ___
This setting determines what the EAC system will do
(mode) when the magnets are sensed. The choices
are:
• Slowdown - When the truck travels to the end of an

aisle and senses the floor magnets, Slowdown
mode will cause the truck to slow down to the
speed set in P12.2.1 and P12.3.1 Slowdown
Speed submenus. Slowdown guided travel speed
is maintained until the truck exits the aisle and
manual steering is selected. If reverse direction is Figure 22574
selected before exiting the aisle, normal guided
travel speed is permitted. When entering the aisle 1 Floor Magnets
and switching to auto guided steering and prior to 2 Power Unit First Resume Distance
the truck sensors sensing the magnets, the opera- 3 Magnet Spread
tor can press and hold the override button (ORS1 - 4 Forks First Resume Distance
see Componentry section) to override the slow-
down speed. After entering the aisle and switching If the truck is traveling power unit first within the power
to auto guided steering and after the truck sensors unit first Resume Distance, speed is limited to the
sense the magnets, normal guided travel speed is power unit first Slowdown speed. If the truck is
permitted. traveling power unit first beyond the Resume Distance,
full guided travel speed is resumed. Operation in the
forks first direction is the same.
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NOTE • P12.2.4 Stop Distance

Resume Distance is measured from the magnet sen-
sor bar located under the trucks battery box. NOTE
• Slowdown with Auto Stop - When the truck travels Dependent on the mode selected, some adjustments
(submenus) listed above may not be available.
and senses the floor magnets, Slowdown with Auto
Stop mode will cause the truck to slow down to the P12.2.1 Slowdown Speed = ___
speed set in P12.2.1 and P12.3.1 Slowdown
This setting adjusts the truck speed when traveling
Speed menus and, after traveling the distance set
forks first in Slowdown mode. The adjustment range is
in P12.2.4 and P12.3.4 Stop Distance submenus,
1.0 to 6.0 kph (1.0 to 6.0 mph). The factory setting is
cause the truck to stop. The operator must return
3.2 kph (2.0 mph).
the traction twist grip to neutral and press the over-
ride button for travel to be permitted. Slowdown P12.2.2 Decel Rate = ___
guided travel speed is maintained until the truck
This setting adjusts the deceleration rate that the truck
exits the aisle and manual steering is selected.
will use in order to reach the slowdown speed set in
When entering the aisle and switching to guided
P12.2.1. The range of adjustment for this setting is 1 to
steering and prior to the truck sensors sensing the
9 with 1 being the least aggressive deceleration and 9
magnets, the operator can press and hold the over-
being the most aggressive. The factory setting is 3.
ride button to override the slowdown speed. After
entering the aisle and switching to guided steering
and the truck sensors sense the magnets, normal NOTE
guided travel speed is permitted. If Stop Using Brake mode is selected, this submenu
• Stop Using Motor - When the truck travels and will not be available.
senses the floor magnets, Stop Using Motor mode P12.2.3 Resume Distance = ___
will cause the truck to stop using regenerative mo-
This setting adjusts the forks first distance that the
tor current decelerating at a rate set in P12.2.2 and
truck must travel beyond the EAC magnets before trac-
P12.3.2 Decel Rate submenus. The operator must
tion speed is released from the slowdown speed. The
return the traction twist grip to neutral and press
adjustment range is 3 to 18 m (10 to 60 ft). Factory
the override button for travel to be permitted. Slow-
setting is 14 m (45 ft.). This setting is used on trucks set
down guided travel speed is maintained until the
to Slowdown with Auto Resume mode (see P12.1
truck exits the aisle.
Mode).
• Stop Using Brake - When the truck travels and
senses the floor magnets, Stop Using Brake mode NOTE
will cause the truck to stop using the traction brake
If Slowdown with Auto Resume mode is not selected,
and at the same decelerating rate as if the operator
this submenu will not be available.
released the brake pedal. The operator must return
the traction twist grip to neutral and press the over- P12.2.4 Stop Distance = ___
ride button for travel to be permitted. Slowdown
This submenu adjusts the distance that the truck must
guided travel speed is maintained until the truck
travel beyond the EAC magnets (into the slowdown
exits the aisle.
zone) before the truck stops. The adjustment range is
P12.2 FF Direction (Reverse Travel) 0 to 12 m (0 to 40 ft). The factory setting is 6 m (20 ft).
This setting is used on trucks set to Slowdown with
In this submenu, adjustments are made to the mode
Auto Stop mode (see P12.1 mode).
(see P12.1 Mode) performance when traveling in the
forks first (FF) direction. The adjustments are:
NOTE
• P12.2.1 Slowdown Speed
If Slowdown with Auto Stop mode is not selected,
• P12.2.2 Deceleration Rate this submenu will not be available.
P12.3 PUF Direction (Forward Travel)
• P12.2.3 Resume Distance
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This submenu is the same as P12.2 except the settings P13.1 FF Direction (Reverse Travel)
are for the power unit first direction.
This submenu is used to adjust PDS settings for the
P12.3.1 Slowdown Speed = ___ forks first direction of travel. The settings are:
This submenu is the same as P12.2.1 except the set- • P13.1.1 Max Speed
tings are for the power unit first direction.
P12.3.2 Decel Rate = ___
• P13.1.2 Slowdown Speed
This submenu is the same as P12.2.2 except the set- • P13.1.3 Decel Rate
P13.1.1 Max Speed = ___
P12.3.3 Resume Distance = ___
This submenu sets the maximum speed in the forks
This submenu is the same as P12.2.3 except the set- first direction when PDS is active. The adjustment
tings are for the power unit first direction. range is 1.0 to 10.5 kph (1.0 to 6.5 mph). Factory set-
ting is 9.7 kph (6.0 mph).
P12.4 Slowdown Direction = ___
P13.1.2 Slowdown Speed = ___
This submenu programs the truck so it will slowdown
when traveling out of the aisle or in and out of the aisle. This submenu adjusts the truck speed when traveling
Choices are Out of Aisle Only or Into and Out of Aisle. in the forks first direction and PDS senses a person or
an object. The adjustment range is 1.0 to 6.0 kph (1.0
The factory setting is Out of Aisle Only.
to 6.0 mph). The factory setting is 2.5 kph (1.5 mph).
NOTE P13.1.3 Decel Rate = ___
If Slowdown with Auto Resume is selected, this sub- This submenu adjusts the deceleration rate that the
menu will not be available. truck will use in order to reach the slowdown speed set
in P13.1.2. The range of adjustment for this setting is 1
P12.5 Magnet Spread = ___ to 9 with 1 being the least aggressive deceleration and
Refer to Figure 22574. This setting tells the truck the 9 being the most aggressive. The factory setting is 9.
distance between the inside magnets at a cross aisle. P13.2 PUF Direction (Forward Travel)
The adjustment range is 6 to 46 m (20 to 150 ft). This
setting is used on trucks set to Slowdown with Auto This submenu is the same as P13.1 except the settings
Resume. The factory setting is 24 m (80 ft). are for the power unit first direction.
P13.2.1 Max Speed = ___
NOTE This submenu is the same as P13.1.1 except the set-
If Slowdown with Auto Resume is not selected, this tings are for the power unit first direction.
submenu will not be available. P13.2.2 Slowdown Speed = ___
P13 PDS Setup This submenu is the same as P13.1.2 except the set-
This submenu is used to setup the operating parame- tings are for the power unit first direction.
ters for the optional Personnel Detection System. PDS P13.2.3 Decel Rate = ___
uses sensors mounted on the truck to warn the opera-
tor of any obstruction or person in the aisle. This submenu is the same as P13.1.3 except the set-
NOTE P14 Low Speed Lower
If F17 is set to Disable, P13 PDS Setup submenu will This submenu adjusts the low speed lowering speeds.
not be available. The low speed lowering speed submenus are:
• P14.1 Low Speed Lower 1
• P14.2 Low Speed Lower 2
• P14.3 Aux Lower Speed
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P14.1 Low Speed Lower 1 = ___

This submenu adjusts the low speed lowering when the
platform is above 380 mm (15 in) (HGRTS switch con-
tacts are open). Adjusting to a setting of 1 provides the
slowest lowering speed. Adjusting to a setting of 9 pro-
vides the fastest lowering speed. The factory setting is
5.
P14.2 Low Speed Lower 2 = ___
This submenu adjusts the lowering speed when the
platform is at or below 380 mm (15 in) (HGRTS switch
contacts are closed). Adjusting to a setting of 1 pro-
vides the slowest/softest lowering speed. Adjusting to
a setting of 9 provides the fastest/hardest lowering
speed. The factory setting is 1.
P14.3 Aux Lower Speed = ___
This submenu affects the lowering speed of the auxil-
iary mast on SP 3512 and SP 3522 trucks. Adjusting to
a setting of 1 decreases the auxiliary lowering speed.
Adjusting to a setting of 9 decreases the auxiliary low-
ering speed. The factory setting is 5.
NOTE
If F5 is not set to 3512-1.0 or 3522-1.0, this submenu
will not available.
P15 Soft Stop = ___
This setting adjusts the deceleration rate of the plat-
form lowering after the lower switch has been released.
Adjusting to a setting of 1 provides the slowest/softest
stop. Adjusting to a setting of 9 provides the fastest/
hardest stop. The factory setting is 5.
P99 Load Factory Defaults = ___
With this submenu you can load the factory settings for
all Performance menu levels.
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Chart 1 -
Chart 1 - Factory Setting Chart
Factory Setting Chart
P12.1 Slowdown Mode
Menu Factory Setting P12.2.1 3.2 kph (2.0 mph)
P12.2.2 3
P1.1 9
P12.2.3 14 m (45 ft)
P1.2.1.1 9
P12.2.4 6 m (20 ft)
P12.3.1 3.2 kph (2.0 mph)
P12.3.2 5
P1.2.2.1 9
P12.3.3 14 m (45 ft)
P12.3.4 6 m (20 ft)
P12.4 Out of Aisle Only
P2.1 7
P12.5 24 m (80 ft)
P2.2.1.1 7
P13.1.1 9.7 kph (6.0 mph)
P13.1.2 2.5 kph (1.5 mph)
P13.1.3 9
P2.2.2.1 7
P13.2.1 9.7 kph (6.0 mph)
P13.2.2 2.5 kph (1.5 mph)
P13.2.3 9
P3.1 5
P14.1 5
P3.2.1.1 5
P14.2 1
P14.3 5
P15 5
P3.2.2.1 5
P4 9
P5 9
P6.1 7
P6.2 7
P7.1 1524 cm (600 in)
P7.2 1524 cm (600 in)
P8.1 1524 cm (600 in)
P8.2 1524 cm (600 in)
P8.3 4.0 kph (2.5 mph)
P9 5
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Chart 2 - P1 Performance Chart
P1 Default and Maximum

FF PUF FF PUF
9.7 kph 10.5 kph 9.7 kph 10.5 kph
SP3505
(6.0 mph) (6.5 mph) (6.0 mph) (6.5 mph)
10.5 kph 12.1 kph 10.5 kph 12.1 kph
SP3510
SP3520
(6.5 mph) (7.5 mph) (6.5 mph) (7.5 mph)
11.3 kph 12.1 kph 11.3 kph 12.1 kph
SP3550
(7.0 mph) (7.5 mph) (7.0 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3511
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3512
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
Europe
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3521
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3522
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3510
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3520
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
Australia
9.0 kph 9.0 kph 10.5 kph 12.1 kph
SP3522
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 kph 9.0 kph 11.3 kph 12.1 kph
SP3550
(5.6 mph) (5.6 mph) (7.0 mph) (7.5 mph)
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P2 Default
FF PUF FF PUF
8.9 kph 9.7 kph 8.9 kph 9.7 kph
SP3505
(5.5 mph) (6.0 mph) (5.5 mph) (6.0 mph)
9.7 kph 11.3 kph 9.7 kph 11.3 kph
SP3510
SP3520
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
10.5 kph 11.3 kph 10.5 kph 11.3 kph
SP3550
(6.5 mph) (7.0 mph) (6.5 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3511
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3512
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
Europe
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3521
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3522
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3510
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3520
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
Australia
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3522
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 kph 9.0 kph 9.7 kph 11.3 kph
SP3550
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
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P3 Default
FF PUF FF PUF
8.0 kph 8.9 kph 8.0 kph 8.9 kph
SP3505
(5.0 mph) (5.5 mph) (5.0 mph) (5.5 mph)
8.9 kph 10.5 kph 8.9 kph 10.5 kph
SP3510
SP3520
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
9.7 kph 10.5 kph 9.7 kph 10.5 kph
SP3550
(6.0 mph) (6.5 mph) (6.0 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3511
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3512
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
Europe
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3521
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3522
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3510
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3520
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
Australia
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3522
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
(8.0 kph (8.0 kph 8.9 kph 10.5 kph
SP3550
5.0 mph) 5.0 mph) (5.5 mph) (6.5 mph)
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Calibration • FF Direction - Rotate the twist grip to the full forks

first direction and press the enter button.
The calibration menu explanations follow.
• Center - Release the twist grip allowing
Calibration Access
• Press the left arrow and the display will ask Save?
The calibration menu is only available in Level 2 and is N. Change the N to Y and press the enter button to
not available in Level 3. To view the Calibration menu, save the settings.
you must not depress the brake pedal. If you stand on
the brake pedal, the Calibration menu will not be visi- • Press the down arrow to continue calibration. C2
ble. Once you select the Calibration menu, you can Valves menu should be displayed.
stand on the pedal to operate the truck functions for
calibration. C2 Valves
Power up the truck, keep your foot off the brake pedal, This calibration allows ACCESS 5 to determine the
and navigate to the SERVICE menu by pressing the amount of current needed to open the proportional low-
down arrow button. At the SERVICE menu, enter ering valve (PVL). This calibration should be performed
LEVEL 2. Press the right arrow again to enter the Ac- after replacing or adjusting PVL or an ACCESS 123
cess password. Use the up or down arrow buttons to module.
change number, press the right arrow to move to the • Press the right arrow and C2.1 Main Lower menu
next number. Once all numbers in the Access code
have been entered, press the enter or return button.
Using the down arrow navigate to the Calibration • Press the right arrow to enter C2.1 Main Lower
menu, and then press the right arrow. The message menu and the display will ask you Sure? N.
displayed will be C1 Handles. Change the N to Y and press the enter button.
The following messages will be displayed:
NOTE
To prevent nuisance event codes, as a general rule, if • Raise above reset, lower to begin - Raise the
any ACCESS 123® module is replaced, Crown recom- platform above the Height Reset Switch (2). The
mends performing all calibrations. Also, if the replace- HGTRS is located on the back of the platform. The
ment module includes updated software, the software bar that actuates the switch (1) is approximately
in the remaining modules will have to be updated so all 380 mm (15 in) tall. Therefore, you will need to
module software is compatible. raise the platform at least 380 mm (15 in), but not
high enough to start staging the mast. Refer to Fig-
C1 Handles ure 21957.
This calibration allows the truck to learn the values of
the traction potentiometer (POT1). The traction poten-
tiometer should be calibrated after replacing POT1, FS,
RS, or an ACCESS 123 module.
• Press the right arrow and C1.1 Traction menu

• Press the right arrow to enter C1.1 Traction menu

and the display will ask you Sure? N. Change the
N to Y and press the enter button.
You will then be asked to set three positions for the
twist grip. As you perform the following commands,
press the right arrow to view the percent of POT1 volt-
age seen by ACCESS 4. Figure 21957
• PUF Direction - Rotate the twist grip to the full • After raising the platform, press the enter button
power unit first direction and press the enter but- and lower (maintain command) the platform. Con-
ton. tinue to follow the instructions on the display. The
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menus will automatically advance as you perform

each step. As the following messages appear,
press the right arrow to view the current flowing
through PVL (from ACCESS 5).
• Finding Breakout, Maintain Command
• Finding Speed 1, Maintain Command
• Finding Speed 2, Maintain Command
• Paused - Raise, Lower to begin - This message Figure 29165

appears when you have lowered to the reset
switch while finding the two speeds. Raise the plat- This calibration should be performed after replacing an
form and lower again. ACCESS 123® module.
• Stop Command NOTE

• Lower forks to floor, press enter Although, ECR4 provides platform height input to
ACCESS 4, this encoder does not require calibration.
• Press the left arrow and the display will ask Save? Each time the height reset switch, HGRTS, is actuated,
N. Change the N to Y and press the enter button to ACCESS 123 checks the height input to be sure the
save the settings. input is correct. This is how ACCESS 123 maintains
the correct height of the height cutouts.
• Press the down arrow to continue calibration. C3
Height Cutouts menu should be displayed. • Press the right arrow and C3.1 Cutout 1 menu
C3 Height Cutouts
If the truck is equipped with an override switch (refer to • Press the right arrow and C3.1.1 Set Height should
Figure 21964) a total of six raise and lower cutouts can be displayed.
be programmed. If the truck is not equipped with an
override switch one raise cutout can be programmed.
• Press the right arrow and R/L to Cutout then Enter
message should be displayed.
The cutouts can also be programmed to work all the
time, only while outside of the guided aisle, and/or • Raise or lower the platform to the desired height. If
while in a certain zone (must be equipped with a zone you wish to view the height of the platform, press
select switch - refer to Figure 21965). the right arrow.
• After positioning the platform at the desired height,

press enter. Pressing enter will set the height and
return you to the C3.1.1 Set Height menu.
• Press the down arrow and the C3.1.2 Type =

_____ menu will be displayed.
Figure 21964
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• Press the right arrow and then the down or up ar- • To program additional cutouts, push the down ar-
row to scroll to one of the following cutout types: row. Up to six different cutouts can be programmed
at one time. The process to program these cutouts
– None - No cutout desired.
is performed the same as just described.
– PCT - Positive (raise) Cutout: allows override
when equipped with the required override • Press the left arrow and the message Save? N will
switch. appear.
– PST - Positive (raise) Stop: no override option. – If you press the up arrow, Clear All message
will appear. Pushing the enter button after this
– NCT - Negative (lower) Cutout: allows override message appears will delete all the cutouts.
when equipped with the required override The display will then return to C3 Height Cut-
switch. outs menu.
• Once you have scrolled to the type of cut out de- – If you press the down arrow Save Y message
sired, press enter to select it. The display should will appear. Pushing the enter button after this
return to the C3.1.2 Type = _____ menu. message appears will save all the cutouts. The
display will then return to C3 Height Cutouts
• Press the down arrow and the menu C3.1.3 When menu.
= _____ should be displayed.
• Press the down arrow to continue calibration. C4
• Press the right arrow and then the down or up ar- Steer Encoder menu should be displayed.
row to scroll to when the cutout will occur:
C4 Steer Encoder
– Always - With this setting the cut out will occur
all of the time. The C4 Steer Encoder menu is where the encoder in-
dex is set to the straight-ahead steer wheel position.
– Free Range Only - With this setting the cutout This step is important for optimal wire and rail guidance
will occur only when the truck is outside of the performance. Perform C4 calibration after replacing or
guided aisle. adjusting ECR2 or an ACCESS 123 module.
• Once you have navigated to the desired setting • Rotate the steering tiller so that the alignment
press enter to select it. The display should return to marks located on the drive unit and drive unit
the C3.1.3 When = _____ menu. mounting bracket form a straight line as shown in
Figure 23050.
• Press the down arrow. If your truck is equipped
with the optional three position zone select switch
and it is enabled in the features menu F25, C3.1.4
Zone menu option will appear (NOTE: If this mes-
sage does not appear, disregard this step and the
next two steps and proceed with the step Press the
left arrow to return to C3.1 Cutout 1 menu …).
• Press the right arrow and the menu will allow you
to program different cutout scenarios for multiple
zones:
– A, B, C, All
• Select the desired zone (selected by the zone se-

lect switch) and press the enter button. The display
should return to the C3.1.4 Zone menu.
• Press the left arrow to return to C3.1 Cutout 1 Figure 23050
menu. 1 Alignment Marks
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• Press the right arrow to enter C4 Steer Encoder To calibrate an SP 3500 truck you'll need a wire guided
menu and the display will ask you Sure? N. aisle approximately 12 m (40 ft) long. (9 m [30 ft] is
Change the N to Y and press the enter button. needed for offset null calibration. Additional distance is
needed to stop the truck before the truck comes off the
• The message Encoder at Index should be dis- wire and an event code is logged.)
played and a continuous alarm. If the display The components that directly affect wire guidance in-
doesn't indicate the encoder is at index when you clude the front and rear sensor bars, the steer angle
enter the menu, remove the steering feedback en- feedback encoder (ECR-2), the floor signal strength
coder cover. Then loosen the two steering encoder and the ACCESS 123 modules. Whenever any of
screws shown in Figure 23042 just enough to ro- these components are changed or adjusted, the wire
tate the encoder with resistance. guidance system must be calibrated. The mechanical
items that can affect wire guidance are covered in the
following Pre-Calibration Checks.
Pre-Calibration Checks
The wire guidance system operates through the exist-
ing truck steering mechanism. Slack, lag or excessive
wear within this system will prevent guidance within
specifications. Prior to performing the wire guidance
calibration, the trucks steering system should be thor-
oughly checked by verifying the following:
• Check the steering gear box output gear (1), the

gear on the drive unit (2) and the steering encoder
gear (3). Look for chipped or missing teeth or any
dirt or debris between the teeth of each gear. The
gears should have a light coat of evenly applied
Figure 23042 grease. Refer to Figure 23043.
1 Steering Feedback Encoder Mounting Screws
• Rotate the encoder until the index is reached. If the

encoder is off index, the display will show you how
many counts the encoder is off index. At first there
will be no alarm, but as you rotate the encoder
closer to index, the alarm will start to beep. If the
display shows a positive count, then rotate the en-
coder clockwise. If the display shows a negative
count then rotate the encoder counterclockwise.
When the encoder is at index, a continuous alarm
will sound and the display will show encoder at in-
dex. While the encoder is at index, tighten the two
screws. After tightening the two screws, the en-
coder should still show encoder at index and the
continuous alarm should still sound.
• Press the enter button to save your setting. Figure 23043
C5 Wire Guidance • The steering feedback encoder gear (3) is a split

gear. A spring inside the gear prevents backlash.
The wire guidance system is calibrated so the truck au-
Place a screwdriver between the two halves and
tomatically travels with optimum performance over the
twist to see if the halves spring back into place.
guide wire embedded in the floor.
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• Check the condition of the steer motor brushes (1)

and inspect the commentator. Refer to Figure
23044.
Figure 23046
• Lubricate the drive unit thrust bearing. The thrust

bearing lubrication fitting is shown in Figure 23047.
Figure 23044
• Check the fluid level (1) of the steering gearbox.

Refer to Figure 23045.
Figure 23047
• Check to be sure the drive tire is not flat spotted or

chunked. Look for debris like shrink wrap or band-
ing that could be wrapped around the drive axle.
Figure 23045
• Check for bent or damaged outriggers.
• Check to be sure the drive unit stud mounting bolts
(1) are secure (two mounting bolts are hidden be-
• Check the condition of the load wheels and bear-
hind the pump in the photo). Refer to Figure 23046. ings.Remove any debris that might be wrapped
around the load wheel.
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• Check the height (a) of both the power unit and a higher strength, the system can become saturated
mainframe sensor bars (b). They should measure and allow the truck to weave.
approximately 83 to 86 mm (3-1/4 to 3-3/8 in) from
the floor (c). Refer to Figure 21984. NOTE
For field strength specifications, refer to the Wire Guid-
ance Line Driver section in this service manual.
To determine the highest average field strength, take a
reading with field strength meter (part number 112953,
see Figure 23049) approximately every 3 m (10 ft). To-
tal the readings and divide by the number of readings
taken.
Example: In a warehouse that has 3 aisles and each
aisle is 33 m (100 ft long). Take and record 10 readings
in each aisle approximately 3 m (10 ft apart).
Refer to the following Field Strength Readings Chart.
Field Strength Readings Chart

Figure 21984 Aisle 1 Aisle 2 Aisle 3
• After calibration you'll need to check to be sure the 175 169 175
truck is centered over the guide wire when 172 169 186
traveling. At this time, secure a cable tie (1) cen-
tered on the mainframe sensor bar (2) as shown in 167 170 179
Figure 23048. 174 172 180
168 171 182
183 182 187
193 187 177
184 190 176
187 182 183
184 177 185
1787 1769 1810
Total the readings and then divide by 10.

Aisle 1: 1787 ÷ 10 = 179
Figure 23048 Aisle 2: 1769 ÷ 10 = 177
• Check to be sure the steering feedback encoder Aisle 3: 1810 ÷ 10 = 181

ECR 2 is set to index when the drive unit alignment In this example, the truck should be calibrated in Aisle
marks are aligned (C4 calibration). 3 since it has the highest average reading of 181.
For the best wire guidance performance, calibrate the
truck at the installation or part of the warehouse with
the highest average field strength reading (field
strength will vary with the depth of the wire). If the truck
has been calibrated on wire at the lowest average
strength, then when the truck is operating on wire with
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• Place the truck in the manual steering mode. Drive

the truck over an active wire at a shallow angle
(should be 5 degrees or less). Both sensor bars (all
eight coils) must completely pass over the wire at
least two times. There's different ways to do this:
1. One way is to drive forward so at least the main-
frame or power unit sensor bar passes over the
guide wire then turn around and pass over the
guide wire so the other sensor bar passes over the
guide wire. Refer to Figure 23051.
Figure 23049
1 Guide Wire
2 112953 Field Strength Meter
NOTE
Crown recommends calibration of the field strength
meter annually, and will perform this service free. Any
repairs needed for calibration will incur a reasonable
charge. Please allow a minimum of two (2) weeks for
normal calibration. Meters needing repair may require
additional time. Meters will be returned freight collect.
For information regarding the field strength meter, refer
to Technical Service Bulletin No. 317.
• Press the down arrow to scroll to C5 Wire Guid-

ance menu.
Sensor Coil Calibration
• Press the right arrow and C5.1 Sensor menu

• Press the right arrow and C5.1.2 Sensor Coil menu

should be displayed. During C5.1.2 sensor coil cal-
ibration, the wire guidance system, through the
sensor coils, determines the frequency and ampli-
tude of the floor signal. The system will then com-
pare the signal returned from each sensor coil and
scale the weaker coils to make each coil signal
equal so the truck guides centered on the guide
wire.
• Press the right arrow to enter C5.1.2 Sensor Coil

menu and the display will ask you Sure? N.
Change the N to Y and press the enter button.
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ELECTRICAL SYSTEM
ACCESS 123®
1 Do not allow the sensor bars to pass over the end of the
guide wire. This may corrupt the calibration.
2 Guide Wire
3 Truck angle to the wire should be 5 degrees or less.
(1)
(2) 4 Power unit sensor bar
(3) 5 Rack
6 After the power unit sensor bar passes completely over the
guide wire, backup and turn around and travel so the main-
frame sensor bar passes completely over the guide wire.
7 Mainframe sensor bar
(4)
(5) (5)
(6)
(3)
(7)
(5) (5)
Figure 23051
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ELECTRICAL SYSTEM
ACCESS 123®
2. If the aisles are wide enough, an alternative way is

to weave back and forth over the guide wire as
shown in Figure 23052. It doesn't matter how the
truck passes over the guide wire just as long as
both sensor bars pass over the guide wire twice
and at an angle of 5 degrees or less so the maxi-
mum strength signal can be sensed by the coils.
Figure 23052
1 During peak sensor coil search, power unit and mainframe

sensor bars must travel completely over the guide wire a
minimum of two times at an angle of 5 degrees or less.
2 Guide wire
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ELECTRICAL SYSTEM
ACCESS 123®
NOTE
If you receive Coil Saturated, go to auto when done
message during sensor coil calibration perform the fol-
lowing checks:
1. Verify that the field strength of the wire meets
Crown's recommendations.
2. Verify the sensor bars are mounted 82 to 86 mm
(3.25 to 3.38 in) from the floor.
A saturated coil does not invalidate the sensor coil cal-
ibration. If a sensor bar is repositioned or the field
strength is adjusted, perform sensor coil calibration
again.
• After each coil has traveled over the guide wire

twice, center the truck over the guide wire and tog-
gle the guidance switch to Auto. The display mes-
sage will change to C5.1.3 Wheel Angle, travel on
wire.
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ELECTRICAL SYSTEM
ACCESS 123®
Wheel Angle Calibration

Wheel Angle calibration determines the steer wheel
position that will provide straight line travel.
• Drive the truck on an active wire for 18 m (60 ft) in

each direction. This is an accumulative travel dis- (3)
tance. Therefore, if you can't travel a full 18 m
(60 ft) in one direction because you're limited by
space, then travel as far as you can, reverse direc-
tion and travel as far as you can again repeating
this process until you've traveled a total of 18 m Truck must travel the length of
(60 ft). When you reach the accumulated distance the guide wire approximately 2
of 18 m (60 ft) you'll be prompted by a beep. In the times (18 m [60 ft]) in one di-
example shown in Figure 23053, the truck must rection, reverse direction and
travel the length of the guide wire approximately 2 travel another approximately 2
times in each direction. times (18 m [60 ft]) for a total of
36 m (120 ft).
(2)
(1)
(3)
Figure 23053
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ELECTRICAL SYSTEM
ACCESS 123®
1 12 meters (40 feet) • Drive the truck on an active wire continuously in

2 Guide Wire one direction for 9 m (30 ft) and then change direc-
3 Wall
tions and travel continuously for 9 m (30 ft). The
9 m (30 ft) must be one continuous direction.
• If you want to check the percentage of distance An audible beep is given when a direction has
traveled, press the right button and the display will achieved 100% of the required distance.
specify the percentage. If you want to check the percentage of distance
An audible beep is given when a direction has traveled, press the right button and the display will
achieved 100% of the required distance. specify the percentage.
• After traveling 18 m or 60 ft in both directions, you'll • After traveling 9 m or 30 ft in both directions, you'll
here a beep and the message will change to come here a beep and the message will change to come
to a stop. Stop the truck. to a stop. Stop the truck.
• After you come to a stop the message will change • After you come to a stop the message will change
to Switch to Manual. Toggle the guidance switch to to Switch to Manual. Toggle the guidance switch to
manual. manual. The display message will again change to
C5.1.2 Sensor Coil.
• Then the message will change to Switch to Auto.
Toggle the guidance switch to Auto. The display
• Press the left arrow twice and the message Save?
message will change to C5.1.4 Truck Angle Travel N will appear.
on Wire. • Press the down arrow and Save? Y message will
Truck Angle Calibration appear. Push the enter button after this message
appears to save the C5 wire guidance calibrations.
Truck Angle calibration electronically offsets the sen-
The display will then return to the Calibration
sors to compensate for the truck tracking at an angle
menu.
on the guide wire.
• Drive the truck on an active wire for 18 m (60 ft) in NOTE

each direction. The 18 m (60 ft) does not have to
Refer to the previous two steps. If you press the up ar-
be a continuous run, the distance will accumulate.
row instead of the down arrow after Save? N message
If you want to check the percentage of distance
appears a Load Factory Defaults message will ap-
traveled, press the right button and the display will
pear. Pushing the enter button after this message ap-
specify the percentage.
pears will load the factory defaults for C5 wire guidance
An audible beep is given when a direction has
calibration (includes sensor coil, wheel angle, truck an-
achieved 100% of the required distance.
gle and offset null calibration).
• After traveling 18 m or 60 ft in both directions, you When the Calibration menu appears (refer to Figure
will here a beep and the message will change to 21946), calibration is complete.
come to a stop. Stop the truck.
• After you come to a stop the message will change NOTE

to Switch to Manual. Toggle the guidance switch to C5.2 X-Offset Calibration is not explained in this sec-
manual. Then the message will change to Switch tion because Crown recommends that C5.2 X-Offset
to Auto. Toggle the guidance switch to Auto. The Calibration not be used to center the truck on the guide
display message will change to C5.1.5 Offset Null wire. If an offset is needed, the truck likely has an issue
Travel on Wire. that affects wire guidance and the issue should be cor-
Offset Null Calibration rected.
During Offset Null, the guidance module checks to be

sure the sensors are centered over the wire while
traveling and makes adjustments if necessary.
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ELECTRICAL SYSTEM
ACCESS 123®
Hour H13 PM Timer = ______

The purpose of the planned maintenance timer is to
While in Level 2, the Hour menu allows you to view
alert the operator when the truck is due for service. In
(only) all the hour meters and the PM timer.
Level 2, the H13 PM timer allows you to view whether
While in level 3, you can change some of the hour me- or not a planned maintenance reminder is set, what
ters, the time of delay for the H2 hour meter and set the hour meter the timer will monitor and the hours the
PM timer. timer is set to activate.
The following Level 2 and Level 3 hour menu explana- H13.1 Tag = ______
tions don't explain how to navigate through the menus
H13.1 submenu shows you the meter (H1 through12 or
and submenus or how to change the selection. To nav-
none) that is monitored for the PM timer. For example,
igate through and/or change a menu selection, refer to
if H13.1 Tag = H1, the timer is set to monitor H1 hours.
the Service Level 2 and 3 - Hour Menus charts in this
section of the service manual. The charts show the but-
tons that must be pushed to navigate through and NOTE
change the menus.
If H13.1 is set to none, H13.2 will not be available.
Level 2 Hour Access H13.2 Interval = ______
Power up the truck. From Service Level 2, press the The PM timer will decrease in hours as the other hour
right arrow to enter the Service submenus. Use the up meters increase. When the PM timer decreases to
and down arrows to navigate to the Hour menus. zero, the display will show the message Service Due
for a few seconds to prompt the operator to bring the
Hour Submenus truck in for service. If the timer is not reset, each time
Hours can be viewed in Level 2. Refer to the chart be- the truck is powered-up, the message Service Due will
low for hours monitored. briefly be displayed.
Chart 1
Level 3 Hour Access
Submenu Hours Monitored Power up the truck. From Service Level 3, press the
right arrow to enter the Service submenus. Use the up
H1 Traction, Raise and Lower and down arrows to navigate to the Hour menus.
H2 H1 Hours Plus Delay Hour Submenus
H3 Odometer (Miles or Kilometers) Just like in level 2, you can view all the hour meters in
H4 Lift Pump Motor “On” Time level 3. Level 3 also allows you to change some of the
meters and set the PM timer. Refer to the following
H5 Platform Lower “On” Time chart to determine how or if a meter can be changed.
H6 Traction Motor “On” Time
H7 Steer Motor “On” Time
H8 ACCESS 1 “On” Time
H13 PM Timer
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ELECTRICAL SYSTEM
ACCESS 123®
H13.1 Tag = ______
Submenu Hours Change H13.1 submenu displays/sets the meter (H1 through12
Monitored Permitted or none) that is monitored for the PM timer.
After selecting the hour meter, you need to set the
H1 traction, raise and lower Increase Only hours the timer will activate. Navigate to H13.2 Interval
H2 H1 hours plus delay* Increase Only to set the hours.
odometer H13.2 Interval = ______

H3 Increase Only
(mikes or kilometers) Use this submenu to change/set the hours the PM
Increase/ timer will activate. During truck operation, the PM timer
H4 lift motor “on” time will count down or decrease in hours. When the PM
Decrease
timer counts down to zero the display will momentarily
Increase/ show the message Service Due. This prompts the op-
H5 platform lower “on” time
Decrease erator to bring the truck in for service.
Increase/
H6 traction motor “on” time
Decrease
Increase/
H7 steer motor “on” time
Decrease
H8 ACCESS 1 “on” time No Change
* H2 hour meter can only be increased, but the delay

can be increased or decreased.
• For an example of how to change an hour meter,

navigate to H4 Lift Motor submenu.
• Press the right arrow to scroll to the submenu that

shows the lift motor hours.
• Use the right or left arrow to select a digit. Use the

up or down arrow to change the hours. After
changing hours to desired setting, press return.
H2 Runtime2 = ______
The H2 Runtime2 hour meter delay is adjustable from
0 to 15 minutes in 1 minute increments. The factory
default is 0. Navigate to H2.2 Timeout submenu to
change delay.
H13 PM Timer = ______
To activate the PM timer and select/change the hour
meter the timer will monitor and the hours the timer is
set to activate, navigate to H13.1 Tag submenu and
H13.2 Interval.
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ELECTRICAL SYSTEM
ACCESS 123®
Events E2 Accum History
The last 16 event codes in the order they occurred and • Press the right arrow to view the first event in the
the total count of each code can be viewed in this Accumulated History and the number of times the
menu. Codes can also be erased. event occurred. For example, if the message dis-
played is 133 = 7 Events. This means Event 133
Events Access occurred 7 times.
• Power up the truck. From Service Level 2 or Level

• To scroll through all the events stored in Accumu-
3, press the right arrow to enter the Service menus. lated History, press the down arrow.
Use the up and down arrows to navigate to the • Press the left arrow until you scroll back to E2 Ac-
Events menu. Press the right arrow to enter the
cum History, then press the down arrow to scroll to
Events menu.
E3 Clear History.
E1 Chronological History
E3 Clear History
In E1 Chronological History submenu you can view the
last 16 event codes in the order in which they occurred. • There are two ways to clear event codes: clear
chronological and clear all. To clear chronological,
• Press the right arrow to navigate to the first sub- press the right arrow.
menu. E3.1 Clear Chronological
E1.1 Last
• After E3.1 Clear Chronological is displayed, press
• By pressing the right arrow you can display the last the right arrow. The display will show Sure? N. If
event code and then find out the hour it occurred you don't want to clear history, press the return ar-
and the battery state of charge. Press the right arrow. If yes, press the up arrow to change the N to
row. Y and then press the return arrow.
Code = ______
NOTE
This submenu displays the last code.
Accumulated history will still be available if you clear
• Press the down arrow. the chronological events.
Hour = ______ • To clear all the chronological and accumulated
Hour submenu displays the H1 Runtime1 when the last events, you must select the E3.2 Clear All menu.
code occurred. To do this, from E3.1 press the down arrow.
E3.2 Clear All
• Press the down arrow.
Soc = ______ • After E3.2 Clear All is displayed, press the right ar-
row. The display will ask Sure? N. If you don't want
Soc submenu displays the battery state of charge to clear all, press the return arrow. If yes, press the
when the last code occurred. up arrow to change the N to Y and then press the
return arrow.
• To view the remaining events, press the left arrow
until you navigate back to E1.1 Last submenu.
Press the down arrow to scroll to the next 15
codes.
You can view the total count each event occurred in
Accumulated History.
• To do this, press the left arrow until you navigate

back to E1 Chron History. Then, press the down
arrow.
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ELECTRICAL SYSTEM
ACCESS 123®
Utilities U2 Tow Mode

With the tow mode active, the brakes are released and
The Utilities menu allows you to view module and soft-
are not available for stopping the truck. All functions
ware part numbers, activate the tow mode and elec-
except traction are enabled. Before making the tow
tronically disable the truck.
mode active, be sure to read and follow the procedures
in the Control of Hazardous Energy section in the Serv-
Utilities Access ice and Parts Manual.
• Power up the truck. From Service Level 2 or Level • To activate the tow mode, press the right arrow.
3, press the right arrow to enter the Service menus. The display will ask Sure? N. If you don't want to
Use the up and down arrows to navigate to the Util- activate the tow mode, press the return arrow. If
ities menu. Press the right arrow to enter the Utili- yes, press the up arrow to change the N to Y and
ties menu. then press the return arrow.
U1 Part Numbers
• With the tow mode active, you can't scroll through
• This submenu allows you to view part numbers and other menus. To deactivate tow mode, turn the key
software numbers for all the modules. Press the switch to off and then power up the truck.
right arrow.
• Press the left arrow, and then scroll down to truck
U1.1 ACCESS 1 operation.
• Press the right arrow again to display part numbers U3 Truck Operation
for ACCESS 1. The U3 Truck Operation submenu can be used to elec-
U1.1.1 Module PN = ______ tronically disable the truck in the event the truck is be-
ing serviced. If disabled, no message will be displayed
This submenu shows the part number for the after power up and an operator will not be able to oper-
ACCESS 1 module. ate the truck.
• Press the down arrow to view the ACCESS 1 soft- • To enable/disable truck operation, press the right
ware part number. arrow, select enable or disable using the up or
U1.1.2 Software PN = ______ down arrow and then press the return arrow.
The software part number includes two dash numbers.

The last dash number denotes the software version.
For example, if ACCESS 1 software part number is
122734-001-02, the part number ends with a dash 02
indicating the software version is 2.
• To view the part numbers for the remaining mod-

ules, press the left arrow until you navigate back to
U1.1 ACCESS 1, then press the down arrow to se-
lect other modules and repeat the above process.
• Press the left arrow until you navigate to U1 Part

Numbers and then press the down arrow.
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Notes:
242
ELECTRICAL SYSTEM
End Aisle Control (EAC) Sensors are positioned:

Standard Applications
The purpose of EAC is to remind the operator that the
end or an intersection of a warehouse aisle is ap- – "A" sensors are 200 mm (8 in) from the truck's
proaching. This system incorporates magnets in the centerline.
warehouse floor and magnetic sensors on the truck.
– "B" sensors 305 mm (12 in) from the truck's
Upon detection of magnets, when approaching end of
centerline.
aisle, sensors send a signal to the truck's computer to
apply a traction plug condition to slow the vehicle. A – Sensor bar is 20 mm (0.75 in) from the floor.
text message indicating EAC zone "entered" is dis-
Special Applications
played on ACCESS 1.
– "A" sensors can be positioned any distance
End Aisle Control is divided into two modes of opera-
more than 200 mm (8 in) from the truck's cen-
tion. Auto Guide mode is in force when the truck is in
terline provided that
wire or rail guide tracking mode. Traction speed is con-
trolled by fork height versus the speed curve. End of – "B" sensors are a minimum of 100 mm (4 in)
Aisle, Auto Guided mode is in force when a truck, in from "A" sensors.
wire or rail guide tracking mode, detects magnets while
– Sensor bar is 20 mm (0.75 in) from the floor.
traveling toward the end of an aisle. End of Aisle result
is selectable as stop or slowdown via plug or brake. Different sensors must be used for sensing north or
south magnetic poles. Sensors for sensing north mag-
A traction automatic speed resume is a selectable fea-
netic poles are standard.
ture. This feature will automatically release traction
speed limit actuated by EAC zone and once truck has
traveled its preset distance beyond the EAC magnets.
The EAC system consists of a front bumper sensor bar
which includes four sensors and a sensor distribution
board.
Figure 23374 provides a pictorial view of some compo-
nents involved with the end aisle control. A sensor
bracket containing four sensors is mounted to the main
frame of the truck, in front bumper. Sensors A1 and B1
activate during travel in forward (power unit first) direc-
tion and sensors A2 and B2 active in reverse (forks
first) direction. A text message appears on operator
display to provide an indication of when truck enters or
operates in an end of aisle control area.
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ELECTRICAL SYSTEM
Figure 23374
1 End Aisle Sensors Forward Direction (Power Unit First) • 652-659 - EAC Sensor Signal Range Fault
2 End Aisle Sensors Reverse Direction (Forks First)
• 660-663 - EAC Sensor Digital Fault
Located under the battery compartment is a distribution
module for interconnection of EAC components. Sig- • 664-667 - EAC Weak Magnet Fault
nals from the sensors and EAC distribution module are
connected to CA602, pins 1 through 14 on the wire
• 668-671 - EAC Sensor Hardware Fault
guidance module. • 672 - EAC Multiple Sensors Active Fault
Codes 566 through 572 and 652 through 672 all pertain
EAC Setup to the EAC system issues.
The display is used to setup how the truck will react While in Level 2 or 3 of ACCESS 123, the Analyzer
when the EAC system senses the magnets near the menu, A2 Inputs can be used to check any one of the
end of an aisle or intersection. To setup EAC, modify four EAC sensors (Refer to ACCESS 123 section). The
the settings or for more information on EAC, refer to state of digital input shall change as the truck passes
ACCESS 123® section, Performance menu, P12 EAC over its corresponding floor magnet.
Setup submenus.
If issues are realized, verify the height of the sensors
above the floor, distance of center line of guidance bars
Troubleshooting to EAC sensors and proper magnet positioning.
EAC components are monitored by system software

and will log a fault into memory whenever a problem
with the EAC system occurs:
EAC Event Codes:
• 566 - EAC Hardware Fault
• 567-570 - EAC Sensor Latched ON
• 571-572 - EAC Magnet Missed
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ELECTRICAL SYSTEM
Termination Point Locations
Chart 1 - Access 6 (Wire Guidance Module)
Pin Function Voltage Level Connection

1 EAC Sensor Power 12 V CA602-1
2 EAC Sensor Battery Negative CA602-2
3 EAC A1 Test 7 V in Test Mode CA602-3
4 EAC A1 Analog 0-5 V When Over Magnet CA602-4
0 V When Sensing Magnet, 5V When Not
Sensing Magnet
6 EAC A2 Test 7 V in Test Mode CA602-6
0 V When Sensing Magnet, 5 V When Not
Sensing Magnet
10 EAC B1 Analog CA602-10
Sensing Magnet
Sensing Magnet
12 EAC B2 Test 7 V in Test Mode CA602-12
13 EAC B2 Analog 0-5 V When Over Magnet CA602-13
Sensing Magnet
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Notes:
246
ELECTRICAL SYSTEM
Contactor
Contactor Contacts
• In normal operation, the contacts will become
blackened, discolored, and roughened. This will
not interfere with proper operation and cleaning is
not necessary.
• The contacts should be replaced before the silver

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

placed in mating pairs.
Coil
• Remove all electrical connections.
Figure 10554-01 • Resistance reading of the coil should be between

15 - 19 ohms.
The purpose of this information is to instruct the techni-
cian on proper care and maintenance to obtain satis- • If reading does not fall within the limits, replace coil.
factory service from these devices. Crown has tested
and applied these contactors according to the require-
ments of our vehicle. No modifications or changes
should be made in the layout, physical arrangement or
electrical connections without permission from Crown.
CAUTION
Before any inspection, adjustments, servicing, parts re-
placement or any other act is performed requiring
physical contact with the electrical working compo-
nents or wiring of these contactors, disconnect battery,
raise drive wheels clear of floor and place blocks under
truck frame.
Inspection
The following information is intended to assist during
periods of normal maintenance and to provide checks
for maintaining adjustments. As these devices are
tested and adjusted at the factory, they should not nor-
mally require further adjustments. However, if factory
adjustments are tampered with or otherwise changed,
the checks contained in the following information may
be made.
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ELECTRICAL SYSTEM
Contactor
Component Replacement Coil Replacement

Refer to Figure 5674 and parts breakdown in Parts 1. Disconnect all electrical wiring.
Section of manual when replacing components.
2. Remove four mounting screws that secure contac-
tor to mounting bracket and remove contactor from
truck.
3. Remove two screws (5) and separate contact as-
sembly from coil assembly.
4. Select replacement coil and transfer plunger (9)
from existing coil to replacement coil.
5. Reassemble contact assembly to coil and secure
with two screws (5).
6. Mount contactor on truck and reconnect all electri-
cal wiring removed in step 1.
Figure 5674
Contact Replacement
1. Remove electrical connections to contacts (coils
do not have to be disconnected for this procedure).
2. Remove two screws (5) from top of contact and re-
move contact top cover (6).
3. Remove and replace contacts (contacts always
should be replaced in pairs).
4. Place contact assembly on coils and install top
cover and secure with two screws removed in step
1.
5. Connect electrical wiring removed in step 1.
M4.4-04.2-002 SP3500 Crown 1992 PF9313-2 Rev. 7/07
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248
ELECTRICAL SYSTEM
Control Module
Control Module WARNING

The Control Module, located in the operator compart-
ment, contains all operator controls within easy reach. When making "live" voltage checks, chock load wheels
of truck, raise drive wheel clear of floor and place hard-
A planned maintenance program should include wood blocks under truck frame.
checking these operator controls for binding, sticking
or other unusual operation. An audio check should also
be made. Press buttons or turn twist grip in both direc- Troubleshooting
tions slowly, while listening for switch actuation-reset-
If an event code is displayed, refer to the Event Code
ting (signified by a "click"). There should be a "double
section of this service manual and follow the trouble-
click" for two speed lift/lower.
shooting steps for the code.
If a code is not displayed, many of the switches, trac-
Access tion request potentiometer (POT1) and their circuits
can be checked through the display using
ACCESS 123® Analyzer menu. To check, enter level 2
CAUTION of the display, scroll to the Analyzer menu and navigate
to the proper submenu listed in Chart 1 on the next
Disconnect battery before performing disassembly pro-
page. Actuate the component and check the display
cedures.
message for the proper input. For more information, re-
To gain access to components in directional and speed fer to ACCESS 123 section in this service manual.
control compartment, remove five mounting screws
from console and lift console from platform wall.
Directional & Speed Control Compartment
Figure 12546-01
To access remaining switches rotate console down.

While in this position, do not apply unnecessary pres-
sure to the module which may damage the wiring har-
ness. Due to weight, some form of support is needed.
Reverse disassembly procedure for assembly.
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ELECTRICAL SYSTEM
Control Module
Chart 1
Polarity
Analyzer
Component Display Message of Input Note 2
Submenu
Signal
EDS See Note 1 below positive When closed, EDS provides
+BV to the key switch.
FNS1 See Note 1 below positive When closed, FNS1 provides
+BV to the operator fan FAN1.
FS A2.3.7 FS 0 = switch open, 1 = switch closed positive
GUS A2.1.2 GUS1 0 = switch open, 1 = switch closed negative
HNS See Note 1 below positive When closed, HNS provides
+BV to the key switch.
KYS A2.2.7 Key Switch 0 volts = switch open, approxi- positive
mately battery volts = switch closed
LGS1 See Note 1 below When closed, LGS1 provides
+BV to PS2 power supply.
+BV to PS1 power supply.
+BV to the spot lights.
LOS1 A2.3.12 LOS1 0 = switch open, 1 = switch closed positive
LOS2 A2.3.13 LOS2 0 = switch open, 1 = switch closed positive
ORS1 A2.1.3 ORS1 0 = switch open, 1 = switch closed negative
POT1 A2.3.3.1 Raw Max FF = approximately 0.8V. Neu- positive
tral = approximately 2.6 V, Max
PUF = approximately 4.6 V
A2.3.3.2 Scaled Max FF = approximately 16%. Neu- positive
tral = approximately 50%, Max PUF
= approximately 92%
RAS1 A2.3.11 RAS1 0 = switch open, 1 = switch closed positive
RAS2 See Note 1 below When closed, RAS2 provides
+BV to P2 pump contactor coil.
RS A2.3.6 RS 0 = switch open, 1 = switch closed positive
ZSS A2.3.14 ZSS A 0 = switch open, 1 = switch closed negative
A2.3.15 ZSS B 0 = switch open, 1 = switch closed negative
A2.3.16 ZSS C 0 = switch open, 1 = switch closed negative
Note 1: No Analyzer submenu is available for checking component input because the component doesn't provide
an input to an ACCESS 123 module.
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ELECTRICAL SYSTEM
Control Module
Switches Traction Request Potentiometer (POT1)

If a switch input is not correct or if no analyzer submenu If the potentiometer wiper input signal is not correct,
is available for the switch, check the switch with a then check the potentiometer with a DVOM. Refer to
DVOM. If the switch provides a positive signal (refer to Figure 23336 for connections and signals.
Chart 1) to the module or another component, then
connect the black DVOM lead to test point TP16 (refer
to Figure 23336) on the platform distribution panel or
any other good battery negative reference. If the switch
provides a negative signal (refer to Chart 1), then con-
nect the red DVOM lead to test point TP2 (refer to Fig-
ure 23336) on the platform distribution panel or any
other good battery positive reference.
Close the switch and check the voltage across the
switch. The DVOM should register battery volts on both
sides of the switch. If battery volts is not displayed,
there is an open circuit, incorrect switch connection or
a bad switch. For example, if battery volts is read on
one side of a switch, but a voltage less than battery
volts is obtained from other side of switch, the switch
contacts are making poor contact and the switch
should be replaced.
Refer to the Wiring Diagrams to trace the problem cir-
cuit(s).
Figure 23336
1 Platform Distribution Panel
When checking the wiper input signal and +5V signal

to POT1, connect the black DVOM lead to test point
TP16 (refer to Figure 23336) on the platform distribu-
tion panel or any other good battery negative refer-
ence. When checking the wiper signal, the DVOM
should display:
– approximately 0.8 V when the travel twist grip
is fully rotated in the forks first direction.
is not rotated (neutral).
is fully rotated in the forks first direction.
If the potentiometer wiper input is not correct and the
potentiometer is receiving +5V, check for a missing
negative signal. When checking the negative signal,
connect red DVOM lead to TP2 (refer to Figure 23336)
on the platform distribution panel or any other good
battery positive reference.
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ELECTRICAL SYSTEM
Control Module
Adjustments – Press the left arrow and the display will ask
Save? N. Change the N to Y and press the en-
Components which are adjustable are contained within ter button to save the settings.
directional and speed control compartment.
Traction Request Potentiometer (POT1)
1. With twist grip in neutral position, turn adjustment
1. When installing new potentiometer, before mesh- screws slowly on both directional switches, clock-
ing gears, adjust the wiper signal to approximately wise, until switch activates.
50%. To do this:
2. Turn both screws 1/2 turn counterclockwise.
– From the display, enter Level 2 and navigate to
3. From the display, enter Level 2 and navigate to the
the Analyzer menu.
Analyzer menu.
– Navigate to A2.3.3 POT1 submenu.
4. Navigate to A2.3.3 POT1 submenu.
– Press the right arrow and then the down arrow
5. Press the right arrow and then the down arrow to
to navigate to A2.3.3.2 Scaled submenu.
navigate to A2.3.3.2 Scaled submenu.
– Rotate potentiometer shaft until the display
6. With the travel twist grip released, observe the per-
shows 50%.
cent of voltage on the display. The reading should
be 48% to 52% in the center, released position.
NOTE Record reading.
For ACCESS 123 menu navigational charts (Analyzer, 7. Slowly turn twist grip until one of the directional
Calibration, etc.) and more information, refer to switches activates (signified by a "click").
ACCESS 123 section.
2. Mesh gear teeth, tighten screws on mounting
bracket and calibrate potentiometer. To do this: 9. Slowly turn twist grip opposite way until other direc-
tional switch activates (signified by a "click").
– Keep your foot off the brake pedal and from the
display, in Level 2, navigate to the Calibration 10. Record voltage reading on display.
menu. 11. Difference of each reading from nominal center po-
– Press the right arrow. The message displayed sition reading should be within 2% of each other
will be C1 Handles. (i.e., 3% and 4.2% is OK, 3% and 5.4% is not).
– Press the right arrow and C1.1 Traction menu

should be displayed. Component Replacement
– Press the right arrow to enter C1.1 Traction
menu and the display will ask you Sure? N. Directional Switches (FS & RS)
Change the N to Y and press the enter button.
• You will then be asked to set three positions for the
twist grip. As you perform the following commands,
(index 54).
press the right arrow to view the percent of POT1
voltage seen by ACCESS 4. 2. Move switch and bracket assembly over top of
cams and out.
– PUF Direction - Rotate the twist grip to the full
power unit first direction and press the enter 3. Remove mounting bolts (index 58) of switch to be
button. replaced.
– FF Direction - Rotate the twist grip to the full 4. Transfer wires to replacement switch and tighten
forks first direction and press the enter button. screws.
– Center - Release the twist grip and press the 5. Assemble switch, insulator and spacer.
enter button.
6. Secure in place with screws, lockwashers and
nuts.
M4.5-7335-004 SP3500 Crown 2007 Pf15817-4 Rev. 1/10
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ELECTRICAL SYSTEM
Control Module
7. Move switch and bracket assembly under cam, on Potentiometer (POT1)

top of posts and secure in place.
8. Adjust both switches as described in Adjustments. (Refer to Figure 18223-01)
9. Calibrate traction request potentiometer, POT1 as 1. Loosen screws (index 45) on adjustable mounting
described in Adjustments. bracket (index 49).
2. Access to lower pivot point is through hole on left
side of directional and speed control compartment.
3. Push potentiometer back so gear teeth unmesh.
4. Slide pinion gear (index 52) off potentiometer
shaft.
5. Disconnect potentiometer pins at JC309, noting lo-
cation for proper installation.
Chart 2 - JC309 Pot Wiring
Pin Color
1 Green
2 Orange
Figure 18222
3 Violet
Actuator Arm 6. Remove insulator (index 51).

7. Pull potentiometer (index 42) from mounting
(Refer to Figure 18222) bracket and remove insulator (index 44) and
washer (index 43).
(index 54). 8. Place insulator and washer, with washer against
potentiometer, on replacement potentiometer.
cams and out. 9. Slide potentiometer through hole in mounting
bracket and assemble insulator (index 51) so small
3. Remove speed nut (index 57) from rod (index 59)
diameter slides through hole in bracket.
and slide rod out until actuator (index 64) to be re-
placed can be removed. 10. Turn potentiometer so wires are pointing out back
of panel.
4. Remove adjusting screw (index 65) and install in
replacement actuator. 11. Slide pinion gear (index 52) on potentiometer shaft
so gear teeth will mesh completely.
5. Slide rod into switch bracket, aligning actuator over
switches so rod goes through pivot point. 12. Re-connect wires to JC309.
6. Install speed nut. 13. Adjust potentiometer as described in Adjustments.
7. Move switch and bracket assembly under cam, on 14. Make certain mounting bracket screws are tight-
top of mounting posts and secure in place. ened.
8. Adjust both switches as described in Adjustments.
9. Calibrate traction request potentiometer, POT1 as
described in Adjustments.
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ELECTRICAL SYSTEM
Control Module
Figure 18223-01
(a) To Control Module
Cam, Torsion Spring, Stop

1. Remove two cotter pins (index 11).
2. Remove washers (index 12) on outside of housing.
3. Make note of physical arrangement of components
with respect to each other and arrows on twist grip.
4. Slowly slide twist grip with square shaft to the right.
5. Replace component in question.
6. When assembling, apply grease (Crown no.
063002-025) to inside of torsion spring (index 17).
7. Install one washer (index 12) onto square shaft (in-
dex 21).
8. Slide cam (index 13) onto shaft (index 21) so cam
lobes are toward switches when arrows on twist
grip are toward top.
9. Install spacer (index 14).
M4.5-7335-006 SP3500 Crown 2007 Pf15817-6 Rev. 1/10
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ELECTRICAL SYSTEM
Control Module
Figure 17855-01
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ELECTRICAL SYSTEM
Control Module
4. Depending on operator preference, position re-

placement grip with lobe toward module or away
from module with arrows up.
5. Trucks are manufactured with lobe toward module.
6. Install grip in module.
Stop & Return Assembly
7. Align key on extension with slot in grip and assem-
Figure 18247 ble extension to grip.
10. Install Stop and Return Assembly (index 15, 16, 17 8. Slide grip onto square shaft, lining up hole in shaft
and 18) on shaft, making certain torsion spring (in- with hole in grip.
dex 17) is over tab in Control Module Housing, as 9. Assemble roll pins in each end of grip.
shown in Figure 18247 and 1347-02.
Figure 1347-02
11. Install spacer (index 19) and slide shaft through

housing making certain split bushing (index 10),
washer (index 12) and bushing (index 8) remain in
housing.
12. Install cotter pin (index 11) in shaft inside direc-
tional and speed control compartment.
13. Install washers (index 12) as required to remove
any lateral movement of twist grip when final cotter
pin is installed.
14. Perform switch and potentiometer adjustments be-
ginning with potentiometer adjustment.
Twist Grip

1. Remove roll pin (index 3) from each end of twist
grip (index 2).
2. Slide twist grip to the right, out of control module
housing to access extension (index 1) on end of
twist grip.
3. Remove extension from twist grip and remove grip
from module.
M4.5-7335-008 SP3500 Crown 2007 Pf15817-8 Rev. 1/10
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ELECTRICAL SYSTEM
Control Module
Figure 17855-01
(a) Part of Platform RAS1, RAS2, LOS1, LOS2, HNS,

EDS
When replacing HNS (index 11), the key switch will
need to be removed to allow access to mounting
screws.
Switch terminals are to be tightened within 388 -
459 mNm (55 - 65 in oz).
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ELECTRICAL SYSTEM
Control Module
Figure 23339
(a) Located on Back of Control Module
M4.5-7335-010 SP3500 Crown 2007 Pf15817-10 Rev. 1/10
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ELECTRICAL SYSTEM
Control Module
Button Return Springs Power Disconnect Button Springs
(Refer to Figure 23339) (Refer to Figure 23342)

To replace Raise, Lower and Horn button return 1. Remove screws and washers from button post
springs proceed as follows: while holding button depressed.
1. Secure control module with a wire, between top 2. Pull button and springs from module.
mounting bolt hole of control module and platform
3. Replace springs, insert button through housing
wall.
and secure in place with screws and washers.
2. Remove three mounting screws (index 4) from
After assembly, test all controls for proper operation.
spring plate (index 1).
3. Lift spring plate from assembly.
4. Raise and lower buttons require two compression
springs (index 10 and 66) and the horn button re-
quires one spring (index 10).
5. Replace spring(s) in question and assemble on re-
spective actuator lever (index 17) spring guide (in-
dex 9).
6. Position spring plate so spring guides locate
springs.
7. Start mounting screws. Mounting screw closest to
key switch also holds wiring harness clamp (index
6).
8. When screws are started and harness clamp is in
place, tighten screws.
9. Remove wire securing control module.
Figure 23342
Buttons

1. To replace buttons, remove two screws (index 14)
from button and remove.
2. Position replacement button correctly and secure
in place with screws.
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Notes:
260
ELECTRICAL SYSTEM
Steering Feedback
Steering Feedback
Gear Assembly
Whenever assembling the steering feedback gears, it
is important that all gear backlash be removed. If this is
not done, steering accuracy and response is reduced
and an event code may occur.
Refer to Figure 23365.
Place the nyliner bearing (4) onto the gear shaft (9).
Next place one end of the torsion spring (6) into the
small hole in the gear (5) as shown. Slide the gear (5)
onto the gear shaft (9) aligning the other end of the tor-
sion spring (6) with the small hole on that gear (9).
Slide the second nyliner bearing (4) onto the gear shaft
(9). Install the third nyliner bearing (4) on top of the
power unit as shown.
Turn the top gear (5) until the larger hole on both gears
(5 and 9) are aligned, approximately 2 teeth. Slide a
3 mm (1/8 in) drill bit into the holes from the bottom to
keep the gears aligned.
Slide gear shaft (9) up through the power unit. Once
the gears are meshed with the steering gearbox and
drive unit gears, install the flatwasher(s) (3) and the re-
taining ring (8) to keep the gear assembly from sliding
out.
Insert the encoder shaft into the gear shaft. Make sure
the extension spring (2) is installed. If necessary rotate
the gear shaft (9) so the set screw faces straight back
to allow for easy access for tightening. Tighten set
screw to secure encoder shaft to gear shaft.
Make certain the set screw is tightened on the flat part Figure 23365
of the encoder shaft. Remove drill bit from gear assem-
bly. 1 Cover
The steer wheel feedback encoder must be calibrated. 2 Extension Spring

To calibrate, refer to ACCESS 123 section, Calibration, 3 Flatwashers
C4 Steer Encoder. 4 Nyliner Bearing
5 Gear
6 Torsion Spring
CAUTION
7 Set Screw
The steering indicators will not represent the proper 8 Retaining Ring
steer angle. The steering feedback encoder must be 9 Gear and Shaft
calibrated to ensure the steered wheel is set to straight
10 Alignment Holes - Insert Drill Bit
ahead position.
Crown 2010 PF17882-1 SP3500 M4.5-7335-100
261
Notes:
262
ELECTRICAL SYSTEM
Battery
Battery The care and maintenance of the battery is very impor-

tant to obtain efficient truck operation and maximum
battery life. Refer to Control Of Hazardous Energy
CAUTION Lockout/Tagout for additional information on care and
handling of batteries.
Gases produced by a battery can be explosive. Do not Leakage voltage from battery terminals to battery case
smoke, use an open flame, create an arc or sparks in can cause misleading trouble symptoms with the truck
the vicinity of the battery. Ventilate an enclosed area electrical system. Since components of the truck elec-
well when charging. trical system are insulated from truck frame, leakage
Batteries contain sulfuric acid which may cause severe voltage will not normally affect truck operation unless a
burns. Avoid contact with eyes, skin or clothing. In case short circuit or breakdown of circuit wire insulation to
of contact, flush immediately and thoroughly with clean truck frame occurs.
water. Obtain medical attention when eyes are af-
fected. A baking soda solution (0.45 kg (1 lb) to 3.79 l A voltage check from battery connector terminal to bat-
(1.0 gal) of water) applied to spilled acid until bubbling tery case should indicate less than 50% battery volts. If
stops, neutralizes the acid for safe handling and dis- the voltage check for leakage voltage is greater than
posal. 50% this leakage voltage will discharge the battery. As
battery cleanliness deteriorates, the usable charge of
the battery decreases due to this self discharge.
Safety Rules
A clean battery will have more usable charge for truck
• Wear protective clothing, such as, rubber apron, operation and not affect operation of electronic devices
gloves, boots and goggles when performing any on the unit.
maintenance on batteries. Do not allow electrolyte
to come in contact with eyes, skin, clothing or floor. Checking
If electrolyte comes in contact with eyes, flush im-
mediately and thoroughly with clean water. Obtain Battery electrolyte level should be checked before
medical attention immediately. Should electrolyte each charge of the battery. The level should be main-
be spilled on skin, rinse promptly with clean water tained at 13 mm (0.5 in) above the element protector
and wash with soap. A baking soda solution (one plates. If low, add distilled water or approved local sup-
pound to one gallon of water) will neutralize acid ply (consult battery manufacturer) at the end of a
spilled on clothing, floor or any other surface. Apply charge cycle. Do not overfill. For maximum battery life,
solution until bubbling stops and rinse with clean specific gravity readings should be taken daily on a pi-
water. lot cell and recorded. A different pilot cell should be se-
lected on a monthly basis with readings taken on all
• Keep vent plugs firmly in place at all times except cells at semi annual or annual intervals. Do not take
when adding water or taking hydrometer readings. specific gravity readings immediately after adding wa-
ter. Water and electrolyte must be thoroughly mixed by
• Do not bring any type of flame, spark, etc., near the
charging before a reliable reading can be taken. Nor-
battery. Gas formed while the battery is charging, mal full charged specific gravity should be between
is highly explosive. This gas remains in the cells 1.280 and 1.320.

• Do not allow dirt, cleaning solution or other foreign

material to enter cells. Impurities in electrolyte
charge.
• If battery repair is planned, follow the battery man-

ufacturer's instructions concerning repair practices
and procedures.
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ELECTRICAL SYSTEM
Battery
Battery Care
Your Crown truck is powered by an electrical storage Truck Data Plate
battery. Here are a few suggestions which will help you
give the battery proper care.
The battery for your stockpicker is located in front of the
operator's platform.
Battery
Location
Figure 14599
1. Charge the battery only in areas designated for

that use.
Lower Right Corner of
2. Make certain the charger being used matches the
Mast Side of Platform
voltage is listed on the truck data plate and is lo-
cated on the lower portion of the platform.
Figure 14603
3. Before disconnecting or connecting batteries to a

charger, make sure the charger is OFF. If an at-
tempt is made to do this while the charger is ON,
serious injury to you, the battery and charger could
result.
4. Before charging, make sure the battery cells con-
tain the correct amount of water. Charging batter-
ies with a low water level might result in damage to
the cells. When checking water levels, never use a
match or lighter. Battery fumes are explosive.
M4.6-7434-002 SP3500 Crown 2006 PF15460-2 Rev. 2/10
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ELECTRICAL SYSTEM
Battery
5. Before connecting the battery cable to the truck's – Connect battery to charger and make certain
receptacle, make sure the key switch is OFF and connectors are mated completely.
all controls are in the OFF position and the brakes
– Set timer for specified time. Set for Normal
are applied. The battery cable must be fully con-
(Daily Charge, except one night a week when
nected before the truck is used. If the plug is not
the Equalize [Weekend] Charge should be
making good contact, heat will weld the two parts
used).
of the battery connector together, making it difficult
to remove and necessary to replace. – Check charger ammeter to make certain it
shows charge.
6. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal con- Removing battery from charge:
tact is essential not only for operation, but also for
– Make certain charger is turned off.
proper charging of the battery.
– Unplug the connector, using both hands with a
7. Battery cover should be closed except when
straight pulling motion.
charging.
– Hang up the charger cable to prevent damage
8. The charging requirements will vary depending on
to the cable. (Broken connectors can cause
the use of the truck. The battery should be given an
poor connections and connector failures).
equalizing charge on a weekly basis. This charge
should normally be an additional three hours at the – Make daily battery checks, add water as
finish rate. needed.
9. Refer to charger manufacturer's instruction for – Connect battery to truck. Make certain connec-
specific charging procedures. tors are mated completely.
10. Make certain battery used meets weight, type, amp Battery Stop Adjustment
hour, voltage and size requirements of truck (refer
To minimize the side to side (lateral) movement of the
to data plate). NEVER operate truck with an under-
battery in the truck, the left battery cover is equipped
sized battery or incorrect voltage battery. Refer to
with an adjustable stop. First, the battery must be
Chart 1 for battery weights and type.
pushed completely in the battery compartment until it
contacts the stops on the right side then the adjustment
Charging screw on the left battery retainer should be adjusted
until it just contacts the battery surface. Snug the lock-
Charging requirements will vary depending on use of ing screw down on the adjustment screw and tighten
truck. A battery with a specific gravity of 1.160 or less jam nut. Do not over tighten the locking screw. Once
should be recharged. In some applications more than the battery stop is adjusted, the battery covers should
one battery is required to provide ample power to the be removable without loosening the battery stop ad-
unit during the service period. justment. Any time a battery of different size is in-
stalled, this adjustment is necessary. Refer to Figure
10589-01.
CAUTION
Never smoke or bring flame near the battery. Gas
formed during charging is highly explosive and can
cause serious injury.
Consult the charger manufacturer's manual covering
your charger for hints on operation and maintenance.
Some of the basic rules are as follows:
Placing battery on charge:
– Park truck at charging station with forks low-
ered and key removed.
– Make certain charger control is in the off posi-
tion.
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ELECTRICAL SYSTEM
Battery
Locking
Screw &
Jam Nut
Adjustment
Screw
Figure 10589-01
Chart 1 Battery Weights And Type
BATTERY WEIGHT BATTERY RATING

MINIMUM MAXIMUM BATTERY TYPE VOLTAGE HOUR RATE CAPACITY
690 kg (1520 lb) 860 kg (1900 lb) "E” 24 6 1085
Battery Removal
OFF
ON
CAUTION
Don't allow any metallic object to come in contact with TEST
tery. Use an insulator (such as plywood) to cover the Turn Key
top of the battery before and during removal and instal- Switch OFF
lation.
1. Turn key switch OFF. Figure 3171-01
2. Open top cover and disconnect battery.
M4.6-7434-004 SP3500 Crown 2006 PF15460-4 Rev. 2/10
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ELECTRICAL SYSTEM
Battery
Battery Installation
CAUTION
Don't allow any metallic object to come in contact with
Top the top of the battery cells. This may cause a short cir-
Cover cuit when removing, installing or transporting the bat-
top of the battery before and during removal and instal-
lation.
Make certain same battery or battery of equal weight is
loaded into truck for truck stability. See data plate for
minimum battery weight and type.
1. Check to be sure key switch is turned off.
2. Using approved spreader bar, move battery onto
Battery roller stand and push battery into battery compart-
Cover ment.
Figure 14600
3. Remove battery cover (one side only).

4. Position battery roller stand next to truck. Align
stand with battery. Battery roller stand should be
the same height as the truck's battery compart-
ment rollers and as long as or longer than battery. Spreader
5. Roll battery onto stand. Using approved spreader Bar
bar, lift and move battery to charging area.
Push into
Spreader Compartment
Bar Figure 14602
3. Remove roller stand and install battery cover.

Make sure battery retainers are properly adjusted
for the battery installed.
Roll Battery
Onto Stand
Figure 14601
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ELECTRICAL SYSTEM
Battery
shooting aid. Contact your dealer for charts designed

specifically for this purpose.
Voltage readings of each cell taken at the normal
charger finish rate also indicate battery condition. New
batteries will have cell voltages ranging from
2.055 volts to 2.065 volts. Older batteries may however
Top range from 2.045 volts to 2.055 volts. These readings
Cover still indicate a battery in good condition.
A variation of 0.20 volts may be normal if certain cells
are exposed to higher temperatures during discharge.
Voltage differences that cannot be attributed to battery
age or operating conditions indicate a weak cell(s) and
maintenance is required.
CAUTION
Battery
Cover Only qualified and experienced personnel should per-
form maintenance and repair on batteries.
Figure 14600
Checking the Battery Under Load
WARNING Even though the battery charges fully, electrolyte levels
are good and the specific gravity readings are within
Battery can slide out and hurt someone if battery the acceptable range, issues may still exist.
cover(s) are not properly installed. Be sure both battery
covers are in place and secure. Batteries are rated for approximately 300 charging cy-
cles per year which means they can be discharged and
4. Connect battery and close top cover. recharged about 2000 times, depending on how well
5. Turn key switch on and check truck operation. they are taken care of. Eventually they will reach a
point were they need to be repaired or replaced. The
best way to confirm this is by testing a battery when it's
Battery Cleaning under load.
Always keep vent plugs tightly in place when cleaning To do this, connect a fully charged battery to the truck
battery. When properly watered and charged, the bat- and connect a DVOM across the positive and negative
tery will remain clean and dry. All that is necessary is to terminals of the battery. Power up the truck and raise
brush or blow off any dust or dirt which may accumulate the platform until the forks lightly contact the mechani-
on them. However, if electrolyte is spilled or overflows cal stops. Select raise momentarily and read the volt-
from a cell, it should be neutralized with a solution of age. A battery under load should not drop more than
baking soda and water (0.45 kg (1 lb) to 3.79 l (1.0 gal) 0.5 volts per cell. An SP 3500 is equipped with a 24 volt
of water). To do this, remove battery from truck and battery and the battery has 12 cells. So if the voltage
clean with the solution of soda and water, brushing the drops more than 6 volts, the battery needs to be re-
soda solution beneath the connectors and removing paired or replaced.
grime from the covers. Then rinse the battery with cool
If the battery under load is in the acceptable range un-
water from a low pressure supply to remove the soda
der load, but is still suspect, check the voltage of each
and loosened dirt. If batteries stay wet consistently,
cell under load. Check for uniformity among cells. Also,
they may be either overcharged or overfilled. This con-
the voltage under load should not drop more than
dition should be investigated and corrected.
0.5 volts per cell. All cells should read almost exactly
the same voltage when performing a load test. If a cell’s
Troubleshooting voltage under load is lower than the others there may
be an issue with cell.
Records of battery specific gravity readings, charger
used, truck used, etc. can be the most effective trouble-
M4.6-7434-006 SP3500 Crown 2006 PF15460-6 Rev. 2/10
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ELECTRICAL SYSTEM
Motors
Motors
Chart 1 - Traction Motor Information
Traction
021189, 021217 (EE) with Thermal Sensors
Motor Type: AC Induction
Winding Type: Delta
Bearings:
Lubricant Double Row Bearing: Chevron SRI-2
Sensor Bearing: GWB (Ansonic GHY 72)
Stator Winding Resistance:
At 20° C (68° F)
Between any Two Terminals 0.00349 ohm
Direction of Rotation: Bi-directional
Nominal Stator Diameter: 188 mm (7.4 in)
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ELECTRICAL SYSTEM
Motors
Chart 2 - Lift Motor Information
Lift
114330, 118838 with temperature and brush wear sensors
Brushes:
No. of Brush Holders 4
No. of Brush Assemblies 4
No. of Brush Springs 4
Brush Length - New 28 mm (1.10 in)
Spring Tension on New Brushes 1560 gm (55 oz)
Min. Brush Length - Replace 15 mm (0.60 in)
Spring Tension Before Replacement 992 gm (35 oz)
Commutator:
Max. Diameter - New 54 mm (2.12 in)
Min. Diameter - Reslotting 52 mm (2.05 in)
Min. Diameter - Replace 49 mm (1.93 in)
Bearings:
Lubricant Sealed
Cond. of Performance:
(No Load)
Volts 6
Max. Amperes 27
RPM 3000 min
Field Resistance:
(Each at 25° C [75° F])
Series Ohm .0035
Armature Resistance:
(Each at 25° C [75° F])
Ohm .0045
Measured Between Bars 1 and 8
Frame Diameter: 170 mm (6.7 in)
Wound in: Series
Direction of Rotation: CWDE
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Event Codes
Event Codes To ensure your truck’s ACCESS 123 software is up-to-

date, use ACCESS 1 and scroll to the Utilities menu.
ACCESS 123® Module Listing: From here you will be able to view the module and soft-
ware part numbers applicable to your truck.
ACCESS 1: Display Control Module (DCM)
No Event Code?
ACCESS 3: Traction Control Module (TCM)
When the truck malfunctions and no event code is dis-
ACCESS 4: Vehicle Control Module (VCM) played it usually means the malfunction is not electri-
ACCESS 5: Steering Control Module (SCM) cal.
ACCESS 6: Guidance Control Module (GCM) If the truck powers up, but a code is not displayed, the
malfunction is probably mechanical or hydraulic rather
than electrical. Information regarding mechanical and
CAUTION hydraulic troubleshooting is located in the appropriate
section in this Manual.
When replacing an ACCESS module or updating mod-
ule software, verify settings and recalibrate as needed. To Locate Malfunctioning Components
Some Troubleshooting Basics Component and Wiring Location Maps are provided at
strategic locations to help you quickly determine the
physical location of items in question.
WARNING All components are clearly marked at the connection
Never key ON truck with any control connectors dis- points.
connected. In addition, never remove or connect any Test Points
control connectors while truck is keyed ON.
Test points referenced in the event code descriptions
Statistically the majority of malfunctions occur in or at are located on the distribution panel.
hardware components, contactors and motors. The
next components to test are connectors, wiring and in- Power Cable Connections
put devices such as switches, potentiometers or en-
coders. When measuring voltage and resistance of
these components, use a Digital Volt-Ohm Meter
CAUTION
(DVOM). Be sure to connect all components previously Due to capacitance voltage present in the traction mo-
disconnected after completing event code steps. The tor controller and lift motor controller, whenever per-
last component to suspect is the motor control system. forming maintenance which may permit contact with
In all instances, you should begin your troubleshooting the bus bars and associated power cables, discharge
procedure at the driven device, proceed to inputs de- the capacitors.
vices, then, and only then, move on to the control to
which these devices attach.
When a Malfunction Occurs • Lockout or tagout truck as described in Lockout -
• Go to ACCESS 1 and access the Level 2: Field Tagout in this section.
Service Mode as follows. • Disconnecting the battery will discharge the capac-
itors. Once the dash display flashes, the capacitors
NOTE are discharged. Two alternative methods of dis-
charging these capacitors are to disconnect the
Your monitoring system can be accessed at three lev- battery and hold the key switch in the start position
els of authorization: for 10 seconds or disconnect the battery and con-
Level 1: Operator Mode nect a 200 ohm, two watt resistor between the pos-
Level 2: Field Service Mode (Full Truck Operation) itive and negative terminals on the controller.
Level 3: Analyzer/Test Mode (No Truck Operation) • Turn key switch to OFF, remove key.
This section deals with Level 2 and Level 3. For infor-
mation on Level 1, see the Operator’s Manual. Refer to
Electrical for ACCESS 1 information.
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Event Codes
ACCESS 1 Display Control Module (DCM)
Figure 16722-02
1 Display Screen
2 Battery Retainer Switch Indicator*
3 Enter or Return Key - used to navigate in and out of menus
and accept inputs.
4 Wire Guidance Display (optional)
5 Navigation Keys - up, down, left and right arrows; used to
scroll through menus.
6 Operator Improper Sequence Error Indicator*
7 Service Required Indicator*
8 Battery Discharge Indicator
* NOTE: These three indicators are viewable during initial
key-on, self test and indicator functioning.
ACCESS 1 - Display Control Module (DCM)

ACCESS 3 - Traction Control Module (TCM)
ACCESS 4 - Vehicle Control Module (VCM)
ACCESS 5 - Steering Control Module (SCM)
ACCESS 6 - Guidance Control Module (GCM)
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Event Codes
Notes:
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Event Code 101
Event Code 101 Step 4: CAN communications line test:

Key OFF truck and use a DVOM to check resistance
ACCESS 1 CAN Initialization Error. between CAN_H and CAN_L on platform distribution
panel TP13 and TP14, should be 60 ohm.
Note: Absence of B- to ACCESSES on the CAN bus • If: Greater than 60 ohm.
will load the bus and impede CAN communications. – Then CAN bus terminating resistors are open.
Step 1:Check ACCESS 1 CAN wiring. Wire 003 Remove CA402 from ACCESS 5 and, using a
CA302-8 to CA105-2 and wire 004 CA302-9 to DVOM, check resistance between CA402-4
CA105-8. and CA402-5.
• If: Wiring is correct and event code continues. • If: Greater than 120 ohm.
– Then proceed to Step 2. – Then replace ACCESS 5.
• If: Wiring incorrect. • If: Greater than 60 ohm.
– Then repair/replace as necessary. – Then CAN bus terminating resistors are open.
Step 2: Check power to ACCESS 1, wire 2941 DVOM, check resistance between CA302-8
CA302-3 to CA103-10 and wire 513 CA302-4 to and CA302-9.
CA107-8.
Step 5: Check for CAN line short to battery negative,
• If: Wiring incorrect. battery positive and truck frame. Key OFF truck discon-
nect battery, then, using a DVOM, check resistance at
the power unit from CAN_L to -BV bus bar, CAN_L to
Step 3: Check for B- to other ACCESSES on CAN bus TP3 on the power unit distribution panel and CAN_L to
by verifying power lamps are ON. truck frame. Resistance should be greater than 10,000
ohm.
• If: ACCESS has no power.
– Then, using a DVOM, check for B+ and B-.
Should either be missing check associated wir- – Then repair/replace wiring as necessary.
ing, connector and fuse.
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ELECTRICAL SYSTEM
Event Code 101
Figure 16649
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ELECTRICAL SYSTEM
Event Code 103

All functions disabled. frame. Key OFF truck, disconnect battery and, using a
power ON lamps.

cable.
• If: 24V.
• If: 0V.
• If: 0 ohm.
CAN_L. Check associated wiring, connections
and fuses. Repair/replace as necessary.

DVOM, check resistance between CA402-4
and CA402-5.


and CA302-9.
Figure 16651
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ELECTRICAL SYSTEM
Event Code 104

power ON lamps.

CA304-3.
• If: 24V.
• If: 0V.
– Then check wire 2937, CA304-1 to CA103-12;
wire 525, CA304-3 to CA107-9 and fuse FU2
power unit distribution panel. Repair/replace as
necessary.
Step 2: Check CAN Communications Lines. Key OFF
• If: 0 ohm.

and CA402-5.


Remove CA302 from ACCESS 1 and, using a Figure 16661
and CA302-9.
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Event Code 105
All truck functions disabled. • If: 0 ohm.
Note: ACCESS 1 CAN bus communication with – Then short exists between CAN_H and
ACCESS 5 has not occurred within specified time. CAN_L. Check associated wiring, connections
power ON lamps. • If: Greater than 60 ohm.
• If: ACCESS 5 power lamps are ON and event code – Then CAN bus terminating resistors are open.
continues. Remove CA402 from ACCESS 5 and, using a
– Then proceed to Step 2. and CA402-5.
• If: ACCESS 5 power lamps are OFF. • If: Greater than 60 ohm.
– Then check for BV between CA403-26 and – Then replace ACCESS 5.
CA403-10.
• If: 24V.
– Then replace ACCESS 5. Remove CA302 from ACCESS 3 and, using a
• If: 0V. DVOM, check resistance between CA302-8
and CA302-9.
2966 CA403-10 to CA201-6, fuse FU3 power • If: Greater than 60 ohm.
unit distribution panel. – Then replace ACCESS 1.
frame. Key OFF truck, disconnect battery and, using a
DVOM, check resistance at the power unit from CAN_L
to -BV bus bar, CAN_L to TP3 on the power unit distri-

M4.8-7335-008 SP3500 Crown 2007 PF15819-8 Rev. 3/08
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Event Code 105
Figure 16668
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Event Code 106

power ON lamps.

CA601-2.
• If: 24V.
• If: 0V.
wire 552 CA601-2 to -BV bus bar, fuse FU3
power unit distribution panel.
• If: 0 ohm.
and fuses.

and CA402-5.


and CA302-9.
Figure 16683
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Event Code 111
Event Code 111

ACCESS 1 Software Parameter Error.
Step 1: Download latest software.
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Event Code 113
Event Code 113

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Event Code 114
Event Code 114

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ELECTRICAL SYSTEM
Event Code 115
Event Code 115

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ELECTRICAL SYSTEM
Event Code 116
Event Code 116

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ELECTRICAL SYSTEM
Event Code 123

ACCESS 3 CAN Error.
power ON lamps.

cable.
• If: 24V.
• If: 0V.
• If: 0 ohm.
and fuses.

and CA402-5.


and CA302-9.
Figure 16684
M4.8-7335-012 SP3500 Crown 2007 PF15819-16 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 124

ACCESS 4 CAN Error.
power ON lamps.

CA304-3.
• If: 24V.
• If: 0V.
wire 525 CA304-3 to CA107-9, fuse FU2 power
• If: 0 ohm.
and fuses.

and CA402-5.


Remove CA302 from ACCESS 1. Check re-
sistance between CA302-8 and CA302-9 using Figure 16661
a DVOM.
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Event Code 125

ACCESS 5 CAN Error.
power ON lamps.

CA403-10.
• If: 24V.
• If: 0V.
2966 CA403-10 to CA201-6, fuse FU3 power
• If: 0 Ohm.
and fuses.

and CA402-5.


and CA302-9.
Figure 16685
M4.8-7335-014 SP3500 Crown 2007 PF15819-18 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 126

ACCESS 6 CAN Error.
power ON lamps.

CA601-2.
• If: 24V.
• If: 0V.
wire 552 CA601-2 to B- BB, fuse FU3 power
unit distribution panel. Repair/replace as nec-
essary.
• If: 0 ohm.
and fuses.

and CA402-5.


and CA302-9.
Figure 16683
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Event Code 131
Event Code 131

ACCESS 1 Alarm 1 (ALM1) Driver Shorted.
No action taken.
Step 1: Using a DVOM check for 24V between TP8
and TP7 on platform distribution panel. Energize output
for ALM1 in analyzer mode.
• If: 0V.
platform distribution panel. Energize output for
ALM1 in analyzer mode.
• If: 0V.
• If: 24V.
– Then check continuity of wire 5917.
• If: Open.
– Then repair/replace wiring.
Figure 16686
M4.8-7335-016 SP3500 Crown 2007 PF15819-20 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 133
Event Code 133 CAN_L/CAN_H between TP15 and TP16 and CAN_L/
than 10,000 ohm.
Guidance Steer Indicator (GSI) CAN Error.
No truck functions are disabled. • If: Less than 10,000 ohm.
Step 1: Key ON truck, check status of GSI. – Then repair/replace as necessary.
• If: GSI power light is on.

• If: GSI lights are off.

CA206-5.
• If: 0V.
– Then check FU3.
• If: 24V.
CA403-26.
• If: 24V.
– Then replace GSI.
• If: 0V.
or CA403-26.
Step 2: Check connection of CAN to GSI.

– Then key OFF truck and, using a DVOM, check
resistance between CAN_H and CAN_L plat-
form distribution panels CA105-4 and
CA105-10. Resistance should be 60 ohm.
• If: 0 ohm.
CAN_L, repair as necessary.
• If: Greater than 60 to 65 ohm with all connectors

connected.
or damaged. CAN bus contains 2 terminating
resistors, one is located in the ACCESS 5 the
other in ACCESS 1.
Figure 16687
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ELECTRICAL SYSTEM
Event Code 134
ACCESS 4 CAN Error.
Full speed traction and raise 2 disabled.
• If: 0 ohm.
power ON lamps. – Then short exists between CAN_H and
• If: ACCESS 4 power lamps are ON. and fuses.
– Then proceed to Step 2. • If: Greater than 60 ohm.
• If: ACCESS 4 lamps are OFF. – Then CAN bus terminating resistors are open.
CA107-9.
and CA402-5.
• If: 24V.
CA304-3.
• If: 24V.
• If: 0V. DVOM, check resistance between CA302-8
and CA302-9.
– Then issue exists in wiring connected to
CA304-1 to CA304-3. • If: Greater than 120 ohm.
CAN_L/CAN_H between TP15 and TP16 and CAN_L/
than 10,000 ohm.

M4.8-7335-018 SP3500 Crown 2007 PF15819-22 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 134
Figure 16688
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ELECTRICAL SYSTEM
Event Code 301
Event Code 301

ACCESS 1 CAN Error.
tion panel CA204-7, RED wire CA203-3 to platform dis-
tribution panel CA104-3, wire 004 CA105-8 to
ACCESS 1 CA302-9.
tion panel CA204-1, WHITE wire CA203-2 to platform
distribution panel CA104-2, wire 003 CA105-2 to
ACCESS 1 CA302-8.

• If: 0 ohm.
and fuses.

and CA402-5.

Figure 16689
and CA302-9.

M4.8-7335-020 SP3500 Crown 2007 PF15819-24 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 302
Event Code 302

THRU
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ELECTRICAL SYSTEM
Event Code 303
Event Code 303

Traction disabled.

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ELECTRICAL SYSTEM
Event Code 304

ACCESS 3/ACCESS 4 CAN Error. Remove CA302 from ACCESS 1 and, using a
Traction and raise disabled. DVOM, check resistance between CA302-8
and CA302-9.
tion panel CA204-7, wire 002 CA105-7 to ACCESS 4 – Then replace ACCESS 1.
CA303-8.
CA303-7.

• If: 0 ohm.
and fuses.

and CA402-5.

Figure 16690
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ELECTRICAL SYSTEM
Event Code 305
Event Code 305

CA402-5.
CA402-4.

• If: 0 ohm.
and fuses.

and CA402-5.

Figure 16695
and CA302-9.

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ELECTRICAL SYSTEM
Event Code 306
Event Code 306

CA601-4.
CA601-5.

• If: 0 ohm.
and fuses.

and CA402-5.

Figure 16696

and CA302-9.

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ELECTRICAL SYSTEM
Event Code 307
Event Code 307

THRU
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ELECTRICAL SYSTEM
Event Code 309

THRU
ACCESS 3 Short.
Traction disabled.
Event Code 307: Short Between -BV and Terminal V.
Event Code 308: Short Between +BV and Terminal W.
Event Code 309: Short between -BV and Terminal W.



Figure 16697
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ELECTRICAL SYSTEM
Event Code 312

THRU
ACCESS 3 Short Between Terminal U and V.
Traction disabled.



Figure 16697
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ELECTRICAL SYSTEM
Event Code 315

THRU
ACCESS 3 Short Between Terminal W and V.
Traction disabled.



Figure 16697
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ELECTRICAL SYSTEM
Event Code 318

THRU
ACCESS 3 Short Between Terminal W and U.
Traction disabled.



Figure 16697
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ELECTRICAL SYSTEM
Event Code 320
Event Code 320


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ELECTRICAL SYSTEM
Event Code 322
Event Code 322

ACCESS 3 BV Low.
Traction disabled.
Step 1: Using a DVOM, check for 24V ACCESS 3 +BV
terminal and -BV terminal.
• If: Voltage is under 24V.

• If: Battery, power cable connections, FU10 and

ED2 are correct.
– Then check battery charge level.
• If: Battery is properly charged.

configuration.

Figure 16698
M4.8-7335-026 SP3500 Crown 2007 PF15819-36 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 323

ACCESS 3 BV High. ACCESS 3 Internal temperature Less than -25°C
(-13°F).
then refer to ED system event code 541 first. Full traction disabled.
Traction disabled. Step 1: Determine air temperature of environment.
Step 1: Using a DVOM check for 24V ACCESS 3 +BV • If: Ambient temperature is below -25°C (-13°F) and
terminal and -BV terminal. the truck has set idle for and extended time.
• If: Voltage is over 24V (i.e. 36V). – Then ACCESS 3 heat sink must be warmed to
operate with full traction capabilities.
– Then check for correct battery.

• If: Ambient temperature is well above -25°C
(-13°F) and event continues.
configuration.

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Event Code 325
Event Code 325

ACCESS 3 Internal Temperature Less than -4°C
(25°F).
Traction disabled.
Step 1: Determine air temperature of environment.
• If: Ambient temperature is below -4°C (25°F) and

– Then ACCESS 3 heat sink must be warmed to
operate.
• If: Ambient temperature is well above -4°C (25°F)

and event continues.
M4.8-7335-027 SP3500 Crown 2007 PF15819-38 Rev. 3/08
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Event Code 326
Event Code 326

ACCESS 3 Internal Temperature More than 85°C
(185°F).
No effect.


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Event Code 327
Event Code 327

ACCESS 3 Internal Temperature in Excess of 105°C
(221°F).
Traction disabled.


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Event Code 328

ACCESS 3 Traction Motor (M1) Temperature Sen- ACCESS 3 Traction Motor M1 Temperature Sensor
sor (TS1) Above Acceptable Operating Range of TS1 Signal Out of Range.
165°C (329°F).
Traction disabled.
No effect.
Step 1: Using a DVOM check TS1 wiring for a short to
Step 1: Check traction motor setups. truck frame. Check CA411-1 and CA411-2 encoder
wires, CA411-1 wire 579 to B- BB and CA411-2 wire
• If: Incorrect setups. 105 to CA401-16 to truck frame.
– Then change. • If: Wire(s) are shorted.
• If: Setups are correct. – Then repair as necessary.
– Then check TS1/M1 lead/cable connections • If: Wire(s) are correct.
and clean dirt off M1.
– Then using a DVOM check TS1 wiring for an
• If: This action does not correct overheating. open. Check CA411-1 and CA411-2 encoder
– Then check battery condition. wires, CA411-1 wire 579 to B- BB and CA411-2
wire 105 to CA401-16.
Note: Extreme duty cycle and/or high ambient temper-
atures could also cause 328 event code logging.
Figure 16699
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Event Code 330
Event Code 330

ACCESS 3 Encoder ECR3 Count Error.
Traction disabled. One or both channels lost at
ACCESS 3 while truck is traveling.
Step 1: Check for event codes 366, 367, 376 and 377,
which indicate that ECR3 power supply or logic ground
is out of range. If these codes have been logged, re-
solve them before proceeding with procedure below.
• If: None of these event codes have occurred.

Note: Use Service Mode 2 to view ECR3 operation.
• If: Event code 330 logs.

– Then check ECR3 channel A and B wiring.
WHITE and BLUE wires between ECR3 and
CA411-4, -5. Wires 028, 029 between
CA411-4, -5 and ACCESS 3 CA401-6, -5.

Figure 16702
• If: No event codes slow traction and/or shut downs

continue.
Wires 315 and 549 between CA411-3, -6 and
ACCESS 3 CA401-3 and -4.
• If: Connections are good and slow traction and/or

shut downs continue.
M4.8-7335-029 SP3500 Crown 2007 PF15819-42 Rev. 3/08
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Event Code 332

ACCESS 3 Drive Motor (M1) Rotation More than ACCESS 3 BV Under Range.
4000 RPM.
Traction disabled.
Step 1: Check ECR3 channel A and B wiring. WHITE then refer to ED system event code 541 first.
and BLUE wires between ECR3 and CA411-4 and -5.
Step 1: Using a DVOM check for 24V on ACCESS 3
Wires 028 and 029 between CA411-4, -5 and ACCESS
between +BV terminal and -BV terminal.
3 CA401-6, -5.
• If: ECR3 channel A and B wiring is correct.

• If: Under 24V.
Wires 315, 549 between CA411-3, -6 and AC- • If: Battery, power cable connections, FU10 and
CESS 3 CA401-3, -4. ED2 correct.
• If: ECR3 power wiring is correct. – Then check battery charge level.
– Then replace ECR3. • If: Battery is properly charged.
configuration.

Figure 16698
Figure 16702
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Event Code 336
Event Code 336

ACCESS 3 BV Over Range.
Step 1: Using a DVOM check for 24V on ACCESS 3
between +BV terminal and -BV terminal.
• If: Over 24V (i.e. 36V).

– Then check for correct battery.

configuration.

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ELECTRICAL SYSTEM
Event Code 337

ACCESS 3 24V Battery Voltage Fluctuating. ACCESS 3 +BV Under Voltage.
Full traction disabled. All functions disabled.
Note: Battery voltage is dropping excessively under Step 1: Check battery status.
load.
Step 1: Check ACCESS 3 B- and B+ power cable con-
nections. – Then proceed to Step 2.
• If: Connections in poor condition. • If: Battery does not have correct voltage or not
properly charged.
– Then repair/replace.
• If: Connections in good condition.
– Then check condition of battery and/or install a 24V between CA401-1 and -B on ACCESS 3.
known good battery and monitor event code
337. • If: 24V.
– Then proceed with Step 3.

ACCESS 3 -B.
• If: 24V.
bution panel CA201 5 to ACCESS 3 CA401-1.

panel.
terminals.
• If: Voltage is below 24V.

– Then check power cable condition and connec-
tion.
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Event Code 339
Event Code 339

ACCESS 3 +BV Over Voltage.
Step 1: Check feature menu for proper battery config-
uration.
• If: Configuration is correct.

– Then check for proper battery.
• If: Battery is correct.

• If: Battery is not correct.

CA401-1 and ACCESS 3 -B.
• If: 24V.
Figure 16704 – Then check voltage between CA201-5 and

ACCESS 3 -B.
• If: 24V.

panel.
terminals.
• If: Voltage is above 24V but less than 28V and

event code continues.
M4.8-7335-032 SP3500 Crown 2007 PF15819-46 Rev. 3/08
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ELECTRICAL SYSTEM
Event Code 339
Figure 16704
Crown 2007 PF15819-47 Rev. 3/08 SP3500 M4.8-7335-032

01 Rev. 3/08
317
ELECTRICAL SYSTEM
Event Code 340

ACCESS 3 ED2 Contactor Coil Driver Over Current. ACCESS 3 P1 Contactor Coil Driver Over Current.
Steering, traction and hydraulics disabled. Raise disabled.
Step 1: Follow trouble shooting steps for event code Step 1: Disconnect wires 2961 and 5923 from P1 con-
541. tactor coil and, using a DVOM, check resistance of P1
contactor coil.

• If: 20 ohm and event code continues.

– Then check P1 contactor coil wiring for a short.
Wire 5923 to ACCESS 3 CA401-18 and wire
2961 to power unit distribution panel CA202-6.
• If: Wires are not shorted remove wire 5924 from P2

contactor coil.
5923 at P1 contactor coil while depressing
raise 1 switch.
• If: 0V.
Figure 16705
M4.8-7335-033 SP3500 Crown 2007 PF15819-48 Rev. 3/08
01 Rev. 3/08
318
ELECTRICAL SYSTEM
Event Code 342
Event Code 342

ACCESS 3 P2 Contactor Coil Driver Over Current.
Raise speed 2 disabled.
contactor coil.

• If: 20 ohm and event code continues.

– Then check P2 contactor coil wiring for a short.
Wire 5924 to ACCESS 3 CA401-21 and wire
2962 to power unit distribution panel CA202-7.
• If: Wires are not shorted remove wire 5923 from P1

contactor coil.
raise 2 switch.
• If: 0V.
Figure 16706
Crown 2007 PF15819-49 Rev. 3/08 SP3500 M4.8-7335-033

01 Rev. 3/08
319
ELECTRICAL SYSTEM
Event Code 343
Event Code 343

ACCESS 3 Lowering Solenoid (SVL) Driver Over
Current.
Raise and lower disabled.
Step 1: Disconnect wire 5925 from SVL coil and, using
a DVOM, check resistance of SVL coil.

• If: 29 ohm.
wire 2959 (opposite side of SVL coil) while de-
• If: 0V.
– Then remove wire 5925 from connector
CA401-22 and, using a DVOM, check for 24V
between wire 2959 and CA401-22 while de-
Figure 16707
• If: 0V.
• If: 24V.
– Then key OFF truck reconnect wire 5925 to
SVL. Connect DVOM lead to wire 2959 and
TP3 on the power unit distribution panel. Key
ON truck, depress lower switch and check for
24V.
• If: 0V.
M4.8-7335-034 SP3500 Crown 2007 PF15819-50 Rev. 3/08
01 Rev. 3/08
320
ELECTRICAL SYSTEM
Event Code 344
Event Code 344

ACCESS 3 Fan2 Driver Over Current.
Step 1: Disconnect wires 29122 and 5908 from Fan2
29122 and wire 5908. Energize output for Fan2 in ana-
lyzer mode.
• If: 0V.
power unit distribution panel. Energize output
for Fan2 in analyzer mode.
• If: 0V.
• If: 24V.
between wire 29122 and TP3 on power unit
distribution panel.
• If: 0V.
– Then check connection of wire 29122 to Figure 16708
CA201-8.
Crown 2007 PF15819-51 Rev. 8/08 SP3500 M4.8-7335-035

01 Rev. 3/08
321
ELECTRICAL SYSTEM
Event Code 345

ACCESS 3 ED2 Contactor Driver Open. ACCESS 3 P1 Contactor Driver Open.
Steering and traction disabled. Raise 1 disabled.
Step 1: Follow trouble shooting procedure for event Step 1: Disconnect wires 2961 and 5923 from P1 con-
code 541. tactor coil and, using a DVOM, check resistance of P1
contactor coil.


coil.
raise 1 switch.
• If: 0V.
check for 24V between CA401-18 and TP4
while depressing raise 1 switch.
• If: 0V.
• If: 24V.
switch.
• If: 0V.
– Then check raise 1 switch and associated wir-
ing.
M4.8-7335-036 SP3500 Crown 2007 PF15819-52 Rev. 8/08
01 Rev. 3/08
322
ELECTRICAL SYSTEM
Event Code 348
Event Code 348

ACCESS 3 Lowering Solenoid (SVL) Driver Open.
Raise disabled.

• If: 29 ohm.
• If: 0V.
while depressing lower switch.
• If: 0V.
• If: 24V.
Figure 16709
• If: 0V.
ing.
Crown 2007 PF15819-53 Rev. 8/08 SP3500 M4.8-7335-037

01 Rev. 3/08
323
ELECTRICAL SYSTEM
Event Code 349
Event Code 349

ACCESS 3 FAN2 Driver Open.
Step 1: Using a DVOM check for 24V between wire
29122 and 5908 at FAN2 (use analyzer mode to ener-
gize output).
• If: 0V.
check for 24V between CA401-8 to TP4 (use
analyzer mode to energize output).
• If: 0V.
• If: 24V.
TP4.
• If: 0V.
Figure 16710 – Then check wiring.
Figure 16715
M4.8-7335-038 SP3500 Crown 2007 PF15819-54 Rev. 8/08
01 Rev. 3/08
324
ELECTRICAL SYSTEM
Event Code 350

ACCESS 3 ED2 Contactor Driver Shorted. ACCESS 3 P1 Contactor Driver Shorted.
Full traction disabled. Full traction, auxiliary raise and raise2 disabled.
Step 1: Refer to ED2 trouble shooting procedure for Step 1: Disconnect wires 2961 and 5923 from P1 con-
event code 541. tactor coil and, using a DVOM, check resistance of P1
contactor coil.


coil.
raise 1 switch.
• If: 0V.
check for 24V between CA401-18 to TP4 while
• If: 0V.
• If: 24V.
switch.
• If: 0V.
Crown 2007 PF15819-55 Rev. 8/08 SP3500 M4.8-7335-039

01 Rev. 3/08
325
ELECTRICAL SYSTEM
Event Code 352
Event Code 352

contactor coil.


coil.
raise 2 switch.
• If: 0V.
check for 24V between CA401-21 to TP4 while
• If: 0V.
Figure 16716
• If: 24V.
switch.
• If: 0V.
M4.8-7335-040 SP3500 Crown 2007 PF15819-56 Rev. 8/08
01 Rev. 3/08
326
ELECTRICAL SYSTEM
Event Code 353
Event Code 353

ACCESS 3 Lowering Solenoid (SVL) Driver
Shorted.
Raise disabled.

• If: 29 ohm.
• If: 0V.
while depressing lower switch.
• If: 0V.
• If: 24V.
Figure 16717
• If: 0V.
Crown 2007 PF15819-57 Rev. 8/08 SP3500 M4.8-7335-041

01 Rev. 3/08
327
ELECTRICAL SYSTEM
Event Code 354
Event Code 354

ACCESS 3 FAN2 Driver Shorted.
No action taken.
Step 1: Disconnect wires 29122 and 5908 from FAN2
29122 and wire 5908. Energize output for FAN2 in an-
alyzer mode.
• If: 0V.
power unit distribution panel. Energize output
for Fan2 in analyzer mode.
• If: 0V.
• If: 24V.
between wire 29122 and TP3 on power unit
distribution panel.
• If: 0V.
Figure 16718
– Then check wiring connection at CA201-8 and
FU4.
M4.8-7335-042 SP3500 Crown 2007 PF15819-58 Rev. 8/08
01 Rev. 3/08
328
ELECTRICAL SYSTEM
Event Code 355
Event Code 355

ACCESS 3 PWM Driver Over Voltage.
Step 1: Using a DVOM for 24V between CA201-5 and
TP3 on the power unit distribution panel.
• If: 0V.
– Then check FU3.
• If: 24V.
TP3.
• If: 0V.
– Then repair connection of wire 2953.
• If: 24V.
Figure 16719
Figure 16720
Crown 2007 PF15819-59 Rev. 8/08 SP3500 M4.8-7335-043

01 Rev. 3/08
329
ELECTRICAL SYSTEM
Event Code 356
Event Code 356

ACCESS 3 Detected Open Circuit in ED2 Wiring.
Step 1: Follow the ED System Trouble shooting proce-
dure specified for event code 541.
M4.8-7335-043 SP3500 Crown 2007 PF15819-60 Rev. 8/08
01 Rev. 3/08
330
ELECTRICAL SYSTEM
Event Code 357

ACCESS 3 ED2 Contactor Error. ACCESS 3 Pre-Charge Power Limit Out of Range.
Step 1: Check ED2 contact tips. Note: Power limit of pre-charge resistor internal to
ACCESS 3 has been exceeded.
• If: Contacts are worn.
• If: Contacts correct.
– Then key OFF truck and check ED2 load bus
connections. • If: Battery is not correct voltage or not properly
charged.
• If: Connections correct.
– Then follow procedures for event code 541.
Step 2: Key ON truck and cycle pedal. Using a DVOM
check for 24V between +BV and -BV power lug on
ACCESS 3.
• If: 24V.

– Then check cables to ACCESS 3.

ACCESS 3 -BV.
• If: 24V.

panel.
Crown 2007 PF15819-61 Rev. 8/08 SP3500 M4.8-7335-044

01 Rev. 3/08
331
ELECTRICAL SYSTEM
Event Code 359
Event Code 359

ACCESS 3 Pre-Charge Time Limit Exceeded.


properly charged.
• If: 24V.

ACCESS 3 -BV.
• If: 24V.
Figure 16704

panel.
M4.8-7335-045 SP3500 Crown 2007 PF15819-62 Rev. 8/08
01 Rev. 3/08
332
ELECTRICAL SYSTEM
Event Code 359
Figure 16704
Crown 2007 PF15819-63 Rev. 8/08 SP3500 M4.8-7335-045

01 Rev. 3/08
333
ELECTRICAL SYSTEM
Event Code 360

ACCESS 3 Pre-Charge Electrical Error. ACCESS 3 Error.
Note: Resistive load is present on the ED2 bus during Step 1: Replace ACCESS 3.
pre-charge this condition is most likely a driver shorted
issue.


charged.
Step 2: Check other events logged along side the 360.
M4.8-7335-046 SP3500 Crown 2007 PF15819-64 Rev. 8/08
01 Rev. 3/08
334
ELECTRICAL SYSTEM
Event Code 362
Event Code 362

THRU
Crown 2007 PF15819-65 Rev. 8/08 SP3500 M4.8-7335-046

01 Rev. 3/08
335
ELECTRICAL SYSTEM
Event Code 363
Event Code 363

No action taken.

Event Code 364

THRU
M4.8-7335-046 SP3500 Crown 2007 PF15819-66 Rev. 8/08
01 Rev. 3/08
336
ELECTRICAL SYSTEM
Event Code 365
Event Code 365

ACCESS 3 Internal 5V Supply Out of Range.

Crown 2007 PF15819-67 Rev. 8/08 SP3500 M4.8-7335-046

01 Rev. 3/08
337
ELECTRICAL SYSTEM
Event Code 366
Event Code 366

THRU
M4.8-7335-046 SP3500 Crown 2007 PF15819-68 Rev. 8/08
01 Rev. 3/08
338
ELECTRICAL SYSTEM
Event Code 367
Event Code 367

ACCESS 3 +12V Power Supply for Encoder 3
(ECR3) Out of Range.
Event Code 366: Supply voltage high.
Event Code 367: Supply voltage low.
Step 1: Using a DVOM, check for 12 V between wire
315 CA401-3 and TP3 (-B) power unit distribution
panel. When 12 V and event code continues, then
check for 12 V at CA411-3 and TP3 (B-).
• If: 0V.
• If: Less than 12 V and event code continues.

ing a DVOM, check for 12 V between CA401-3
and TP3 (-B). When 12 V, then replace
ECR3.When less than 12 V and event code
continues, then replace ACCESS 3.
Figure 16721
Crown 2007 PF15819-69 Rev. 8/08 SP3500 M4.8-7335-046

01 Rev. 3/08
339
ELECTRICAL SYSTEM
Event Code 368
Event Code 368

THRU
M4.8-7335-047 SP3500 Crown 2007 PF15819-70 Rev. 8/08
01 Rev. 3/08
340
ELECTRICAL SYSTEM
Event Code 369
Event Code 369


Crown 2007 PF15819-71 Rev. 8/08 SP3500 M4.8-7335-047

01 Rev. 3/08
341
ELECTRICAL SYSTEM
Event Code 370
Event Code 370

THRU
M4.8-7335-047 SP3500 Crown 2007 PF15819-72 Rev. 8/08
01 Rev. 3/08
342
ELECTRICAL SYSTEM
Event Code 371
Event Code 371


Crown 2007 PF15819-73 Rev. 8/08 SP3500 M4.8-7335-047

01 Rev. 3/08
343
ELECTRICAL SYSTEM
Event Code 372
Event Code 372

THRU
M4.8-7335-047 SP3500 Crown 2007 PF15819-74 Rev. 8/08
01 Rev. 3/08
344
ELECTRICAL SYSTEM
Event Code 373

THRU
ACCESS 3 Internal 227 mV Reference Voltage Out
of Range.

Crown 2007 PF15819-75 Rev. 8/08 SP3500 M4.8-7335-047

01 Rev. 3/08
345
ELECTRICAL SYSTEM
Event Code 375

ACCESS 3 Internal 2.5V Reference Voltage Out of ACCESS 3 Over Current Condition.
Range.
Traction disabled.
Step 1: Disconnect traction motor (M1) phase cabling
Step 1: Internal failure. from ACCESS 3 and Key ON truck.


– Then using a DVOM check M1 and cabling for
phase-to-phase and phase-to-frame shorts.
• If: Short circuit exists between U, V, W cables or

frame.
– Then remove phase cabling and check for M1
winding shorts to frame.
• If: Short exists in M1.

Figure 16723
M4.8-7335-048 SP3500 Crown 2007 PF15819-76 Rev. 8/08
01 Rev. 3/08
346
ELECTRICAL SYSTEM
Event Code 379
Event Code 379

THRU
Crown 2007 PF15819-77 Rev. 8/08 SP3500 M4.8-7335-048

01 Rev. 3/08
347
ELECTRICAL SYSTEM
Event Code 380
Event Code 380

Traction disabled.

M4.8-7335-048 SP3500 Crown 2007 PF15819-78 Rev. 8/08
01 Rev. 3/08
348
ELECTRICAL SYSTEM
Event Code 381
Event Code 381

THRU
Crown 2007 PF15819-79 Rev. 8/08 SP3500 M4.8-7335-048

01 Rev. 3/08
349
ELECTRICAL SYSTEM
Event Code 382

THRU
ACCESS 3 Short.
Traction disabled.
Event Code 381: Short between +BV and terminal U.
Event Code 382: Short between -BV and terminal U.



Figure 16697
M4.8-7335-049 SP3500 Crown 2007 PF15819-80 Rev. 8/08
01 Rev. 3/08
350
ELECTRICAL SYSTEM
Event Code 384

THRU
ACCESS 3 Short.
Traction disabled.
Event Code 383: Short between +BV and terminal V.
Event Code 384: Short between -BV and terminal V.



Figure 16697
Crown 2007 PF15819-81 Rev. 8/08 SP3500 M4.8-7335-049

01 Rev. 3/08
351
ELECTRICAL SYSTEM
Event Code 386

THRU
ACCESS 3 Short.
Traction disabled.
Event Code 385: Short between +BV and terminal W.
Event Code 386: Short between -BV and terminal W.



Figure 16697
M4.8-7335-049 SP3500 Crown 2007 PF15819-82 Rev. 8/08
01 Rev. 3/08
352
ELECTRICAL SYSTEM
Event Code 389
Event Code 389

ACCESS 3 Short Terminal U to V.
Traction disabled.
Event Code 387: Short U to V.
Event Code 388: Short UL to VH.
Event Code 389: Short UH to VL.
Step 1: Check motor cable connections.
• If: Short exists between U and V.

• If: No short exists.

– Then disconnect motor cables from ACCESS 3
and key ON truck.


– Then repair or replace M1.
Crown 2007 PF15819-83 Rev. 8/08 SP3500 M4.8-7335-049

01 Rev. 3/08
353
ELECTRICAL SYSTEM
Event Code 390
Event Code 390

THRU
M4.8-7335-050 SP3500 Crown 2007 PF15819-84 Rev. 8/08
01 Rev. 3/08
354
ELECTRICAL SYSTEM
Event Code 392

ACCESS 3 Traction Motor (M1) Short. bling from ACCESS 3 and Key ON truck.
Traction disabled.
Event Code 390: Short V to W.
Event Code 391: Short VL to WH.
Event Code 392: Short VH to WL.

Crown 2007 PF15819-85 Rev. 8/08 SP3500 M4.8-7335-050

01 Rev. 3/08
355
ELECTRICAL SYSTEM
Event Code 393
Event Code 393

THRU
M4.8-7335-050 SP3500 Crown 2007 PF15819-86 Rev. 8/08
01 Rev. 3/08
356
ELECTRICAL SYSTEM
Event Code 395

THRU
Traction disabled.
Event Code 393: Short W to U.
Event Code 394: Short WL to UH.
Event Code 395: Short WH to UL.




Crown 2007 PF15819-87 Rev. 8/08 SP3500 M4.8-7335-051

02 Rev. 8/08
357
ELECTRICAL SYSTEM
Event Code 397
Event Code 397

Pump Motor Over Temperature.
Pump motor has worn brushes. No action taken.
Event Code 396: Pump motor M3.
Event Code 397: Pump motor M4.
Step 1: Check appropriate pump motor for dirt build up.
• If: Dirt is present.

– Then clean as needed.
Step 2: Check for loose connections and corroded ter-
minals.
• If: Loose connections and corroded terminals

found.
– Then tighten or clean as needed.
Step 3: Check pump assembly to ensure mechanical
binding does not exist.
• If: Mechanical issues exist.

– Then repair or replace pump as needed.
M4.8-7335-051 SP3500 Crown 2007 PF15819-88 Rev. 8/08
02 Rev. 8/08
358
ELECTRICAL SYSTEM
Event Code 398
Event Code 398

Pump Motor Brush Wear.
Pump motor M3 or M4 has worn brushes. No action
taken.
Step 1: Check brushes.
• If: Brushes are worn.

– Then replace as needed.
Note: Brush springs should also be replaced.
Crown 2007 PF15819-89 Rev. 8/08 SP3500 M4.8-7335-051

02 Rev. 8/08
359
ELECTRICAL SYSTEM
Event Code 401
Event Code 401 – Then CAN bus terminating resistors are miss-
ing CAN bus contains two terminating resis-
tors, one located in ACCESS 5 and the other in
ACCESS 1.
No action taken.
• If: All wiring is correct and event continues.
Note 1: If event code 401 is displayed on ACCESS 1
issue was caused by an intermittent open wire condi- – Then replace ACCESS 1 and/or ACCESS 5.
tion. Refer to intermittent connection test at the end of Intermittent connection test.
Step 2.
Note 2: If event code 401 is flashing on ACCESS 4 but
• If: Codes 104 or 106 are also displayed.
is not displayed on ACCESS 1, then proceed to Step 1. – Then intermittent connection exists in wiring
Step 1: Key truck ON check status of ACCESS 1 lights. (003 and 004) between ACCESS 1 CA302-9,
-8 and platform distribution panel CA105-8, -2.
• If: ACCESS 1 lights are ON. Locate and repair/replace as necessary.
– Then issue exists in wiring (003 and 004) be- Step 3: Check for CAN line for short to -BV, +BV and
tween ACCESS 1 CA302-9, 8 and platform dis- truck frame. Key OFF truck and disconnect battery. Us-
tribution panel CA105-8, 2. Check connector ing a DVOM, check resistance at the power unit from
mating, connector contact condition, proper CAN_L to BV bus bar, CAN_L to TP15 and TP16 on
contact insertion, contact crimps and wire con- power unit distribution panel and CAN_L to truck
dition. Check CAN_H and CAN_L wires are not frame. Resistance should be greater than 10,000 ohm.
reversed.
– Then replace wiring as necessary.
CA302-4.
• If: 24V.
• If: 0V.
– Then issue exists in the wiring connected to
CA302-3 or CA302-4.
• If: Issue continues.

– Then trace wiring from ACCESS 1, CA302-8 to
platform distribution panel CA105-8, -2.
Step 2: Key OFF truck using a DVOM check resistance
between CAN_H and CAN_L platform distribution
panel TP13 and TP14. Resistance should be approxi-
mately 60 ohm.
• If: 0 ohm.
CESSES. Find short by unhooking AC-
CESSES from the CAN bus one at a time and
check resistance between CAN_H and CAN_L. Figure 16967
M4.8-7335-052 SP3500 Crown 2007 PF15819-90 Rev. 8/08
02 Rev. 8/08
360
ELECTRICAL SYSTEM
Event Code 405
Event Code 405 Step 3: Check CAN line short to -BV, +BV and truck
frame. Key OFF truck disconnect battery, using a
DVOM check resistance at the power unit CAN_L to -
ACCESS 5 CAN timeout.
BV bus bar, CAN_L to TP15 and TP16 on power unit
No action taken. distribution panel and CAN_L to truck frame. Resist-
ance should be greater than 10,000 ohm.
Step 1: Key ON truck check status of ACCESS 5 lights.

– Then repair wiring as necessary.
– Then issue exists in wiring (019 and 020) be-
tween ACCESS 5 CA402-4, -5 and power unit • If: All wiring is correct.
distribution panel CA204-2, -8. Check connec-
tor mating, connector contact condition, proper – Then replace ACCESS 5 and/or ACCESS 4.
contact insertion, contact crimps and wire con-
dition. Verify that CAN_H and CAN_L wires are
not reversed.

-BV.
• If: 24V.
• If: 0V.
– Then issue exists in wiring to CA403-10.

– Then check wiring between ACCESS 5,
CA402-4, -5 and power distribution panel
Figure 16968
CA204-8, -2.
Step 2: Key OFF truck check resistance between
CAN_H and CAN_L at power unit distribution panel
TP15 and TP16. Resistance should be approximately
60 ohm.
• If: 0 ohm.
CESSES. Find short by unhooking AC-

ing. CAN bus contains two terminating resis-
ACCESS 1.
Crown 2007 PF15819-91 Rev. 8/08 SP3500 M4.8-7335-053

02 Rev. 8/08
361
ELECTRICAL SYSTEM
Event Code 411
panel CAN_L to BV bus bar and CAN_L to TP15 and
All functions disabled. TP16 and to truck frame. Resistance should be greater
than 10,000 ohm.
Step 1: Key ON truck check status of ACCESS 1

– Then check for 24V to ACCESS 1. Place
DVOM leads +BV on CA302-3 and -BV on
CA302-4.
• If: 24V.
– Then check connector terminals and wiring for
• If: 0V.
– Then issue exists in wiring between CA302-3,
CA105-10, CA302-4 and CA107-8 on the plat-
form distribution panel.
• If: Event code continues and ACCESS 1 is on.

– Then key OFF truck. Check resistance be-
tween CAN_H and CAN_L on either the power
unit or platform distribution panel. Resistance
should be 60 ohm.
• If: 0 ohm.
CESSES. Find short by unplugging AC-

nected. Figure 16969

or damaged, or wiring to the terminating resis-
tor is open. CAN bus contains two terminating
resistors, one in the ACCESS 5 and the other
in ACCESS 1.
M4.8-7335-054 SP3500 Crown 2007 PF15819-92 Rev. 8/08
02 Rev. 8/08
362
ELECTRICAL SYSTEM
Event Code 413
panel CAN_L to -BV bus bar also CAN_L to TP15 and
All functions disabled. TP16 and CAN_L to truck frame. Resistance should be
greater than 10,000 ohm.
Step 1: Turn the truck on. Verify status of ACCESS 3

– Then check for 24V to ACCESS 3 connect a
DVOM between +BV CA401-1 and -BV power
terminal.
• If: 24V.
– Then check connector, terminals and wiring for
• If: 0V.
and CA201-5 on the power unit distribution
panel.
• If: Event code continues - ACCESS 1 is ON.

unit or platform distribution panels. Resistance
should be 60 ohm.
Figure 16970
• If: 0 ohm.

nected.
resistors, one in ACCESS 5 and the other in
ACCESS 1.
Crown 2007 PF15819-93 Rev. 8/08 SP3500 M4.8-7335-055

02 Rev. 8/08
363
ELECTRICAL SYSTEM
Event Code 415
panel between CAN_L and -BV bus bar, CAN_L to

CA403-26.
• If: 24V.
• If: 0V.
– Then issue exists in wiring connected between
CA403-10 or CA403-26 and/or FU8 on the
power unit distribution panel.

ON.
unit or platform distribution panel. Resistance
should be 60 ohm.
• If: 0 ohm.
Figure 16971
nected.
resistors one in ACCESS 5 and the other in
ACCESS 1.
M4.8-7335-056 SP3500 Crown 2007 PF15819-94 Rev. 8/08
02 Rev. 8/08
364
ELECTRICAL SYSTEM
Event Code 416
panel between CAN_L and -BV bus bar also CAN_L to

CA403-26.
• If: 24V.
• If: 0V.
or CA403-26 and/or FU8 on the power unit dis-
tribution panel.

ON.
– Then key truck OFF and check resistance be-
unit or platform distribution panels. Resistance
should be 60 ohm.
• If: 0 ohm.
Figure 16971
nected.
or damaged, or the wiring to the terminating re-
sistor is open. CAN bus contains two terminat-
ing resistors one located in ACCESS 5 and the
other in ACCESS 1.
Crown 2007 PF15819-95 Rev. 8/08 SP3500 M4.8-7335-057

02 Rev. 8/08
365
ELECTRICAL SYSTEM
Event Code 421
Event Code 421

ACCESS 4 Internal Fault.
M4.8-7335-057 SP3500 Crown 2007 PF15819-96 Rev. 8/08
02 Rev. 8/08
366
ELECTRICAL SYSTEM
Event Code 422
Event Code 422

ACCESS 4 Potentiometer 1 (POT1) +5V Power Sup-
ply Out of Range.
Step 1: Using a DVOM, check for 5V between wire 701
CA303-4 and TP16 power unit distribution panel.

– Then check for 5V at CA309-2 and TP16.
• If: 0V.
• If: Less than 5V and event code continues.

– Then remove wire 701 from CA303-4 and, with
a DVOM, check for 5V between CA303-4 and
TP16.

• If: 5V.
– Then a short exists in wiring. Repair/replace
wiring as necessary.
Figure 16972
Crown 2007 PF15819-97 Rev. 8/08 SP3500 M4.8-7335-058

02 Rev. 8/08
367
ELECTRICAL SYSTEM
Event Code 423
Event Code 423

ACCESS 4 Potentiometer 1 (POT1) is Out of Electri-
cal Limits.
Step 1: Enter Service Mode 2 then Analyzer. Select
POT1 A2.3.3 on display menu and view reading on dis-
play.
• If: Approximately 5V or greater.

– Then POT1 is either incorrectly wired, wire be-
tween POT1 and ACCESS 4 is shorted to the
truck frame or an open wire exists. Check con-
dition and correctness of wiring and connector
terminals between ACCESS 4 CA303-1, -4,
-19 and POT1.


– Then multi-task handle in center position.

– Then multi-task handle in full forward position.
Figure 16973
– Then multi-task handle in full reverse position.
• If: Correct POT1 readings are confirmed.

– Then an intermittent connection in POT1 circuit
might exist. Inspect POT1, wiring to POT1 and
terminals in connector at ACCESS 4 CA303-1,
-4, -19.
• If: All check correctly.

• If: Below 0.7V.

– Then POT1 is incorrectly wired, wires between
POT1 and ACCESS 4 are shorted together or
a wire is open. Check condition and correct-
ness of wiring and connector terminals be-
tween ACCESS 4 CA303-1, -4, -19 and POT1.

M4.8-7335-059 SP3500 Crown 2007 PF15819-98 Rev. 8/08
02 Rev. 8/08
368
ELECTRICAL SYSTEM
Event Code 424

ACCESS 4 Potentiometer 1 (POT1) Does Not Match ACCESS 4 Potentiometer 1 (POT1) Does Not Match
Forward Switch (FS). Reverse Switch (RS).
Step 1: FS/POT1 operation. Enter Service Mode 2 and Step 1: RS/POT1 operation enter Service Mode 2. Se-
select handle analyzer menu. Input status of FS, with lect handle Analyzer menu. Input status of RS, with
handle in neutral, should be open as indicated by 0 on handle in neutral, should be open as indicated by 0 on
display A2.3.7. POT1 reading on display A2.3.3 should display A2.3.6. POT1 reading on display A2.3.3 should
be between 2.1 to 2.9 volts. Moving handle to full for- be between 2.1 to 2.9 volts. Moving the handle to full
ward position should toggle switch to closed, display to forward position should toggle switch to closed, display
1 A2.3.7. Reading for POT1 A2.3.3 should go between to 1 A2.3.6. Reading for POT1 A2.3.3 should go be-
4.0 to 4.6 volts. tween 4.0 to 4.6 volts.
• If: Readings are not as listed. • If: Readings are not as listed.
– Then check switch for damaged wiring or phys- – Then check switch for damaged wiring or phys-
ical damage. Wire 2907 to FS and wire 2908 to ical damage. Wire 2907 to FS and wire 2908 to
RS. RS.
• If: Damaged. • If: Damaged.

– Then replace switches as needed, taking care – Then replace switches as needed, taking care
to properly route harness. After switch replace- to properly route harness. After switch replace-
ment, calibrate handle. ment, calibrate handle.
• If: POT1 not within limits. • If: POT1 not within limits.
– Then recalibrate handle. – Then recalibrate handle.
Crown 2007 PF15819-99 Rev. 8/08 SP3500 M4.8-7335-060

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369
ELECTRICAL SYSTEM
Event Code 426

ACCESS 4 Forward Switch (FS) and Reverse ACCESS 4 Potentiometer 1 (POT1) and Reverse
Switch (RS) Closed at Same Time. Switch (RS) Out of Range.
Step 1: Check FS and RS for damage to wiring or Step 1: Using a DVOM, check for 5V between
switch and mounting. CA303-19 and TP16 on the platform distribution panel.
• If: Damaged. • If: Greater than 5V.

– Then replace switch and calibrate handle. – Then check wires 581 CA303-19, wire 506
CA309-3 and wire 519 CA307-5 for shorts to
• If: Correct. +BV or truck frame.
– Then proceed to Step 2. • If: 0V.
Step 2: Enter Service Mode 2 and select analyzer
menu for FS A2.3.7 and RS A2.3.6. Check status of FS
and RS with handle in neutral position.
• If: Either FS or RS is 1.
– Then select that switch to use in Step 3.
• If: Both FS and RS are 1.

– Then choose either switch and proceed to Step
3.
Step 3: Check switch function by disconnecting output
wire of selected switch, wire 2907 on FS or wire 2908
on RS.
• If: Selected switch display changes to 0 when

switch wire is disconnected.
– Then replace switch and calibrate handle.
• If: Selected switch display is 1 with handle in neu-

tral.
Figure 16974
M4.8-7335-061 SP3500 Crown 2007 PF15819-100 Rev. 8/08
02 Rev. 8/08
370
ELECTRICAL SYSTEM
Event Code 429
Event Code 429

ACCESS 4 Encoders ECR1/ECR5 Count Error.
Note: Event code is logged if count between ECR1/
ECR5 is not equal. Possibly due to loss of power and
or Channel A or B of either encoder.



– Then issue may exist due to intermittent ECR1,
ECR5, ACCESS 4 and/or wiring in between
these components. Proceed through Steps 3
and 4, repairing any issues encountered.

Step 3: Key truck OFF. Check steer tiller for slippage Figure 16975
CA318.

-23.
• If: Wiring and/or terminals issues are found.

Crown 2007 PF15819-101 Rev. 8/08 SP3500 M4.8-7335-062

02 Rev. 8/08
371
ELECTRICAL SYSTEM
Event Code 429


12V.



CA304-18, -19.


CA318-3 to CA304-18 and CA318-4 to
CA304-19.
Figure 16976
M4.8-7335-063 SP3500 Crown 2007 PF15819-102 Rev. 8/08
02 Rev. 8/08
372
ELECTRICAL SYSTEM
Event Code 429
Step 6: Disconnect CA318 and key truck ON. Check

for 12V to ECR5 at CA318-7, -8.

– Then reconnect CA318 and check for 5V.


• If: Not between 11.5V-12.5V with CA318 still dis-

connected.
CA304-20, -21.


CA318-7 and CA304-21 also from CA318-8
and CA304-20.
Figure 17024
Step 7: Reconnect CA318 and key truck ON. Check for

encoder counts to ECR1 CHA. Connect DVOM be-
tween CA304-16 (-17 on "forks first steer" trucks) and
-19 turn the steer tiller slowly.

• If: Voltage does not change back and forth from

0.5V to 11.5V.
tween CA318-1, -4.

CA318.

Crown 2007 PF15819-103 Rev. 8/08 SP3500 M4.8-7335-064

02 Rev. 8/08
373
ELECTRICAL SYSTEM
Event Code 429

nected, check ECR1 CHB encoder counts. Connect a
DVOM between CA304-18, -19 and slowly turn the
steer tiller.


– Then check voltage for CH B between
CA318-2, -4.

CA318.

Figure 17025
M4.8-7335-065 SP3500 Crown 2007 PF15819-104 Rev. 8/08
02 Rev. 8/08
374
ELECTRICAL SYSTEM
Event Code 429

nected, check ECR5 CHA for encoder counts. Connect
a DVOM to CA304-22 (-23 on "forks first steer" trucks)
and -20 and slowly turn the steer tiller.


– Then check ECR5 CHA voltage between
CA318-5, -8.

CA318.


code continues.
– Then replace ACCESS 4. Figure 17026

CA318-6, -8.

CA318.

Crown 2007 PF15819-105 Rev. 8/08 SP3500 M4.8-7335-066

02 Rev. 8/08
375
ELECTRICAL SYSTEM
Event Code 430
Event Code 430

ACCESS 4 Encoders ECR1/ECR5 Turn Rate Error.
Note: Event is logged should rate difference between
ECR1/ECR5 occur. ECR1/ECR5 turn at the same rate
through the steer tiller cause for this event code could
be ECR slippage, failure, open or intermittent wiring
between ECR1/ECR5 and ACCESS 4.



– Then issue may be due to intermittent ECR1,
ECR5, ACCESS 4 and/or wiring in between
these components. Proceed through Steps 3
and 4, repairing any issues encountered.

– Then proceed to Step 3. Figure 16975

CA318.

-23.
• If: Wiring and/or terminal issues are found.

M4.8-7335-067 SP3500 Crown 2007 PF15819-106 Rev. 8/08
02 Rev. 8/08
376
ELECTRICAL SYSTEM
Event Code 430


12V.



CA304-18, -19.


CA318-3 and CA304-18 also CA318-4 to
CA304-19.
Figure 17025
Step 6: Disconnect CA318 and key truck ON to check
for 12V to ECR5 at CA318-7, -8. Step 7: Reconnect CA318 and key truck ON to check
for encoder counts to ECR1 CHA. Connect DVOM be-
• If: Between 11.5V-12.5V. tween CA304-16 (-17 on "forks first steer" trucks) and
– Then reconnect CA318 and check for 5V. -19 and turn the steer tiller slowly.
• If: Not between 11.5V-12.5V. • If: Voltage slowly changes from 0.5V to 11.5V.
– Then replace ECR5. – Then proceed to Step 8.
• If: Between 11.5V-12.5V. • If: Voltage does not change back and forth from
0.5V to 11.5V.
• If: Not between 11.5V-12.5V with CA318 still dis- tween CA318-1, -4.
connected.
CA304-20, -21. – Then check wire harness between CA304 and
CA318.
– Then check harness continuity between
CA318-7 and CA304-21, CA318-8 and
CA304-20.
Crown 2007 PF15819-107 Rev. 8/08 SP3500 M4.8-7335-068

02 Rev. 8/08
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ELECTRICAL SYSTEM
Event Code 430
Step 8: Key truck ON with CA318 and CA304 con- Step 9: Key truck ON. With CA318 and CA304 con-
nected check ECR1 CHB encoder counts. Connect a nected, check ECR5 CHA for encoder counts. Connect
DVOM between CA304-18, -19 and slowly turn the a DVOM to CA304-22 (-23 on "forks first steer" trucks)
steer tiller. and -20 and slowly turn the steer tiller.
– Then proceed to Step 9. – Then proceed to Step 10.
– Then check voltage for CHB between – Then check ECR5 CHA voltage between
CA318-2, -4. CA318-5 and -8.
– Then check wire harness between CA304 to – Then check wire harness between CA304 to
CA318. CA318.
– Then replace ECR1. – Then replace ECR5.
–
Figure 17025
M4.8-7335-069 SP3500 Crown 2007 PF15819-108 Rev. 8/08
02 Rev. 8/08
378
ELECTRICAL SYSTEM
Event Code 430

code continues.

CA318-6 and -8.

CA318.

Figure 17026
Crown 2007 PF15819-109 Rev. 8/08 SP3500 M4.8-7335-070

02 Rev. 8/08
379
ELECTRICAL SYSTEM
Event Code 431
Event Code 431

ACCESS 4 Encoders ECR1/ECR5 Direction Error.
Note: ECR1/ECR5 turn at the same time, should a dif-
ference in direction occur due to a wiring error or slip-
page event code 431 will be logged.
Step 1: Enter service mode 2 and select ECR1 A2.3.2


Step 2: Enter service mode 2 select ECR5 A2.3.2 in
analyzer menu. View reading on the display.

– Then the issue may be due to intermittent
ECR1, ECR5, ACCESS 4 and/or wiring in be-
tween these components. Proceed through
Steps 3 and 4, repairing any issues encoun-
tered.

CA318.
Figure 17877
Step 5: ECR1 test. Disconnect CA318 and key truck
– Then repair as necessary. ON. Using a DVOM check for 12V to ECR1 between
CA318-3, -4.
Step 4: Key truck OFF. Check ECR1/ECR5 wire con-
nections at ACCESS 4. ECR1 CA304-18, -16, -17, -19 • If: Between 11.5V/12.5V.
and ECR5 CA304-21, -22, -23, -20.
– Then key truck OFF and reconnect CA318 and
• If: Wire issues exist. again check for 12V.
– Then repair as necessary. • If: Not between 11.5V/12.5V.
• If: Between 11.5V/12.5V.

M4.8-7335-071 SP3500 Crown 2007 PF15819-110 Rev. 8/08
02 Rev. 8/08
380
ELECTRICAL SYSTEM
Event Code 431
Step 6: ECR5 test. Disconnect CA318 and key truck Step 7: Connect CA318 and CA304, key truck ON.
ON. Using a DVOM check for 12V to ECR5 between Connect a DVOM between CA304-11, -19 and slowly
CA318-7, -8. turn the steer tiller.
• If: Between 11.5V/12.5V. • If: Voltage changes from 0.5V to 11.5V.

– Then key truck OFF and reconnect CA318 and – Then proceed to Step 8.
– Then check for CHA voltage between
– Then replace ECR5. CA318-1, -4.
• If: Between 11.5V/12.5V. • If: Voltage changes from 0.5 to 11.5V.

– Then proceed to Step 7. – Then check wire harness from CA304 to
CA318.

Figure 17937
Crown 2007 PF15819-111 Rev. 8/08 SP3500 M4.8-7335-072

02 Rev. 8/08
381
ELECTRICAL SYSTEM
Event Code 431
Step 8: With power on and CA318/CA304 connected,

check for encoder counts to ECR1 CHB. Connect me-
ter between CA304-12, -19 then slowly turn the steer
tiller.


– Then check for CHB voltage between
CA318-2, -4.

CA318.

Figure 17938
M4.8-7335-073 SP3500 Crown 2007 PF15819-112 Rev. 8/08
02 Rev. 8/08
382
ELECTRICAL SYSTEM
Event Code 431

connected, check for encoder counts to ECR5 CHA.
the steer tiller.
• If: Voltage from 0.5V to 11.5V.


– Then check voltage for CHA between
CA318-5, -8.

CA318.

connected, check for encoder counts to ECR5 CHB.
the steer tiller.

code continues.

– Then check for voltage to CHB between
CA318-6, -8.

CA318.

Figure 17939
Crown 2007 PF15819-113 Rev. 8/08 SP3500 M4.8-7335-074

02 Rev. 8/08
383
ELECTRICAL SYSTEM
Event Code 432
Event Code 432

ACCESS 4 Height Encoder 4 (ECR4) Power Supply
Out of Range.
Step 1: Connect DVOM leads between CA303-12 and
-BV then key truck ON.
• If: Voltage is not between 4.75V and 5.5V.

– Then disconnect wire from CA303-12 and
check voltage at CA303-12.
• If: Voltage is between 4.75V and 5.5V with wire re-

moved.
– Then short exists in wiring or ECR4. Check wir-
ing between ECR4 and CA303-12 thru -15.
Verify that insulation is not cut and shorted to
frame.

• If: Voltage is not between 4.75-5.5V with wire re-

moved.
Figure 17878
M4.8-7335-075 SP3500 Crown 2007 PF15819-114 Rev. 8/08
02 Rev. 8/08
384
ELECTRICAL SYSTEM
Event Code 433
Event Code 433

Step 1: Key truck OFF the ON.

Crown 2007 PF15819-115 Rev. 8/08 SP3500 M4.8-7335-075

02 Rev. 8/08
385
ELECTRICAL SYSTEM
Event Code 433
Notes:
M4.8-7335-076 SP3500 Crown 2007 PF15819-116 Rev. 8/08
02 Rev. 8/08
386
ELECTRICAL SYSTEM
Event Code 435
Event Code 435 Step 5: Disconnect CA317 using a DVOM check volt-
age to ECR4 between CA317-3, -4.
ACCESS 4 Height Encoder 4 (ECR4) Reset Error. • If: 5V.
Full traction and raise speed 2 disabled. – Then reconnect CA317 and proceed to Step 6.
Step 1: Fully lower platform then raise approximately
three feet and lower.
• If: Not 5V.
• If: Event code repeats.
and using a DVOM check voltage between pins
– Then proceed to Step 2. CA303-12, -15.
• If: Event code does repeat. • If: 5V.
– Then resume truck operation and monitor. – Then check all wiring. Wire 703 CA303-12 to
A2.3.1.1, fully lowered raise platform and observe dis- • If: Not 5V.
play.
• If: Height in inches changes.
• If: Height in inches does not change.

A2.3.10. A fully lowered raise platform approximately
three feet at 18 inches the height reset switch (HTGRS)
state should change from closed to open.
• If: State does not change.

– Then check HTGRS and associated wiring.
Step 4: Disconnect CA317 and check encoder wiring
for damaged crimps. If necessary remove wires from
connector for inspection.
• If: Wiring crimps are damaged.

– Then repair or replace ECR 4 as necessary.
Pin 1: White
Pin 2: Blue
Pin 3: Red
Pin 4: Black
Crown 2007 PF15819-117 Rev. 8/08 SP3500 M4.8-7335-077

02 Rev. 8/08
387
ELECTRICAL SYSTEM
Event Code 440
Step 6: Check ECR4 channel wiring. Wire 007 Event Code 440
CA317-1 to CA303-13, wire 008 CA317-2 to
CA303-14.
ACCESS 4 Zone Select (ZSS) Switch Wiring Open.
• If: Wiring is correct and event code continues. Raise disabled.
– Then disconnect CA317, remove white and Note: If the zone select option is enabled in the truck
blue wires from JC317-1 and JC317-2. Con- features the truck requires that one of the three outputs
nect a DVOM from white (ECR4 CHA) to -BV, from the switch be closed. This condition indicates that
key ON truck and check voltage. Reading the feature is enabled and none of the three outputs
should be either 0V or 5V depending on posi- are closed or the wire feeding the switch is open.
tion of ECR4. Perform the same test on the
blue wire (ECR4 CH B). Step 1: Check zone select switch.
• If: Not 0V or 5V. • If: Zone switch is broken.
– Then replace ECR4. – Then replace as necessary.
• If: 0V or 5V. • If: Zone switch is enabled and truck is not equipped
with zone select.
– Then reconnect wiring.
– Then access service level 2 mode and disable
• If: 0V or 5V and event code continues. zone select feature.
– Then replace ACCESS 4. • If: Zone switch is enabled and is present.

– Then check wiring between zone select switch
and ACCESS 4.

Figure 17879
M4.8-7335-078 SP3500 Crown 2007 PF15819-118 Rev. 8/08
02 Rev. 8/08
388
ELECTRICAL SYSTEM
Event Code 441
Event Code 441

ACCESS 4 Zone Select (ZSS) Switch Wiring
Shorted.
Raise disabled.
Note: If the zone select option is enabled in the truck
features the truck requires that one of the three outputs
from the switch be closed. This condition indicates that
more than one of the switch outputs are closed simul-
taneously and therefore the truck can not see the re-
quested zone.
Step 1: Check condition of wiring between switch and
CA303-23, CA304-13, -14.
• If: Wires are shorted.

• If: Wires are correct.

Step 2: Using a DVOM check the ZSS for internal
shorts. Each individual internal switch must be isolated
from the other.
• If: Switch is shorted.

– Then replace ZSS switch.
• If: Switch is correct and event code continues.

Figure 17880
Crown 2007 PF15819-119 Rev. 8/08 SP3500 M4.8-7335-079

02 Rev. 8/08
389
ELECTRICAL SYSTEM
Event Code 442
Event Code 442

ACCESS 4 Zone Select Switch (ZSS) Detected, but
Feature Not Enabled.
Raise disabled.
Note: If truck has zone select option refer to Step 1. If
truck does not have zone select option, then refer to
Step 2.
and enable zone select.

Step 2: Enter service mode 2 go to features and zone
select.
• If: Zone select is enabled.

– Then disable.
• If: Zone select is disabled.

– Then connect a DVOM to TP7 on platform dis-
tribution panel and check for 24V between
CA303-23, CA304-13, -14.
• If: 24V is not present at any point.

• If: Any terminal is shorted to negative.

– Then repair short as necessary.
Figure 17881
M4.8-7335-080 SP3500 Crown 2007 PF15819-120 Rev. 8/08
02 Rev. 8/08
390
ELECTRICAL SYSTEM
Event Code 443
Event Code 443

ACCESS 4 Invalid Zone Select Setup.
Raise disabled.
menu, enter correct cutout configuration setups.

Crown 2007 PF15819-121 Rev. 8/08 SP3500 M4.8-7335-080

02 Rev. 8/08
391
ELECTRICAL SYSTEM
Event Code 445
Event Code 445

ACCESS 4 (lifting fork option only) PVLF Driver
Open.
Nothing disabled.
coil.

• If: 29 ohm.
– Then check for 24V between wires 29129,
29130 and 5938 while depressing lifting forks
lower switch.
• If: 0V.
the platform distribution panel while depressing
lower switch.
• If: 0V.
• If: 24V.
– Then check for 24V between wire 29129,
29130 and TP3 on the power unit distribution
panel.
• If: 0V.
ing.
• If: 24V.
– Then check connection of CA325, CA701, and
CA809.
Figure 17882
M4.8-7335-081 SP3500 Crown 2007 PF15819-122 Rev. 8/08
02 Rev. 8/08
392
ELECTRICAL SYSTEM
Event Code 446
Event Code 446

ACCESS 4 (Lifting Fork Option Only) PVLF
Shorted.
Nothing disabled.
coil.

• If: 29 ohm.
5941 from CA304-4 and check for 24V be-
tween PC304-4 and TP7 on the platform distri-
bution panel.
• If: 24V.
– Then wire 5941, 5936, 5938, or the mast cable
red wire is shorted to +BV repair/ replace.
• If: 0V.
Figure 17883
Crown 2007 PF15819-123 Rev. 8/08 SP3500 M4.8-7335-082

02 Rev. 8/08
393
ELECTRICAL SYSTEM
Event Code 447
Event Code 447

ACCESS 4 (Lifting Fork Option Only) SV1 Shorted.
Nothing disabled.
Step 1: Disconnect wires 29130 and 5937 from SV1
coil using a DVOM check resistance of SV1 coil.

– Then replace SV1 coil.
• If: 29 ohm.
5942 from CA304-5. Check for 24V between
panel.
• If: 24V.
– Then wire 5942, 5935, 5937 or mast cable
green wire is shorted to +BV repair/ replace.
• If: 0V.
Figure 17884
M4.8-7335-083 SP3500 Crown 2007 PF15819-124 Rev. 8/08
02 Rev. 8/08
394
ELECTRICAL SYSTEM
Event Code 448

THRU
ACCESS 4 Travel Alarm (ALM2) Driver Shorted.
Step 1: Disconnect wire 5915 from CA304-7. Check for
24V between PC304-7 and TP7 on the platform distri-
bution panel.
• If: 24V.
– Then wire 5915 is shorted to +BV repair/ re-
place.
• If: 0V.
Figure 17885
Crown 2007 PF15819-125 Rev. 8/08 SP3500 M4.8-7335-084

02 Rev. 8/08
395
ELECTRICAL SYSTEM
Event Code 452

ACCESS 4 Internal Driver Shorted. ACCESS 4 Chain Break.
Event Code 449 and 452: Traction and raise disabled. Hydraulics disabled.
Event Code 450: Raise disabled. Step 1: Check lift chain.
Event Code 451: Nothing disabled. • If: Correct.
Step 1: Replace ACCESS 4. – Then proceed to Step 2.
• If: Broken.
Step 2: Check chain break switch wiring.
• If: Correct.
– Then check wire 29123, CA303-3 to CA331
and wire 29124, CA331 to CA103-14 and cable
assembly between harness and switches. Us-
ing a DVOM, check for 24V between CA303-3
and TP7 on platform distribution panel.
• If: 24V.
• If: 0V.
– Then check terminal conditions.
Figure 17027
M4.8-7335-085 SP3500 Crown 2007 PF15819-126 Rev. 8/08
02 Rev. 8/08
396
ELECTRICAL SYSTEM
Event Code 460
Event Code 460

THRU
Crown 2007 PF15819-127 Rev. 8/08 SP3500 M4.8-7335-086

02 Rev. 8/08
397
ELECTRICAL SYSTEM
Event Code 462
Event Code 462 platform distribution panel and CAN_L to truck frame.
Resistance should be greater than 10,000 ohm.
fast.
No action taken.
Step 1: Verify correct ACCESSES are in place on the
truck.
• If: Any new ACCESSES have recently been in-

stalled.
– Then check connections and software.

started or stopped.
ED1 contactor opens or closes check ED1 con-
tactor coil and suppression).
form distribution panels, resistance should be 60 ohm. Figure 17886
• If: 0 ohm.
may exist in an ACCESS. Determine this con-
dition by disconnecting ACCESS from the CAN
bus one at a time and measure resistance be-
tween CAN_H and CAN_L.

nected.
damaged or wiring to terminating resistor is
open. CAN bus contains two terminating resis-
ACCESS 1.
M4.8-7335-086 SP3500 Crown 2007 PF15819-128 Rev. 8/08
02 Rev. 8/08
398
ELECTRICAL SYSTEM
Event Code 463
Event Code 463

THRU
Crown 2007 PF15819-129 Rev. 8/08 SP3500 M4.8-7335-087

02 Rev. 8/08
399
ELECTRICAL SYSTEM
Event Code 465
Event Code 465 • If: If less than 10,000 ohm.

ACCESS 6 CAN Error.
Event Code 463: ACCESS 6 receiving packets too
fast.
No action taken.
Step 1: Verify correct ACCESSES are in place on the
truck.
• If: Any new ACCESS has recently been installed.

– Then check connections and software.

started or stopped.
Figure 17886
• If: 0 ohm.
dition by disconnecting the ACCESS from the
CAN bus one at a time and measure resistance
between CAN_H and CAN_L.

nected.
damaged or wiring to terminating resistor is
open. CAN bus contains two terminating resis-
ACCESS 1.
Resistance should be greater than 10,000 ohm.
M4.8-7335-087 SP3500 Crown 2007 PF15819-130 Rev. 8/08
02 Rev. 8/08
400
ELECTRICAL SYSTEM
Event Code 466
Event Code 466

THRU
Crown 2007 PF15819-131 Rev. 8/08 SP3500 M4.8-7335-088

02 Rev. 8/08
401
ELECTRICAL SYSTEM
Event Code 469
Event Code 469 • If: Greater than 65 ohm with all connectors con-
nected.
ACCESS 1 CAN Error. – Then a CAN bus-terminating resistor is open,
Event Code 466: ACCESS 1 receiving packets too damaged or wiring to terminating resistor is
fast. open. CAN bus contains two terminating resis-
Event Code 467: ACCESS 1 receiving short packets. ACCESS 1.
Event Code 468: ACCESS 1 receiving long packets. Step 4: Check for CAN line short to -BV, +BV and truck
Event Code 469: ACCESS 1 receiving duplicate ID. frame. Key truck OFF and disconnect battery. Using a
No action taken. panel CAN_L to -BV bus bar then CAN_L to TP3 on the
Step 1: Verify correct ACCESSES are in place on the platform distribution panel and CAN_L to truck frame.
truck. Resistance should be greater than 10,000 ohm.
• If: Any new ACCESS has recently been installed. • If: Less than 10,000 ohm.
– Then check connections and software. – Then repair/replace wiring as necessary.


started or stopped.
sion (for example if event code is logging when
• If: 0 ohm.
dition by disconnecting ACCESS from the CAN
bus one at a time and measure resistance be-
tween CAN_H and CAN_L.
Figure 17886
M4.8-7335-088 SP3500 Crown 2007 PF15819-132 Rev. 8/08
02 Rev. 8/08
402
ELECTRICAL SYSTEM
Event Code 470
Event Code 470

THRU
Crown 2007 PF15819-133 Rev. 8/08 SP3500 M4.8-7335-089

02 Rev. 8/08
403
ELECTRICAL SYSTEM
Event Code 473
Event Code 473 • If: Greater than 65 ohm with all connectors con-
nected.
ACCESS 4 CAN Error. – Then a CAN bus-terminating resistor is open,
Event Code 470: ACCESS 4 receiving packets too damaged or wiring to terminating resistor is
fast. open. CAN bus contains two terminating resis-
Event Code 471: ACCESS 4 receiving short packets. ACCESS 1.
Event Code 472: ACCESS 4 receiving long packets. Step 4: Check for CAN line short to -BV, +BV and truck
Event Code 473: ACCESS 4 receiving duplicate ID. frame. Key truck OFF and disconnect battery. Using a
No action taken. panel CAN_L to -BV bus bar then CAN_L to TP3 on the
Step 1: Verify correct ACCESSES are in place on the platform distribution panel and CAN_L to truck frame.
truck. Resistance should be greater than 10,000 ohm.
• If: Any new ACCESS has recently been installed. • If: Less than 10,000 ohm.
– Then check connections and software. – Then repair/replace wiring as necessary.


started or stopped.
• If: 0 ohm.
may exist in an ACCESS). Determine this con-
dition by disconnecting the ACCESS from the
CAN bus one at a time and measure resistance
between CAN_H and CAN_L.
Figure 17886
M4.8-7335-089 SP3500 Crown 2007 PF15819-134 Rev. 8/08
02 Rev. 8/08
404
ELECTRICAL SYSTEM
Event Code 473
Notes:
Crown 2007 PF15819-135 Rev. 8/08 SP3500 M4.8-7335-090

02 Rev. 8/08
405
Event Code 501
ACCESS 5 Communication (CAN) with ACCESS 1 Timeout.
Note 1: Intermittent disruption of CAN communication between ACCESS 5 and ACCESS 1 will log event code
501 (ACCESS 5 will flash event code 501). ACCESS 1 must receive event code 501 from ACCESS 5 to illuminate
the service required indicator (wrench shaped light). Illumination of the indicator shows communication between
ACCESS 5 and ACCESS 1 has been intermittently disrupted.
Note 2: Complete loss of CAN communication between ACCESS 5 and ACCESS 1 after power up and initializa-
tion will log event code 501. ACCESS 5 will flash event code 501. Should this condition exists CAN communication
between ACCESS 5 and ACCESS 1 is disabled, ACCESS 1 will not log event code 501 and the wrench light will
not illuminate.
Step 1: Determine which ACCESS is indicating the event.
• If: ACCESS 1 displays the wrench and event code 501 is logged.
• If: ACCESS 1 has no wrench. Traction, hydraulics and steering are disabled and ACCESS 5 is flashing event
code 501.
406
ELECTRICAL SYSTEM
Event Code 501
Step 2: Intermittent communication event has occurred

between ACCESS 1 and ACCESS 5. Check for addi-
tional event codes.
• If: Event codes 301 or 401 are logged.

– Then disconnect plug CA302 and, using a
DVOM, check for 24V between wire 513
CA302-4 and wire 2941 CA302-3 on the plug.
• If: 24V.
– Then check CAN wiring between ACCESS 1
and platform distribution panel. Wire 003 be-
tween CA302-8 and CA105-2 also wire 004 be-
tween CA302-9 and CA105-8.
• If: Event codes 305, 405 have been logged.

– Then check CAN bus wiring between power
unit distribution panel and ACCESS 5. Wire
019 CA402-4 to CA204-2 and wire 020
CA402-5 to CA204-8.
Step 3: Communication lost between ACCESS 1 and
5. ACCESS 5 is flashing 501 event code. Key truck
OFF then ON.
• If: ACCESS 1 does not turn ON.

wire 2941 CA103-10 and wire 513 CA107-8.
• If: 0V.
– Then check wiring and connections. Wire 2941
CA302-3 to CA103-10 and wire 513 CA302-4
to CA107-8.
• If: 24V and ACCESS 1 does not turn ON.

• If: ACCESS 1 turns ON wrench illuminated and

logs event codes 305 and 405.
power unit distribution panel and ACCESS 5. Figure 16724
Check wire 019 CA402-4 to CA204-2 and wire
020 CA402-5 to CA204-8.
SP3500 M4.8-7335-092
02 Rev. 8/08
407
ELECTRICAL SYSTEM
Event Code 503
Event Code 503

Timeout.

and connections. Wire 018 CA401-15 to


– Then issue exists in the power wiring between
power unit distribution panel and ACCESS 3.
Using a DVOM check for 24V between
CA401-1 and ACCESS 3 -BV.
• If: 24V.
• If: 0V.
and power unit distribution panel check wiring
Figure 16725
CA201-5.
M4.8-7335-093 SP3500
02 Rev. 8/08
408
ELECTRICAL SYSTEM
Event Code 504
Event Code 504

Timeout.



form distribution panel and ACCESS 4, check Figure 16726
wiring and connections. Using a DVOM check
for 24V between CA304-1 and -BV.
• If: 24V.
• If: 0V.
and platform distribution panel check wiring
SP3500 M4.8-7335-094
02 Rev. 8/08
409
ELECTRICAL SYSTEM
Event Code 505
Event Code 505

ACCESS 5 CAN Reset.
No action taken.
Note: Should a reset occur the truck will restore func-
tionality without any changes in performance. There is
no need for service intervention with occasional occur-
rences. However if this event becomes an issue, then
follow Step 1 below.
Step 1: Check CAN connections between ACCESS 5
and power unit distribution panel. Wire 019 CA402-4 to

Figure 16727
M4.8-7335-095 SP3500
02 Rev. 8/08
410
ELECTRICAL SYSTEM
Event Code 506
Event Code 506 • If: ACCESS 6 lights are OFF.

ACCESS 5 /ACCESS 6 CAN Error. form distribution panel and ACCESS 6, check
All functions disabled. wiring and connections. Using a DVOM check
for 24V between CA601-1 and CA601-2.
• If: 24V.
distribution panel and ACCESS 6, check wiring • If: 0V.
CA204-3 and wire 022 CA601-5 to CA204-9. – Then issue exists in wiring between ACCESS 6
and power unit distribution panel check wiring
• If: Wiring is correct. and connections. Wire 2972 CA601-1 to
CA201-6 and wire 552 CA601-2 to -BV.
Figure 16728
SP3500 M4.8-7335-095
02 Rev. 8/08
411
ELECTRICAL SYSTEM
Event Code 511
Event Code 511

THRU
M4.8-7335-096 SP3500
02 Rev. 8/08
412
ELECTRICAL SYSTEM
Event Code 512
Event Code 512

SP3500 M4.8-7335-096
02 Rev. 8/08
413
ELECTRICAL SYSTEM
Event Code 513
Event Code 513

THRU
M4.8-7335-096 SP3500
02 Rev. 8/08
414
ELECTRICAL SYSTEM
Event Code 514
Event Code 514

No action taken.
SP3500 M4.8-7335-096
02 Rev. 8/08
415
ELECTRICAL SYSTEM
Event Code 515
Event Code 515

THRU
M4.8-7335-096 SP3500
02 Rev. 8/08
416
ELECTRICAL SYSTEM
Event Code 521
Event Code 521

SP3500 M4.8-7335-096
02 Rev. 8/08
417
ELECTRICAL SYSTEM
Event Code 522
Event Code 522

THRU
M4.8-7335-096 SP3500
02 Rev. 8/08
418
ELECTRICAL SYSTEM
Event Code 523
Event Code 523

ACCESS 5 +5V Power Supply Out of Range.
Steering and traction disabled. PDS/Forks First (522).
Step 1: Using a DVOM, connect the negative lead to
-B on ACCESS 5 and with the positive lead check for
+5V at CA403-20 and CA403-21.
• If: 5V (+/- 0.1V) and event code continues.


and -B.
• If: 5V (+/- 0.1V).

– Then issue exists in ECR2 or wiring. Recon-
nect wire 706 and proceed to Step 2.
Figure 16729
and -B.
Step 2: Unplug CA410 (ECR2) and, using a DVOM,
check for +5V between CA403-20 and ACCESS 5 -B.

CA403 and CA410. Check wire 706 between
CA410-4 and CA403 20 also wire 540 between
CA410-2 and CA403-12.
• If: 5V.
SP3500 M4.8-7335-096
02 Rev. 8/08
419
ELECTRICAL SYSTEM
Event Code 526
Event Code 526

THRU
M4.8-7335-097 SP3500
02 Rev. 8/08
420
ELECTRICAL SYSTEM
Event Code 527
Event Code 527

ACCESS 5 Brake +BV Out of Range.
Event Code 526: Full traction disabled. This event code
is logged when either inner or outer brake coil is above
range.
Event Code 527: Traction disabled. This event code is
logged when both inner and outer brake coils are below
range.
Step 1: Check status of event codes 540, 528, 529,
530 and 531, if any of these codes have been logged
resolve them before proceeding to 526 and 527.
• If: Only event codes 526 and 527 are constantly

logged.
SP3500 M4.8-7335-097
02 Rev. 8/08
421
ELECTRICAL SYSTEM
Event Code 528
Event Code 528

tinuing.
• If: 36V, 48, 80V.

M4.8-7335-097 SP3500
02 Rev. 8/08
422
ELECTRICAL SYSTEM
Event Code 529
Event Code 529 Step 1: Check FU6.
• If: FU6 in good condition.

contacts also if any other event codes have been • If: ED2 contacts in good condition.
tinuing. – Then check for 24V between CA403-7 and
-BV.
Inner Brake +BV under range. Traction disabled.
Figure 16758
SP3500 M4.8-7335-097
02 Rev. 8/08
423
ELECTRICAL SYSTEM
Event Code 530
Event Code 530

tinuing.
• If: 36V, 48, 80V.

M4.8-7335-097 SP3500
02 Rev. 8/08
424
ELECTRICAL SYSTEM
Event Code 531

ACCESS 5 Inner Brake Coil +B Out of Range. ACCESS 5 +5V Power Supply Voltage Out of
Range.
contacts also if any other event codes have been No action taken.
tinuing.
Inner Brake +BV under range - traction disabled. • If: 5V (+/- 0.1V).
Step 1: Check FU5. – Then monitor for event codes 540 and 541.
• If: FU5 in good condition. • If: Not 5V.
– Then check condition of ED2 contacts. – Then disconnect wire 705 from CA403-27 and
• If: ED2 contacts in good condition.
• If: 5V.
-BV. – Then reconnect wire 705 to CA403-27 and pro-
ceed to Step 2.
• If: Not 5V.
• If: Not 5V.

ACCESS 5 and CA406.
• If: 5V.
Figure 16759
SP3500 M4.8-7335-098
02 Rev. 8/08
425
ELECTRICAL SYSTEM
Event Code 533
Event Code 533

Range.
No action taken.
• If: 5V (+/- 0.1V).

• If: Not 5V.

• If: 5V.
ceed to Step 2.
Figure 16760 • If: Not 5V.

• If: Not 5V.

ACCESS 5 and CA406.
• If: 5V.
M4.8-7335-100 SP3500
02 Rev. 8/08
426
ELECTRICAL SYSTEM
Event Code 534
Event Code 534

THRU
Figure 16760
SP3500 M4.8-7335-100
02 Rev. 8/08
427
ELECTRICAL SYSTEM
Event Code 535

ACCESS 5 Battery Current Out of Range. ACCESS 5 Battery Current Sensor Improperly In-
stalled.
Note: Check for event codes 532, 533, 536 and 537 if
any of these event codes have been logged resolve Note: Check for event code 537 if logged resolve it
first. first.
All functions disabled. No action taken.
Step 1: Check wiring between ACCESS 5 and CS1. Step 1: Enter Service Mode 2 and view CS1 sensor
input. Command full traction then plugging while view-
• If: Wiring is correct. ing CS1 values.
– Then replace CS1. • If: Values are negative during traction acceleration.
– Then check installation of CS1 to bus bar and
wiring between ACCESS 5 and CS1.
• If: CS1 installation is correct and event continues.

• If: CS1 installation is incorrect.

– Then correct.
Figure 16760
Figure 16760
M4.8-7335-101 SP3500
02 Rev. 8/08
428
ELECTRICAL SYSTEM
Event Code 537

THRU
ACCESS 5 Current Sensor 1 (CS1) Zero Reading
Out of Range.
Note: Check for event codes 532 and 533. If either
event has been logged, then resolve first.
No action taken.
Step 1: Step off truck to allow ED2 contacts to open,
wait 2 minutes for ED2 bus to discharge then using a
DVOM check voltage between CA403-24 and -B.
• If: Voltage is between 2.4V/2.6V and the event

code continues.

check for 2.4V/2.6V between wire 104 and -B.
• If: Voltage is between 2.4V/2.6V.

– Then replace the ACCESS 5.

Figure 16761
SP3500 M4.8-7335-102
02 Rev. 8/08
429
ELECTRICAL SYSTEM
Event Code 539

ACCESS 5 BDI Battery Voltage Out of Range. ACCESS 5 Battery Voltage Out of Range.
Note: Check for event code 540. If logged, then re- Note: ACCESS 5 monitors +BV steering motor input
solve first. for correct battery voltage.
Event Code 538: Traction disabled. All functions disabled.
Event Code 539: Full traction, auxiliary raise, auxiliary Step 1: Using a DVOM check battery voltage.
lower and raise disabled.
• If: 24V and battery is known to be good.
Step 1: Check FU2. Replace if open.
Step 2: Check for 24V between CA202-3 and
CA206-5. • If: 12V, 36V or 48V.
• If: 24V and event continues. – Then install correct 24V battery.
– Then check for 24V between CA202-3 and Step 2: Check the status of FU1 through FU9.
CA403-25.
• If: Correct status and event continues.
• If: 0V.
– Then check wiring between CA202-3 and
CA403-25.
• If: Any fuse is open.
– Then replace it.
Step 3: Key ON the truck and check ED contactor op-
eration.
• If: Contactor pulls in (even for only a short time-1/3

second) and the ED coil wiring and contacts ap-
pear to be in good condition.
• If: Contactor does not pull in and the ED bus is not

connecting to ACCESS 5.
– Then follow the procedure of event 544.
Figure 16762 Step 4: Key OFF truck and remove the power cable
from ACCESS 5 +B terminal. Connect DVOM between
the +B cable and -B on ACCESS 5; key ON the truck
and check for 24V.
• If: 24V with ED pulled in (about 1/3 second).

– Then key OFF truck and reinstall ACCESS 5
+B power cable. Connect DVOM between AC-
CESS +B and -B key ON truck and check for
24V.
• If: Not 24V or 24V and event code 540 continues.

• If: Not 24V when ED is pulled-in.
M4.8-7335-103 SP3500
02 Rev. 8/08
430
ELECTRICAL SYSTEM
Event Code 540
– Then issue exists in ED contact wiring follow

procedure for event 541.
Figure 16763
SP3500 M4.8-7335-103
02 Rev. 8/08
431
ELECTRICAL SYSTEM
Event Code 540
Notes:
M4.8-7335-104 SP3500
02 Rev. 8/08
432
ELECTRICAL SYSTEM
Event Code 541
Event Code 541 Step 3: Key ON truck. Using a DVOM check for 24V
between ED2 coil + terminal and -BV.
ACCESS 5 ED2 Contactor Failed to Energize. • If: 24V.
All functions disabled. – Then ED2 coil supply is correct, proceed to
Step 1: Key ON truck. Depress brake pedal to energize Step 4.
ED2 contactor.
• If: 20V.
• If: ED2 fails to energize.
– Then proceed to Step 2. ACCESS 3.
• If: ED2 energizes. • If: 3V.
– Then, using a DVOM, check for 24V between – Then ACCESS 3 ED2 switch is correct, replace
-B and +B on ACCESS 5 also between -B and ED2 contactor.
CA403-7, CA403-9.
• If: 0V.
– Then key OFF truck and check for correct bat- check for 24V between wire 2967 and -BV.
tery.
• If: 24V.
• If: Each test point is 24V.
– Then clear event codes and key ON truck.
• If: 0V.
– Then check wiring between +BV battery termi-
– Then replace ACCESS 5. nal and CA403-18.
• If: Each test point is less than 24V. Step 4: Key OFF truck. Remove wire 5920 from ED2
coil. Using a DVOM, check resistance of ED2 coil.
– Then turn key OFF. Remove CA403 and +B
cable from ACCESS 5, using a DVOM check • If: 0 ohm.
for shorts between CA403-7 (ACCESS pin) – Then remove wire 5920 from ED2 -BV coil ter-
(typical 10,000) and -B terminal, CA403-9 (AC- minal. Using a DVOM, check resistance of ED2
CESS pin) (typical 10,000) and -B terminal also coil.
between +B terminal and -B terminal (typical
40,000). • If: 29 ohm.
• If: Resistance is below value shown. – Then reconnect wire 5920 and proceed to Step
5.
• If: Resistance is not correct.
• If: Resistance value is correct.
– Then replace ED2.
– Then issue exists in ED2 load bus wiring.
Step 5: Check resistance between ED2 +BV coil con-
Step 2: Key OFF truck check fuses FU1 through FU9. nection and CA403-19.
• If: Fuses not functioning correctly. • If: 0 ohm.
– Then replace as necessary. – Then proceed to Step 6.
• If: Not 0 ohm.

– Then repair wiring between ED2 +BV coil con-
nection and CA403-19.
SP3500 M4.8-7335-105
02 Rev. 8/08
433
ELECTRICAL SYSTEM
Event Code 541
Step 6: Enter Service Mode 2. Select ED2 test output

menu to activate ACCESS 5/ACCESS 3 ED2
switches. Connect a DVOM between ED2 -BV coil con-
nection and -BV. Check for 24V with no active
switches.
• If: 0V.
check for 24V.
• If: 24V.
– Then ACCESS 3 is shorted, replace
ACCESS 3.
• If: Not 24V.

– Then ACCESS 5 switch open, replace
ACCESS 5.
• If: 20V.
• If: 20V.
– Then ACCESS 5 is open, replace ACCESS 5.
• If: 24V.

– Then ACCESS 5 switch is shorted (ED may
pull-in), replace ACCESS 5.
• If: 24V. Figure 16764

ACCESS 3.
Step 7: Activate ACCESS 3 ED2 switch and check
M4.8-7335-106 SP3500
02 Rev. 8/08
434
ELECTRICAL SYSTEM
Event Code 542
Event Code 542

ACCESS 5 +BV Power Supply Not Present.
Step 1: Key OFF truck and check fuses FU5, FU6 and
FU11.
• If: Fuses are correct.

• If: Fuse(s) are open.

Step 2: Check power supply wiring from TP5 to
CA403-7, CA403-9 and +BV power terminal.
Figure 16765
SP3500 M4.8-7335-107
02 Rev. 8/08
435
ELECTRICAL SYSTEM
Event Code 544
Event Code 544

ACCESS 5 ED2 Turn ON Error.
Step 1: Follow procedure for event code 541, ED2 sys-
tem troubleshooting.
M4.8-7335-107 SP3500
02 Rev. 8/08
436
ELECTRICAL SYSTEM
Event Code 545
Event Code 545

ACCESS 5 ED2 Turn OFF Error.
Step 1: Follow procedure for event code 541, ED2 sys-
tem troubleshooting.
SP3500 M4.8-7335-107
02 Rev. 8/08
437
ELECTRICAL SYSTEM
Event Code 546
Event Code 546

THRU
M4.8-7335-107 SP3500
02 Rev. 8/08
438
ELECTRICAL SYSTEM
Event Code 548

ACCESS 3 ED Load Bus Pre-charge Error. ACCESS 3 Chain Slack.
All functions disabled. Traction and lower disabled.
Event Code 546: General ED pre-charge error. Note: Prevents issue(s) logging check lift chain adjust-
ments.
Event Code 547: ACCESS 3 pre-charge power out of
range. Step 1: Enter Service Mode 2 and select CHS3/CHS4.
Event Code 548: ACCESS 3 pre-charge error. • If: Switch shows closed.
Step 1: Using a DVOM, check resistance from ED bus – Then status is normal, event code may have
(output contact) to -BV. occurred due chain adjustments.
• If: Less than 25 ohm. • If: Switch shows open.
– Then remove bus load fuses one at a time until – Then check chain adjustment (see Platform in
the resistance increases to normal value of Service and Parts Manual).
1000 ohm.
• If: Chain adjustment is correct and event code con-
• If: ED bus resistance returns to normal.
tinues.
– Then note last fuse removed and replace all – Then check CHS3/CHS4 adjustment.
others to verify bus resistance remains the
same. • If: CHS3/CHS4 adjustment is correct.
– Then check CHS3/CHS4 resistance, should be
0 ohm.
• If: CHS3/CHS4 resistance is correct and event

code continues.
– Then check CHS3/CH4 wiring. ACCESS 3
CA401-11 wire 2973 to CA414-1, CA201-7
wire 2954 to CA415-1, CA401-20 wire 2974 to
CA416-1, CA201-8 wire 2955 to CA417-1.
SP3500 M4.8-7335-108
02 Rev. 8/08
439
ELECTRICAL SYSTEM
Event Code 549
Figure 16766
M4.8-7335-108 SP3500
02 Rev. 8/08
440
ELECTRICAL SYSTEM
Event Code 551

THRU
No action taken.
Step 1: Turn key OFF then ON.


SP3500 M4.8-7335-108
02 Rev. 8/08
441
ELECTRICAL SYSTEM
Event Code 553
Event Code 553

No action taken.
Step 1: Load default parameters and configure as re-
quired.
M4.8-7335-108 SP3500
02 Rev. 8/08
442
ELECTRICAL SYSTEM
Event Code 554
Event Code 554

ACCESS 5 EAC Parameter Error.
No action taken.
Step 1: Drive truck over EAC magnets to reset data.


SP3500 M4.8-7335-108
02 Rev. 8/08
443
ELECTRICAL SYSTEM
Event Code 555
Event Code 555

THRU
M4.8-7335-109 SP3500
02 Rev. 8/08
444
ELECTRICAL SYSTEM
Event Code 556
Event Code 556 Step 2: Check steer wheel synchronization, enter

Service Mode 2 and select analyzer menu to view en-
coder counts. Rotate steer tiller in both directions while
ACCESS 5 Encoder 2 (ECR2) Out of Range.
viewing counts, ECR2 counts should change smoothly
Traction disabled. and continuously as steer wheel moves. Record ECR2
Note: Check status of event codes 522 and 523 if
logged then resolve them before proceeding to 555 • If: ECR2 counts erratic change or no change.
and 556.
Step 1: Using a DVOM check for +5V between CA403-13 and CA410-1, wire 026 between
CA410-2 and CA410-4. CA403-14 and CA410-3, blue wire between
• If: Less than 4.75V or more than 5.25V. CA410 and ECR2, orange wire between
CA410 and ECR2.
and 523. • If: Wiring is correct and event code continues.
• If: 5V. – Then replace ECR2.
– Then proceed to Step 2. • If: ECR2 is correct and event code continues.

Figure 16767
SP3500 M4.8-7335-109
02 Rev. 8/08
445
ELECTRICAL SYSTEM
Event Code 557
Event Code 557

ACCESS 5 Encoder 2 (ECR2) Index Error.
Note 1: ECR2 count indicates the wheel has passed
through zero position, but index signal has not indi-
cated the same.
logged resolve them before proceeding to event code
557.
CA410-2 and CA410-4.

and 523.
• If: 5V.
Step 2: Check ECR2 index wiring, wire 027 between
CA403-23 and CA410-5 and yellow wire between
Figure 16768
ECR2 and CA410.

– Then check steer wheel synchronization, enter
Service Mode 2 and select analyzer menu view
encoder counts. Rotate steer tiller in both direc-
tions while viewing counts, ECR2 counts
should change smoothly and continuously as
steer wheel moves. Record ECR2 counts once
steer wheel is at zero position.
• If: ECR2 counts erratic change or no change.

CA410 and ECR2.



M4.8-7335-110 SP3500
02 Rev. 8/08
446
ELECTRICAL SYSTEM
Event Code 558
Event Code 558

THRU
SP3500 M4.8-7335-111
02 Rev. 8/08
447
ELECTRICAL SYSTEM
Event Code 561
Event Code 561

ACCESS 5 Encoder 2 (ECR2) Error.
Traction and steering disabled.
Note 1: Event will occur if there is no wheel movement
upon command.
logged resolve them before proceeding to 558, 559,
560 and 561.
Step 1: Using a DVOM, check for +5V between
CA410-2 and CA410-4.

and 523.
Figure 16767
• If: 5V.
Step 2: Check wire connections between ACCESS 5
A1 and A2 terminal and M3.

Step 3: Check steer wheel synchronization, enter
Service Mode 2 and select analyzer menu view en-
coder counts. Rotate steer tiller in both directions while
viewing counts, ECR2 counts should change smoothly
and continuously as steer wheel moves. Record ECR2
• If: ECR2 count change is erratic or not at all.

CA410 and ECR2.



– Then perform ECR2 Alignment.
M4.8-7335-111 SP3500
02 Rev. 8/08
448
ELECTRICAL SYSTEM
Event Code 562

ACCESS 5 Steering Error. ACCESS 5 /ACCESS 6 Communication Error.
Traction and steering disabled. Traction disabled.
Note: Check status of event codes 540, 524 and 525 if Note: ACCESS 5 has received a wire guidance com-
logged resolve them before proceeding to 562. mand from the guidance switch but has not received
communication from ACCESS 6.
Step 1: Key OFF truck and unplug battery, remove +B
and -B cables from ACCESS 5. Install a jumper be- Step 1: Verify that truck has guidance feature.
tween +B and -B using a DVOM check the following:
Terminal A1 to +B = 15,000 ohm. • If: Feature is installed.
Terminal A1 to -B = 15,000 ohm. – Then check access wiring.
Terminal A2 to +B = 15,000 ohm.
Terminal A2 to -B = 15,000 ohm. • If: Feature is not installed.
Terminal A1 to A2 = 30,000 ohm.
– Then access the features menu and turn guid-
• If: Any are 5000 ohm below the value shown. ance off.
– Then replace ACCESS 5. • If: Event continues.
• If: Readings are correct. – Then refer to event code 506.
– Then reconnect cables and check A1 and A2

cables for a short.
• If: Cables are correct and the event continues.

Figure 16769
SP3500 M4.8-7335-112
02 Rev. 8/08
449
ELECTRICAL SYSTEM
Event Code 564

ACCESS 5 Wire Guidance Enable Error. ACCESS 5 /ACCESS 3 Traction Encoder 3 (ECR3)
Error.
Traction disabled.
Traction disabled. One or both channels lost at AC-
Note: ACCESS 5 received a wire guidance command
CESS 5 in idle or traveling.
from the guidance switch but wire enable setup is not
active. Note: Check status of event codes 330 and 565 - both
pertain to ECR3. If logged, then resolve them before
Step 1: ACCESS features menu and turn ON wire
proceeding with 565.
guidance.
Step 1: Clear event log; key OFF truck; key ON truck
and request traction.

ACCESS 5 CA403.



ACCESS 3 CA401.


M4.8-7335-113 SP3500
02 Rev. 8/08
450
ELECTRICAL SYSTEM
Event Code 565
Figure 17944
SP3500 M4.8-7335-113
02 Rev. 8/08
451
ELECTRICAL SYSTEM
Event Code 566
Event Code 566

ACCESS 5 EAC Enable Error.
Note: EAC feature enabled, hardware not detected.
Step 1: Verify truck has EAC feature.
• If: Truck does not have EAC feature.

– Then enter features menu and disable EAC.
• If: Truck has EAC feature.

– Then check for event code 105 if logged check
connections to ACCESS 6.
• If: Connections are correct.

– Then check for event code 506 if logged refer
to procedures for event code 506.
M4.8-7335-113 SP3500
02 Rev. 8/08
452
ELECTRICAL SYSTEM
Event Code 567
Event Code 567

569 or 570.
magnets.
• If: 0V.

Figure 16703
• If: 0V.
and -BV.
• If: 5V.
• If: 0V.
-BV.
• If: 0V.
• If: 5V.
CA607-3.
SP3500 M4.8-7335-114
02 Rev. 8/08
453
ELECTRICAL SYSTEM
Event Code 568
Event Code 568

569 or 570.
magnets.
• If: 0V.

Figure 16778
• If: 0V.
and -BV.
• If: 5V.
• If: 0V.
CA602-11, check for 5V between CA602-11
and -BV.
• If: 0V.
• If: 5V.
CA607-9.
M4.8-7335-115 SP3500
02 Rev. 8/08
454
ELECTRICAL SYSTEM
Event Code 569
Event Code 569

569 or 570.
magnets.
• If: 0V.

Figure 16779
• If: 0V.
and -BV.
• If: 5V.
• If: 0V.
-BV.
• If: 0V.
• If: 5V.
CA607-6.
SP3500 M4.8-7335-116
02 Rev. 8/08
455
ELECTRICAL SYSTEM
Event Code 570
Event Code 570

Full traction Disabled.
569 or 570.
magnets.
• If: 0V.

Figure 16806
• If: 0V.
panel CA607-12, check for 5V between wire
end and -BV.
• If: 5V.
• If: 0V.
CA602-14, check for 5V between CA602-14
and -BV.
• If: 0V.
• If: 5V.
CA607-12.
M4.8-7335-117 SP3500
02 Rev. 8/08
456
ELECTRICAL SYSTEM
Event Code 571
Event Code 571

THRU
SP3500 M4.8-7335-118
02 Rev. 8/08
457
ELECTRICAL SYSTEM
Event Code 572
Event Code 572 Step 3: Re-key truck in normal mode. Acquire wire/rail
and stop truck outside the EAC zones, remain idle with
foot on brake. Wait 20 seconds for diagnostics to exe-
ACCESS 5 EAC Magnet Error.
cute.
• If: Sensors fail.
Event Code 571: Inner magnet error event code.
– Then a 500 or 600 event code will be logged.
Event Code 572: Outer magnet error event code. Follow procedures for that event code.
Step 1: Drive truck out of guided aisle then re-enter.
• If: Time elapses and no event occurs.
• If: Event clears.
– Then system is correct; continue to monitor.
– Then monitor.
• If: Event repeats.

Step 2: Enter Service Mode 2 and select View EAC
Sensor Status in EAC monitor menu A2.5.4 and
A2.5.5. Acquire wire/rail position truck in EAC zone,
display state of corresponding sensors. Slowly drive
over EAC magnets while viewing sensor state on dis-
play. State will be closed if not detected, open if de-
tected.
• If: Any magnet fails detection.

– Then check wiring of corresponding sensor.

– Then perform the same test over another mag-
net in the aisle.
• If: Test passes.

– Then check the magnet in the floor. Using a
piece of metal, pass it over the magnet attrac-
tion should be strong. Compare it to another
magnet and if there is a dramatic different in the
magnetic attraction replace the magnet.
• If: All four magnets are detected.

M4.8-7335-118 SP3500
02 Rev. 8/08
458
ELECTRICAL SYSTEM
Event Code 573
Event Code 573

THRU
SP3500 M4.8-7335-119
02 Rev. 8/08
459
ELECTRICAL SYSTEM
Event Code 574
Event Code 574 • If: 0V or 5V.

– Then reconnect wiring.
ACCESS 4 Height Encoder 4 (ECR4) Count Error.
Full traction and raise 2 disabled.
• If: 0V or 5V and event code continues.
Event Code 573: Event code will log if the platform fails – Then replace ACCESS 4.
to lower within an allotted time after operator com-
mand. This event may occur during a lower command
and chain slack condition.
to raise within an allotted time after operator command.
Step 1: Disconnect CA317, check encoder side wiring.
Make sure there are not broken crimps on the encoder
wiring into connector.
• If: Wiring crimp broken or damaged.

Step 2: Disconnect CA317, using a DVOM check for
5V between CA317-3 and CA317-4.
• If: 5V.
– Then reconnect CA317 and proceed to Step 3.

and, using a DVOM, check for 5V between pins Figure 16780-01
CA303-12 and CA303-15.
• If: 5V.
CA317-3, wire 516 CA303-15 to CA317-4.

Step 3: Check ECR4 channel wiring. Wire 007
CA317-1 to CA303-13, wire 008 CA317-2 to
CA303-14.

– Then disconnect CA317, remove white and
blue wires from JC317-1 and JC317-2. Con-
nect a DVOM from white (CH A) to -BV, key ON
truck and check voltage. Reading should be ei-
ther 0V or 5V depending on position of ECR4
disc. Perform the same test on the blue wire
(CH B).
• If: Not 0V or 5V.

M4.8-7335-119 SP3500
02 Rev. 8/08
460
ELECTRICAL SYSTEM
Event Code 576
Event Code 576

THRU
SP3500 M4.8-7335-120
02 Rev. 8/08
461
ELECTRICAL SYSTEM
Event Code 581
Event Code 581

ACCESS 5 Brake Current or Resistance Error.
Event Code 576: Traction disabled. Inner brake low
current.
Event Code 577: Traction disabled. Inner brake hot.
Event Code 578: Full speed traction disabled only. In-
ner brake resistance high.
Event Code 579: Traction disabled. Outer brake low
current.
Event Code 580: Traction disabled. Outer brake hot.
Event Code 581: Full speed traction disabled only.
Outer brake resistance high.
Step 1: Allow brake assembly to cool then remove
brake from traction motor and disassemble to the level
that coils can be inspected.
Step 2: Inspect coils for heat damage.
• If: Lamination material has broken down.

– Then replace brake coils.
• If: Coils do not appear to be damaged.

– Then, with coils at room temperature, use a
DVOM and check resistance, typical resistance
of inner coil is 3.5 ohm outer coil 1.5 ohm.
• If: Either coil is significantly above value.

– Then replace coil.
M4.8-7335-120 SP3500
02 Rev. 8/08
462
ELECTRICAL SYSTEM
Event Code 582
Event Code 582

THRU
SP3500 M4.8-7335-120
02 Rev. 8/08
463
ELECTRICAL SYSTEM
Event Code 585
Event Code 585

ACCESS 5 Brake Current Out of Range.
Traction disabled.
Event Code 582 and 583: Inner brake resistance low.
Event Code 584 and 585: Outer brake resistance low.
leads between CA407-2 and CA407-3 on the brake coil
ohm.

– Then replace inner brake coil.

ues.
Figure 16782
M4.8-7335-120 SP3500
02 Rev. 8/08
464
ELECTRICAL SYSTEM
Event Code 586
Event Code 586

ACCESS 5 Brake Load Error.
Traction disabled.
Note: Inner coil error.
leads between CA407-2 and CA407-3 on the brake coil
ohm.

ues.
Figure 16782
SP3500 M4.8-7335-120
02 Rev. 8/08
465
ELECTRICAL SYSTEM
Event Code 587

ACCESS 5 Brake Load Error. ACCESS 5 Brake Supply Voltage Error.
Note: Outer coil error. Note 1: Brake power supply voltage error could result
sistance of outer coil. Unplug CA407 place DVOM Note 2: Fuse 6 circuit.
leads between CA407-1 and CA407-4 on the brake
Step 1: Check fuse 6.
side typical resistance at room temperature is 1.5 ohm.

• If: Open.
– Then replace outer brake coil.

• If: Correct.
ues. – Then using a DVOM check for 24V between
CA403-7 and B-.
Figure 16782
Figure 16783
M4.8-7335-121 SP3500
02 Rev. 8/08
466
ELECTRICAL SYSTEM
Event Code 589
Event Code 589

ACCESS 5 Brake Supply Voltage Error.
Traction disabled.
Note 1: Brake power supply voltage error could result
Note 2: Fuse 5 circuit.
Step 1: Event code 589 check fuse 5.
• If: Open.
• If: Correct.
CA403-9 and -BV.

Figure 16785
SP3500 M4.8-7335-122
02 Rev. 8/08
467
ELECTRICAL SYSTEM
Event Code 590
Event Code 590

THRU
M4.8-7335-122 SP3500
02 Rev. 8/08
468
ELECTRICAL SYSTEM
Event Code 591
Event Code 591

Step 1: Refer to procedure for event 588 and 589. Use
event code that corresponds to the specific driver (in-
Step 2: Refer to procedure for event 586 and 587. Use
event that code corresponds to the specific driver (in-
• If: Results of Steps 1 and 2 do not indicate a brake

voltage error or shorted brake load.
SP3500 M4.8-7335-122
02 Rev. 8/08
469
ELECTRICAL SYSTEM
Event Code 592
Event Code 592

THRU
M4.8-7335-122 SP3500
02 Rev. 8/08
470
ELECTRICAL SYSTEM
Event Code 593

ACCESS 5 Brake Driver Error. ACCESS 5 Proportional Flow Valve (PVL) Load Er-
ror.
Traction disabled.
Step 1: Key OFF truck and remove connector CA403
from ACCESS 5, using a DVOM check resistance be-
Step 1: Refer to procedure for event 582, 583, 584, tween wire 2958 and 5926.
585. Use event code that corresponds to the specific
driver (inner or outer brake coil). • If: Resistance is 25 to 35 ohm.
• If: Results of Steps 1 and 2 do not indicate a brake – Then replace ACCESS 5.
low resistance. • If: Resistance is 0 ohm.
– Then replace ACCESS 5. – Then disconnect wires from PVL coil and check
resistance at coil.
• If: 0 ohm.
– Then replace PVL.
• If: 25 to 35 ohm.
Figure 16784
SP3500 M4.8-7335-123
02 Rev. 8/08
471
ELECTRICAL SYSTEM
Event Code 595

ACCESS 5 Proportional Flow Valve (PVL) Driver Er- ACCESS 5 Proportional Flow Valve (PVL) Load Er-
ror. ror.
Raise disabled. Raise disabled.
Step 1: Enter Service Mode 2 and select PVL monitor Step 1: Key OFF truck and remove connector CA403
menu A3.4.10. Raise platform then lower the display from ACCESS 5, using a DVOM check resistance be-
will indicate percentage of PVL (lower valve) duty cy- tween wire CA403-11 and CA403-2.
cle.
• If: 25 to 35 ohm.
• If: Display indicates a duty cycle but the platform
does not lower.
– Then check wiring. Wire 5926 CA403-2 to PVL CA201-9 to PVL coil.
coil, wire 2958 CA403-11 to PVL coil and wire
2960 CA201-9 to PVL coil. • If: Wiring is correct and event code continues.
• If: Wiring is correct and event code continues. – Then replace ACCESS 5.
Figure 16784
Figure 16784
M4.8-7335-123 SP3500
02 Rev. 8/08
472
ELECTRICAL SYSTEM
Event Code 597
Event Code 597

ACCESS 5 Proportional Flow Valve (PVL) Driver Er-
ror.
Note: Shorted driver event could be due to outside
short, CA403-2 to -BV or internal short in ACCESS 5.
24V between wire 5926 at PVL coil and -BV.
• If: Not 24V.

– Then remove wire 2958 from CA403-11, key
ON truck using a DVOM check for 24V be-
tween wire 5926 and B+.
• If: 24V.
• If: Not 24V.

– Then check wiring. Wire 2960 PVL to CA201-9,
wire 2958 PVL to CA403-11.
Figure 16784
SP3500 M4.8-7335-124
02 Rev. 8/08
473
ELECTRICAL SYSTEM
Event Code 601
Event Code 601

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
Check connectors CA601, CA204 and wiring.
Wire 021 CA601-4 to CA204-3 and wire 022
CA601-5 to CA204-9.


ACCESS 1 and platform distribution panel.
CA302-9 to CA105-8.

distribution panel and ACCESS 1. Check wire Figure 16786
2941 CA302-3 to CA103-10.
M4.8-7335-125 SP3500
02 Rev. 8/08
474
ELECTRICAL SYSTEM
Event Code 603
Event Code 603

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
CA601-5 to CA204-9.


CA401-15 to CA204-7.

2953 CA401-1 to CA201-5. Figure 16787
SP3500 M4.8-7335-126
02 Rev. 8/08
475
ELECTRICAL SYSTEM
Event Code 604
Event Code 604

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
CA601-5 to CA204-9.


ACCESS 4 and platform distribution panel.
CA303-07 to CA105-1.

Figure 16788
2937 CA304-1 to CA103-12.
M4.8-7335-127 SP3500
02 Rev. 8/08
476
ELECTRICAL SYSTEM
Event Code 605
Event Code 605

ACCESS 6 CAN Error.
Traction disabled.

ACCESS 1.
CA601-5 to CA204-9.


CA402-5 to CA204-8.

2966 CA403-10 to CA201-6. Figure 16789
SP3500 M4.8-7335-128
02 Rev. 8/08
477
ELECTRICAL SYSTEM
Event Code 611
Event Code 611

THRU
M4.8-7335-129 SP3500
02 Rev. 8/08
478
ELECTRICAL SYSTEM
Event Code 612
Event Code 612

SP3500 M4.8-7335-129
02 Rev. 8/08
479
ELECTRICAL SYSTEM
Event Code 621
Event Code 621

THRU
M4.8-7335-129 SP3500
02 Rev. 8/08
480
ELECTRICAL SYSTEM
Event Code 628
Event Code 628

Traction disabled.
SP3500 M4.8-7335-129
02 Rev. 8/08
481
ELECTRICAL SYSTEM
Event Code 631
Event Code 631

ACCESS 6 Wire Guidance Sensor Amplifier Self-
Test Error.
Traction disabled.
M4.8-7335-129 SP3500
02 Rev. 8/08
482
ELECTRICAL SYSTEM
Event Code 632
Event Code 632 Step 2: Enter Service Mode 2 and view GS2 sensor
values (A2.5.3) drive slowly over the wire, values
ACCESS 6 Load Wheel Sensor Bar GS2 Guidance
wire.
Issue.
Traction disabled. • If: Any of the four coil signals fail to indicate the
coil for a short or an open issue per the dia-
Step 1: Check sensor bar 5V supply. Connect DVOM grams.
positive lead to CA602-22 and negative to -BV and key
ON truck. • If: Wiring is correct.
• If: 5V. – Then replace GS2.
– Then sensor bar power supply is correct, pro- • If: Event code continues.
ceed to Step 2.
• If: 0V.
CA602-22 and -BV.
• If: 5V.
– Then issue exists in GS1 bar or the wiring from
ACCESS 6 to GS1. Repair/replace as neces-
sary.
• If: 0V.
• If: 0V.
• If: 5V.
sary.
Figure 16790
SP3500 M4.8-7335-130
02 Rev. 8/08
483
ELECTRICAL SYSTEM
Event Code 633
Event Code 633 Step 2: Enter Service Mode 2 and view the GS1 sensor
values (A2.5.1) driving slowly over the wire, values
ACCESS 6 Steer Wheel Sensor Bar (GS1) Guidance
wire.
Error.
Traction disabled. • If: Any one of the four coil signals fail to indicate the
coil for a short or an open issue per the dia-
Step 1: Check sensor bar 5V supply. Connect DVOM grams.
positive lead to CA602-15 and negative to -BV and key
ON truck. • If: Wiring is correct.
• If: 5V. – Then replace GS1.
– Then sensor bar power supply is correct, pro- • If: Event code continues.
ceed to Step 2.
• If: 0V.
CA602-22 and -BV.
• If: 5V.
sary.
• If: 0V.
• If: 0V.
• If: 5V.
sary.
Figure 16790
M4.8-7335-131 SP3500
02 Rev. 8/08
484
ELECTRICAL SYSTEM
Event Code 636

ACCESS 6 Guide Angle Beyond Acceptable Angle. ACCESS 6 Wire Guidance Signal Loss at Both Sen-
sor Bars.
Traction disabled.
Traction Disabled.
Note 1: Event code 636 could log if truck is driven be-
yond end of wire in auto guide. Step 1: Check for event codes 632/633.
Step 1: If event code 636 is logged by driving beyond • If: Event code 632 or 633 has been logged.
the end of the wire in auto guide system operation is
correct. – Then resolve these event codes before contin-
uing.
• If: Event code 632/633 was also logged.
• If: Event code 632 or 633 has not been logged.
– Then follow procedures for these event codes
before continuing. – Then check line driver power.
• If: Event code 636 was logged while in aisle. • If: Line driver correct.
– Then check alignment of ECR2, condition of – Then check guide wire condition breaks may
sensor bars and wire guidance calibration. be present.
• If: ECR2 requires realignment.

– Then calibrate truck.
• If: Event code was not due to alignment or calibra-

tion.
– Then using the Crown field strength meter
(Part Number 112953) check wire guide field
strength (6.25 KHz, 168ma to 190ma, 5.2KHz
100ma - 118ma).
• If: Field strength is correct and event code contin-

ues.
– Then check floor surface.
Note 2: Floor surface irregularities, corrupted signal
due to rebar, metal pipes, underground electrical wiring
in metal and/or plastic conduit. Any of these issues can
affect wire guidance performance, which could be lo-
calized (i.e. section in one aisle) or wide spread.
SP3500 M4.8-7335-132
02 Rev. 8/08
485
ELECTRICAL SYSTEM
Event Code 638
Event Code 638

THRU
M4.8-7335-133 SP3500
02 Rev. 8/08
486
ELECTRICAL SYSTEM
Event Code 639
Event Code 639

ACCESS 6 Loss of Wire Guidance Signal from One
Sensor Bar.
Traction disabled.
Step 1: Check for event codes 632/633.
• If: Event code 632 or 633 has been logged.

– Then resolve event code 632/633 before con-
tinuing.
• If: Event code 638 (load wheel sensor bar GS2)

continues.
CA602-27, wire 119 CA604-2 to CA602-26,
wire 118 CA604-7 to CA602-25 and wire 117
CA604-8 to CA602-24.
• If: Event code 639 (steer wheel sensor bar GS1)

continues.
CA602-20, wire 115 CA603-2 to CA602-19,
wire 114 CA603-7 to CA602-18 and wire 113
CA603-8 to CA602-17.
• If: Event code 638 or 639 continues.

– Then replace corresponding sensor bar. Figure 16791
• If: Event code continues after replacement of sen-

sor bar.
SP3500 M4.8-7335-133
02 Rev. 8/08
487
ELECTRICAL SYSTEM
Event Code 652
Event Code 652

THRU
M4.8-7335-134 SP3500
02 Rev. 8/08
488
ELECTRICAL SYSTEM
Event Code 659

THRU
ACCESS 6 EAC Sensor Out of Range.
Event Code 652 and 653: Sensor A1 over/under range.
Event Code 654 and 655: Sensor B1 over/under range.
Event Code 656 and 657: Sensor A2 over/under range.
Event Code 658 and 659: Sensor B2 over/under range.
Step 1: Enter Analyzer Mode and select view EAC sig-
nal levels (A2.5.3 - A2.5.6). The signal value displayed
represents the signal strength in percentage of full
scale for the activated sensor. Display will hold the
peak sensed value until next magnet detection cycle
occurs.
Acquire wire and slowly drive over the magnet in the
position of failed sensor while viewing sensor signal
strength. Signal strengths tend towards the lower
range value, rather than the upper.
• If: Signal is close to 100% and event continues.

– Then check sensor wiring per diagram.

with event code.
• If: Signal is close to 40%.

– Then strength is close to lower range thresh-
old. Check sensor wiring per diagram and in-
spect magnet location and floor conditions
around the magnet.
• If: Correct.
with event code.

SP3500 M4.8-7335-134
02 Rev. 8/08
489
ELECTRICAL SYSTEM
Event Code 663
Event Code 663

ACCESS 6 EAC Sensor Digital Signal Error.
Event Code 660: Sensor A1 digital signal error.
Event Code 661: Sensor B1 digital signal error.
Event Code 662: Sensor A2 digital signal error.
Event Code 663: Sensor B2 digital signal error.
Step 1: Enter Analyzer Mode select view EAC digital
signal state (A2.5.3 - A2.5.6). Digital state shall indicate
opened if the magnet is not sensed and closed if it is
sensed. Acquire the wire and slowly drive over the
magnet in the position of failed sensor while viewing
sensor digital state.
• If: Digital state switches from opened to closed

back to opened as sensor passes over the magnet.
– Then digital sense is working properly, enter
Button Mode select view EAC signal level cor-
responding to event code.
• If: Signal is close to 40%.

– Then strength is close to lower range thresh-
old, check sensor wiring per diagram and in-
spect magnet location and floor conditions
around the magnet.

with event code.
• If: Digital state shows opened and does not change

when sensor passes over the magnet.
– Then check magnet is present and the sensor
wiring is correct per the diagram.
• If: Correct.
with event code.

M4.8-7335-134 SP3500
02 Rev. 8/08
490
ELECTRICAL SYSTEM
Event Code 664
Event Code 664

THRU
SP3500 M4.8-7335-135
02 Rev. 8/08
491
ELECTRICAL SYSTEM
Event Code 667
Event Code 667

ACCESS 6 EAC Magnet Field Strength Out of
Range.
Step 1: Check magnet location(s) for improper installa-
tion and/or damage (i.e. wrong pole, positional align-
ment, floor crack through magnet, etc.).
M4.8-7335-135 SP3500
02 Rev. 8/08
492
ELECTRICAL SYSTEM
Event Code 668
Event Code 668

THRU
SP3500 M4.8-7335-135
02 Rev. 8/08
493
ELECTRICAL SYSTEM
Event Code 671

ACCESS 6 EAC Sensor Self-Test Error. ACCESS 6 Multiple EAC Sensors Active.
Event Code 668: Sensor A1. Step 1: Check EAC sensors for damage.
Event Code 669: Sensor B1. • If: Sensor(s) is damaged.
Event Code 670: Sensor A2. – Then repair/replace as necessary.
Event Code 671: Sensor B2.
• If: Sensor(s) are not damaged.
Step 1: Check sensor(s) wiring and connections as it
applies to event code(s). – Then move truck away from EAC zone where
all sensors should be inactive. Check digital
• If: Wiring and/or connections incorrect. signal voltage from CA602-5, -8, -11 and -14 to
-BV.
• If: Digital signal is less than 1V.
– Then remove the corresponding digital signal
– Then replace EAC sensor that corresponds wire from CA602. Check the voltage at
with event code. ACCESS 6 CA602 where the digital signal wire
• If: Event code continues. was removed.
– Then replace ACCESS 6. • If: Less than 1V.

• If: Greater than 3.5V.

– Then check voltage at the corresponding test
signal at CA602.
• If: CA602 pin 0V.

– Then replace the corresponding EAC sensor.
• If: CA602 pin greater than 5V.

Figure 16792
M4.8-7335-135 SP3500
02 Rev. 8/08
494
ELECTRICAL SYSTEM
Event Code 672
Notes:
SP3500 M4.8-7335-135
02 Rev. 8/08
495
ELECTRICAL SYSTEM
Event Code 672
M4.8-7335-135 SP3500
02 Rev. 8/08
496
BRAKE SYSTEM
497
Notes:
498
BRAKE SYSTEM
Brake
Brake Braking Force

There are two sources of drive wheel braking, a 3 step, When a brake request is made by releasing the brake
spring applied, electromagnetically released, friction pedal, switch BRS1, located below the platform floor is
disc brake on the drive motor armature shaft, and mo- activated. The ACCESS 123 system determines the
tor braking, typically called regenerative braking. amount of braking force to be applied. The braking
When a brake request is made the operator releases
and the 3-step disc brake. The forward and reverse
the brake pedal, which activates a switch (BRS1). The
brake force can be independently adjusted through the
ACCESS 123® system then determines the amount of
display Module (ACCESS 1), (performance menu P6,
braking force to be applied based on the programmed
Braking, submenus P6.1 FF Braking and P6.2 PUF
truck weight (includes battery and maximum allowable
Braking).
fork load) and the maximum allowable speed for the
particular travel direction and fork height. The braking
and the 3 step friction brake. The motor regenerative
portion is made as large as practical in order to reduce
wear on the 3 step friction brake. The forward and re-
verse brake force can be further electronically adjusted
through the display in order to address tire slide for the
particular floor condition in the application.
Figure 23367
Crown 2007 PF15820-1 Rev. 2/10 SP3500 M5.0-7335-001

03 Rev. 2/10
499
BRAKE SYSTEM
Brake
Brake Force Adjustment 7. To adjust brake force use the display module
(ACCESS 1), proceed to performance menu mode
1. Braking force should be checked under the follow- P6 braking. To adjust braking in FF direction select
ing conditions: P6.1 for PUF select P6.2. Adjusting to a higher
number will increase braking force (reduce stop-
– Forks lowered.
ping distance). Adjusting to a lower number will de-
– On a floor surface typical of application. crease braking force (increase stopping distance).
– Both forward and reverse travel directions.
– With and without a load. Brake Adjustment
2. Brake force should be adjusted to produce the
shortest possible stopping distance without caus- Air Gap Adjustment
ing the braking wheel to slide or the load to become The "air gap", referred to on this truck, is the distance
unstable. Setting the ACCESS 123 Braking Per- between the brake armature and the electromagnet
formance menus (P6.1 and P6.2) to 6 or 7 is typical body with brakes applied. Refer to Figure 18184-01. As
for a properly functioning brake system on smooth the brake pads and rotor wear normally, the air gap will
dry concrete floors. For reference, a typical stop- increase and should be readjusted, or parts checked
ping distance when traveling at 8 km/h (5 mph) in and replaced, when it exceeds 1.0 mm (0.040 in).
the power unit first direction, with no load is approx-
imately 2.1 meters (7.0 feet).
NOTE
3. If floor conditions are such that tire slide occurs or
a more/less aggressive stop is desired, braking If the air gap measures more than 1.0 mm (0.040 in),
force can be increased or decreased with a corre- the brake may not release properly. If the brake pad
sponding increase or decrease in stopping dis- thickness is less than 2.8 mm (0.110 in), the brake
tance. pads and rotor should be replaced.
The customer shall verify that the stopping dis- 1. Chock load wheels. Open power unit doors to ac-
tance in any part of the application doesn't prevent cess brake assembly.
the operator from performing a specific task safely,
or result in braking characteristics that are signifi- 2. Release brake, using drive/tow switch. Refer to
cantly different from other similar vehicles being Control of Hazardous Energy section of this man-
used in the facility. An alternative is for the cus- ual.
tomer to train the operator to reduce travel speed 3. Using low pressure air, remove any dirt between
and/or allow for longer stopping distances. armatures and magnet body.
4. If brake force adjustments are necessary, verify 4. With a 0.875 (7/8 in) open end wrench, loosen the
the settings in steps 5 and 6 before proceeding to top nut.
step 7.
5. Using a 1.125 (1 1/8 in) open end wrench, turn the
5. Through the display module (ACCESS 1), proceed 1.125 (1 1/8 in) hex nut down until the air gap is
to features mode starting at F5 and continue 0.13 mm (0.005 in) at its tightest location. One
through F11 to verify truck specifications. Informa- complete turn of the nut will change the gap
tion for these settings can be found on truck data 1.4 mm (0.056 in) or 1/6 (60 degrees) turn will
plate and capacity plate. change gap 0.235 mm (0.009 in).
6. Verify the drive brake torque gap setting is correct 6. Torque 0.875 (7/8 in) hex nut to 122 Nm (90 ft lb).
(refer to Brake Torque Gap for GVW chart).
7. Apply brake, using drive/tow switch.
8. Remove chocks and check operation.
M5.0-7335-002 SP3500 Crown 2007 PF15820-2 Rev. 2/10
03 Rev. 2/10
500
BRAKE SYSTEM
Brake
Figure 18184-01
1 Drive Motor 7 Rotor

2 Torque Adjuster Plate 8 Brake Parts
3 Adjuster Disc 9 Armature
4 Electromagnet 10 Torque Adjuster Cap
5 Air Gap 11 1 1/8 in Hex Nut
6 Motor Shaft 12 7/8 in Hex Nut
Torque Gap Adjustment NOTE

The "torque gap", referred to on this truck, is the dis- Refer to the capacity plate for truck GVW as equipped
tance between the torque adjuster plate and the elec- with maximum battery and capacity load.
tromagnet. Refer to Figure 18184-01. The torque plate
is factory preset and no adjustment is required, how-
ever, through routine maintenance it may be necessary
to replace components and the gap may need to be
reset to factory specifications. The torque gap will vary
with each trucks Gross Vehicle Weight (GVW).
Crown 2007 PF15820-3 Rev. 2/10 SP3500 M5.0-7335-003

03 Rev. 2/10
501
BRAKE SYSTEM
Brake
Chart 1 - Brake Torque Gap for GVW
Torque Gap GVW (capacity load and

maximum battery)
mm (in) kg (lb)
0.00 (0.00) greater than 6509 (greater than 14350)
0.51 (0.02) 6214 - 6508 (13700 - 14349)
1.02 (0.04) 5919 - 6213 (13050 - 13699)
1.52 (0.06) 5625 - 5918 (12400 - 13049)
2.03 (0.08) 5330 - 5624 (11750 - 12399)
2.54 (0.10) 5035 - 5329 (11100 - 11749)
3.05 (0.12) 4740 - 5034 (10450 - 11099)
3.56 (0.14) 4445 - 4739 (9800 - 10449)
4.06 (0.16) 4150 - 4444 (9150 - 9799)
4.57 (0.18) 3856 - 4149 (8500 - 9149)
5.08 (0.20) less than 3855 (less than 8500
M5.0-7335-004 SP3500 Crown 2007 PF15820-4 Rev. 2/10
03 Rev. 2/10
502
BRAKE SYSTEM
Brake
Rotor and Brake Pad Replacement Brake Assembly

Tools are available from Crown to permit replacement Before assembling brake, inspect all components for
of the pads on the brake pad assembly. When used wear, grooves, nicks or other damage. If any abnormal
with a press, these tools allow the correct positioning of wear or damage appears that may affect brake opera-
the pads and correct setting of the rivets. A press is tion, replace with new parts. Assemble brake as fol-
required to insure the rivets provide the compression lows:
strength needed to keep brake pads stationary.
1. Turn torque adjuster plate down as far as possible
to reduce spring force. Place adjuster disc on
torque adjuster plate.
2. Apply a light coat of multipurpose grease
(063002-024) to the motor end cap threads and on
top of the torque adjuster plate.
3. Position magnet body on the motor so the coil
wires jack (JC407) can be connected to plug
PC407. Apply blue thread locking adhesive
(061004-026) to the three 0.312 in. (5/16 in)
screws and secure magnet to motor with screws.
4. Assemble springs, inner and outer armatures to
Figure 18186-02 magnet body. Apply a light coat of multipurpose
grease (063002-024) to entire bottom of brake pad
1 119343 Riveter Base plate assembly. Be careful not to contaminate
2 114518 Riveter brake pads with grease.
5. Install compression spring over armature shaft.
To disassemble rotor and brake pad assembly:
6. Slip rotor on motor shaft, hub first. Thread 1.125 in.
1. Block load wheels, disconnect battery and open
(1 1/8 in) hex nut onto motor shaft. Turn nut down
power unit doors.
until the rotor moves down and almost touches the
2. Disconnect brake connector CA407. brake pads. Proper air gap adjustment will be
made later.
3. Remove retaining ring, washers and two hex nuts.
7. Thread the 0.875 in. (7/8 in) hex nut onto motor
4. Remove rotor and brake pad assembly.
shaft. Add flatwasher(s) and install retaining ring
5. Follow Brake Assembly procedure when reassem- on motor shaft.
bling the brake.
8. Set torque adjuster gap to its original factory set-
ting. See torque gap adjustment procedures.
9. Connect wire harness to brake assembly (JC407
to PC407).
10. Adjust air gap. See air gap adjustment procedures.
11. Check brake operation and stopping distance. See
adjustment procedures in truck settings section of
this manual.
Crown 2007 PF15820-5 Rev. 2/10 SP3500 M5.0-7335-005

03 Rev. 2/10
503
BRAKE SYSTEM
Brake
Figure 18189-01
1 Drive Motor 11 Brake Pad Assembly

2 Spring 12 1 1/8 in Hex Nut
3 5/16 in Screw 13 Flatwasher
4 Inner Armature 14 Retaining Ring
5 24 Volt Wire Position 15 7/8 in Hex Nut
6 Magnet Body 16 Rotor
7 Adjuster Disc 17 Brake Pad
8 Torque Adjuster Plate 18 Rivet
9 Screw 19 Outer Armature
10 Compression Spring
M5.0-7335-006 SP3500 Crown 2007 PF15820-6 Rev. 2/10
03 Rev. 2/10
504
BRAKE SYSTEM
Brake
Problem Probable Cause Remedy

Brakes will not release Air gap greater than 1.0 mm (0.040 in) Adjust
Open circuit in brake circuitry or wiring Inspect floorboard switches
and all associated wiring
foreign material
Brake drag Air gap less than 0.25 mm (0.010 in) Adjust
foreign material
Brakes grab Incorrect stopping distance adjustment Adjust (Refer to performance
menu PUF brake and FF
brake)
Brake dust or foreign material restricting Clean with low pressure air
movement
Stopping distance too long Incorrect stopping distance adjustment Adjust (Refer to performance
menu PUF brake and FF
brake)
Brake pads loose or soiled with grease Replace
Abnormal noise and chatter Brake pad mounting plate or rotor distorted Replace
when brakes applied
Brake pads worn out, loose, soiled with Replace
grease or foreign material embedded
Abnormal braking force for lift Rotor thin, cracked or spline worn Replace
height or brakes applied without
Wire Guide Trucks: Guide wire lost power or Troubleshoot wire guidance
request
truck off guide wire system
Open circuit in brake circuitry or wiring Check all switches and
associated wiring
Crown 2007 PF15820-7 Rev. 2/10 SP3500 M5.0-7335-007

03 Rev. 2/10
505
Notes:
506
STEERING
507
Notes:
508
STEERING
Steering
Steering
Steering Indicator
Lights Enhanced
with Optional LED
Access 1
Access 5
Figure 18207
The electronic power steering utilizes a servo motor to Steering Direction

steer the drive wheel. Movement of the steering wheel
turns the steering command encoder (ECR1) anc The truck will turn in the direction the steering wheel is
ECR5 which sends data to the platform Access 1 dis- rotated when traveling forward or power unit first direc-
play module (DCM). This information is converted to a tion. If your truck is equipped with wire guidance, the
direction, rate and position signal. This information is truck will be automatically steered once the guide wire
compared with the position and direction information is acquired. Refer to Electrical Maintenance for wire
that is received from the power unit steering feedback guidance operation.
encoder (ECR2). A composite signal representing the
difference is calculated in the power unit Access 5
steer control module (SCM) and is then applied to the
steering motor (M2). Travel speed and lift height may
be limited in relation to steer wheel position.
Crown 2007 PF15821-1 SP3500 M6.0-7335-001
509
STEERING
Steering
Steering Wheel Direction Indicator The second and third indicator on either side being
glowing indicates a steer angle between 35 and 60 de-
Optional five indicator lights around the power unit end grees in the indicated direction. When the third indica-
of the truck image on the display panel provide a visual tor on either side of the center indicator is the only indi-
indication of approximate steer wheel turn angle. When cator "ON", the steer angle is between 60 and 90
the center indicator only is glowing green, the angle of degrees.
the steered wheel from straight ahead is within ± 1 de-
Steering will be limited to no more than 10 degrees of
gree. If the center indicator and first indicator to either
straight ahead if the forks are raised 4570 mm (180 in)
side of the center are glowing, the steered wheel angle
or more. An alarm will sound and a message will be
is between 1 and 9 degrees in the indicated direction.
displayed (on the display panel) informing you that
The first indicator next to the center indicator being the
steering is limited.
only indicator "ON" indicates steered wheel position
between 10 and 34 degrees in the indicated direction. If steering is positioned beyond 10 degrees of straight
ahead and raise is selected, an alarm will sound notify-
ing you that raise is limited to 4570 mm (180 in). A
message will be displayed (on the display panel) in-
forming you that lift is limited to 4570 mm (180 in). To
raise the forks higher, you must steer the truck no more
than 10 degrees from straight ahead travel.
CAUTION
If the drive tire is physically turned while the truck is

"OFF", on power up, the steering indicators will not rep-
resent the proper steer angle. The steering wheel must
be rotated so drive unit and encoder pass through in-
Steer Angle Indicator dex to reset the electronics.
Figure 3303-02
M6.0-7335-002 SP3500 Crown 2007 PF15821-2
510
STEERING
Steering
Steering Wheel Adjustment ment to this friction block. If the steering wheel rotates
after the operator removes his hand, then the friction
To prevent the steering wheel from rotating "Free block needs to be replaced. This is located behind the
Wheeling", after the operator's hand has been re- steering wheel. To gain access, you must first remove
moved, a friction block is used to keep the steering the six screws securing the console cover on. With the
wheel from rotating. The friction block is tightened cover removed, the steering command assembly will
against the steering wheel shaft. There is no adjust- be visible. Refer to Figure 17865.
Part of
Platform
Figure 17865
Crown 2007 PF15821-3 SP3500 M6.0-7335-003
511
STEERING
Steering
Steering Motor Gearbox

The steering motor gearbox should be filled to the level
indicator plug on the end of the gearbox with DTE 24
lubricant. Capacity of the gearbox is 0.95 liter (2 pints).
Fill Plug
Level Indicator Plug
Figure 3246-01
M6.0-7335-004 SP3500 Crown 2007 PF15821-4
512
LIFTING MECHANISM
513
Notes:
514
LIFTING MECHANISM
Mast
Mast Shim Basics

Your truck is equipped with either a TL or TT style mast The mast is designed to be at its tightest point when
assembly. Masts are constructed of hot rolled carbon fully extended and loosest when fully lowered. This al-
steel I-beams welded to flat formed plates. They tele- lows the mast column rollers to move freely as the mast
scope on alloy steel column rollers. extends while providing maximum stability when fully
extended. Each mast is designed to be wider at the
bottom than the top. If the mast was shimmed so that it
TL Mast was tight when fully lowered, it would not fully extend
because of mast channel to column roller binding at
(Not Available On SP3570/80/71/81) about 75% of lift height causing detrimental effects to
the mast channel. The mast should only be checked for
The TL mast is a two stage mast assembly using two
tightness when near full extension.
lift cylinders mounted to the bottom of the main frame
and at the top of the 2nd stage mast. The lift chain is To add shims behind the column roller, the column
anchored at the top of the main frame and routed over roller must be removed and shims added behind the
the 2nd stage mast and anchored to the bottom of the column roller on the roller stud. Refer to Figure
platform. Refer to Lifting Mechanism for lift chain rout- 17000-01.
ing.
mounted in the power unit, to the top of the main frame
and over the top of the 2nd stage mast through a series
of pulleys and secured on the platform and connected
to CA104 and CA106 on the platform. Refer to Electri-
cal for control cable routing.
TT Mast
The TT mast is a three stage assembly using two lift
cylinders mounted to the bottom of the main frame and
secured at the top of the 2nd stage mast and a free lift
cylinder mounted on the 3rd stage mast. The lift chain
is anchored at the top of the main frame, routed over
the 2nd stage mast and secured at the bottom of the
3rd stage mast. Another lift chain is secured in the mid-
dle of the 3rd stage mast, routed over the free lift cylin- (a) Top of Main Frame
der yoke and anchored to the bottom of the platform. (b) Shims 0.80 mm (0.03 in) AR
Refer to Lifting Mechanism for lift chain routing. (c) Column Roller 100 mm (4 in) Diameter
mounted in the power unit, to the top of the main frame Figure 17000-01
and over the top of the 2nd stage mast. Control cables
are then run through a series of pulleys mounted to the
thick. When shims are installed it is always ideal to
bottom of the 3rd stage mast and routed over the free
have an equal number of shims on each column roller
lift cylinder yoke to the platform and connected to
stud. Often times this is not possible. If an unequal
CA104 and CA106 on the platform. Refer to Electrical
number of shims are required, it is very important that
for control cable routing.
an equal distribution of shims per side be followed. Re-
A hydraulic hose is run off a tee connector at the bot- fer to Figure 17001. An example would be two shims
tom of the left lift cylinder and routed over the top of the
on each roller stud of the left column rollers and one
2nd stage mast down to the bottom of the free lift cylin-
each on the right side column roller studs. If the shims
der mounted on the 3rd stage mast. Refer to Hydraulic
are not installed in this manner, mast tilting will occur.
for hydraulic hose routing.
Crown 2007 PF15797-1 SP3500 M7.0-7335-001
515
LIFTING MECHANISM
Mast

(b) Not Adjustable
(b) 2 Shims (Platform)
(d) 2 Shims (Platform)
(d) 2 Shims (Mast)
(e) 2 Shims (Mast)
(e) 1 Shim (Mast)
(f) 1 Shim (Mast)
Figure 17001 Figure 17002-01
M7.0-7335-002 SP3500 Crown 2007 PF15797-2
516
LIFTING MECHANISM
Mast
screws securing bottom of the lift cylinders to the main

WARNING frame.
them at pinch points. Make sure lifting device is suffi-
ciently rated to lift various parts of the mast sections
securely blocked. Refer to Control of Hazardous En-
ergy Lockout/Tagout for lifting and blocking proce-
dures.
TL Mast Column Roller Removal

shimming, it is a good idea to review Shim Basics and 150 mm
Mast Testing portions of this chapter. To determine (6.0 in)
ances).
The truck must be in an area with enough overhead Hardwood Block
clearance to fully extend the mast. Make lifting equip- (Block Both Outriggers
ment connections to the top of the mast assembly. The and Power Unit)
must be of sufficient capacity or size to safely handle Figure 10066-02
the mast assembly. Lifting equipment such as hoists or Attach lifting device to the 2nd stage mast, raise ap-
other lift trucks with insufficient capacity may break or proximately 40 mm (1.5 in). Once the top of the mast
become unstable and an unsafe condition may arise, clears the lift cylinders, lean the lift cylinders in towards
which must be prevented. The weight of the TL mast the middle of the truck. Refer to the mast clears the lift
assembly is 800 - 1100 kg (1750 - 2350 lb). Platform cylinder, lean the lift cylinders in towards the middle of
weight including forks is 500 - 750 kg (1100 - 1650 lb) the truck. Refer to Figure 0334P-01.
Power unit weight including battery is 1650 - 1900 kg
(3650 - 4130 lb).
Disconnect battery.
If necessary for repairs, remove platform. For platform
removal and shimming procedures refer to Platform
and Control of Hazardous Energy Lockout/ Tagout.
Using a lifting device, raise the load wheels 150 mm
(6.0 in) and block each outrigger and power unit. Avoid
wire guidance sensors under the power unit skirt edge
if present on truck. Refer to Figure 10066-02.
Remove screws securing top of the lift cylinders to the
2nd stage mast. Refer to Figure 17003-01. Loosen
Crown 2007 PF15797-3 SP3500 M7.0-7335-003
517
LIFTING MECHANISM
Mast
NOTE
stage mast.
Figure 0334P-01
Raise platform using a lifting device 75 - 130 mm (3.0 -

5.0 in) and block. Refer to Figure 10064-02.

(b) Lift Cylinders
Figure 17003-01
Remove column rollers and note number of shims on

each roller stud. Remove column rollers carefully.
Many times shims cling to the back of the column roll-
ers and fall off after removal.
Refer to Shim Basics.
Block Platform
75 - 130 mm (3.0 - 5.0 in)
Figure 10064-02
Using a lifting device, lower the 2nd stage mast to ex-

pose the column rollers. This should also expose the
column rollers at the top of the main frame.
M7.0-7335-004 SP3500 Crown 2007 PF15797-4
518
LIFTING MECHANISM
Mast
TT Mast Column Roller Removal

shimming, it is a good idea to review Shim Basics and
Mast Testing portions of this chapter. To determine
ances).
The truck must be in an area with enough overhead
clearance to fully extend the mast. Make lifting equip-
ment connections to the top of the mast assembly. The
must be of sufficient capacity or size to safely handle
the mast assembly. Lifting equipment such as hoists or
other lift trucks with insufficient capacity may break or
become unstable and an unsafe condition may arise,
which must be prevented. The weight of the TT mast
assembly is 1050 - 1850 kg (2350 - 4100 lb). Platform
weight including forks is 500 - 750 kg (1100 - 1650 lb)
Power unit weight including battery is 1650 - 1900 kg (a) Top of Main Frame
(3650 - 4130 lb).
(b) Chain Anchor
WARNING Figure 17005-01
Wear appropriate protective items such as safety Remove control cable pulleys and free lift hose pulley
glasses, steel-toe shoes, etc. whenever performing on 2nd stage mast and secure to one side.
gers, hands, arms or feet through mast or position Lower 3rd stage mast to expose column rollers on the
them at pinch points. Make sure lifting device is suffi- bottom of the 3rd stage mast and top of the 2nd stage
ciently rated to lift various parts of the mast sections mast.
WARNING
securely blocked. Refer to Control of Hazardous En- When lowered, the platform will rest on top of the out-
ergy Lockout/Tagout chapter for lifting and blocking riggers. Keep feet and hands clear when platform is be-
procedures. ing lowered.
Disconnect battery. Remove column rollers and note number of shims on
If necessary for repairs, remove platform. For platform each roller stud. Remove the column rollers carefully.
removal and shimming procedures, refer to Platform Many times shims will cling to the back of the column
and Control of Hazardous Energy Lockout/Tagout. roller and fall off after removal.
Using a lifting device, raise the load wheels 150 mm Remove screws securing top of the lift cylinders to the
(6.0 in) and block each outrigger and power unit. Avoid 2nd stage mast. Remove hydraulic hose guide on the
wire guidance sensors under the power unit skirt edge lift cylinder and secure to one side. Loosen screws that
if present on truck. Refer to Figure 10066-02. secure bottom of the lift cylinders to the main frame.
Using a lifting device, raise the 3rd stage mast enough
to loosen the lift chain anchored to the 3rd stage mast.
Remove nuts from chain anchors at top of main frame.
Remove chain anchors and secure to one side.
Crown 2007 PF15797-5 SP3500 M7.0-7335-005
519
LIFTING MECHANISM
Mast

(b) Lift Cylinders
(c) Hydraulic Hose Guide (TT Only)
Block 3rd Stage Mast
75 - 130 mm (3.0 - 5.0 in)
Figure 17006-01 Figure 10067-02
Attach a lifting device to the 3rd stage mast and raise Attach lifting device to the 2nd stage mast and raise
75 - 130 mm (3.0 - 5.0 in) and block. approximately 40 mm (1.5 in). Once the top of the mast
clears the lift cylinders, lean the lift cylinders in towards
NOTE the middle of the truck. Refer to Figure 0334P-01.
The 3rd stage mast and platform are connected. When With the use of a lifting device, lower the 2nd stage
the 3rd stage mast is raised the platform will also be mast to expose the column rollers. This should also ex-
raised. pose the column rollers on the bottom of the 2nd stage
mast and the column rollers on the top of the main
frame.
M7.0-7335-006 SP3500 Crown 2007 PF15797-6
520
LIFTING MECHANISM
Mast
Shim Measurements (Tolerances)

Once the mast has been reassembled, the mast col-
umn roller travel and clearance should be checked.
Extend the mast to its maximum lift height, and then
lower the mast so the column rollers are 25.4 mm
(1.0 in) away from the stops. This will ensure the mast
does not twist. The reason the mast must be raised is
to bring it to its tightest point. When fully lowered, it is
at its loosest point.
WARNING
them at pinch points.
(a) Bottom of 2nd Stage Mast

(b) Shims 0.80 mm (0.03 in) AR CAUTION
(c) Column Rollers 115 mm (4.5 in) in Diameter Make sure the platform the maintenance person rides
on is secure and the individual is using an operator har-
Figure 17004-01 ness.
NOTE With the use of a man-up vehicle, check all mast col-
umn rollers (four on TL masts and eight on TT masts).
To check column roller(s) with the mast extended, use
a pry-bar to shift the mast channels to one side. This
will force the opposite side tight against the mast chan-
stage mast.
nel. This is necessary to seat each column roller
Remove column rollers and note number of shims on against the roller stud shoulder to allow for an accurate
each roller stud. Remove the column rollers carefully. column roller to channel clearance measurement.
Many times shims cling to the back of the column roll- Once the mast has shifted, retain slight pressure to
ers and fall off after removal. keep the mast from slipping back.
See Shim Basics. Measure the distance between the channel and the
column roller; 10 mm (0.375 in) from the channel face,
refer to Figure 17007-01. Always measure from the
side the column rollers are canted toward. If the dimen-
sion is greater than 0.8 mm (0.031 in) then a shim
needs to be added behind the column roller, refer to
Figure 17007-01. If the dimension is 0.000 and it does
not appear to be too tight, proceed in checking the re-
maining column rollers. The test procedure after as-
sembly will determine if the column rollers with the
0.000 clearance will require shim removal.
Crown 2007 PF15797-7 SP3500 M7.0-7335-007
521
LIFTING MECHANISM
Mast
with a cloth. Spray the channel with a thin coat of paint.

This will allow a visible indication of where the column
rollers are traveling. Repeat as required.
(a) Pry Bar

(b) Feeler Gauge
Channel Should Only Show Wear Here
Figure 17007-01
Figure 0337P-01
Accurate measurements can only be checked from one
side. Once the previously described dimensions are Once the mast meets requirements, grease the mast
obtained, the mast channel column rollers will be within channels (063003-024). When the mast is raised to
tolerance. When adjustment is required, try to even out near full extension, it should not lean left or right; it
the number of shims per side. Example: two shims should appear even and straight. If a leaning condition
right, two shims left. Refer to Shim Installation and exists, it is a sign the shimming is too loose or unbal-
Shim Basics and Figures 17001-01 and 17002-01. anced and will need to be readjusted, refer to Shim Tol-
erance.
Proceed to check the remaining column rollers. For
platform column rollers measurements, refer to Plat-
form. Flaking
It is not uncommon for a new mast to appear as if it's
Mast Testing (Assembled) flaking or peeling. This appearance is an indication the
column rollers are seating to the mast channel and is
Once the mast is assembled there are a few tests that considered normal. Eventually this condition will disap-
can be made to verify that mast column rollers are pear. Grease applied to the mast channel will retain
traveling correctly. these particles.
Inspect each channel for column roller tracking path.
The only area that should show wear is the back por- Shim Removal
tion of the I-beam where the column roller travels. Re-
fer to Figure 0337P-01. The I-beam should not show Under certain circumstances it may be necessary to re-
signs of any cutting or grooving. If cutting or grooving is move shims after the mast is assembled. When neces-
evident, it will normally take place at the side of the col- sary, refer to the following procedures.
umn roller; 10 mm (0.375 in) from the channel face. If
this type of wear is evident, a shim will have to be re-
moved, refer to Shim Removal. WARNING
Once a readjustment has been made by removing or Wear appropriate protective items such as safety
adding shims, a recheck of the mast channel will be glasses, steel-toe shoes, etc. whenever performing
required. To see the new wear pattern, clean the chan- maintenance work. To avoid injury, DO NOT place fin-
nel with a solvent that will remove grease and wipe dry
M7.0-7335-008 SP3500 Crown 2007 PF15797-8
522
LIFTING MECHANISM
Mast

them at pinch points. WARNING
Top Column Rollers glasses, steel-toe shoes, etc. whenever performing
(Refer to Figure 3329-01) gers, hands, arms or feet through mast or position
Completely lower the mast. them at pinch points.
To access the shims behind the column rollers, use a Make sure lifting device is sufficiently rated to lift vari-
pry bar to push the column roller out. ous parts of the mast sections either individually or as
a group. Make sure that the blocking material is strong
Locate a shim and push it away to isolate it from the enough to withstand the weight. Never work under or
remaining shims. around a truck that is not securely blocked. Refer to
Using a hammer and small chisel, break the shim and Control of Hazardous Energy Lockout/Tagout chapter
remove from roller stud. for lifting and blocking procedures.
Bottom Column Rollers Mast Removal

(Refer to Figure 3329-01) The mast assembly and platform can be removed from
the truck as one unit. However, if the platform needs to
Raise the mast to a position where the column roller be removed first, refer to Platform and Control of Haz-
that requires a shim to be removed is accessible. ardous Energy Lockout/Tagout for platform removal
Support and block the mast. Refer to Control of Haz- procedures.
ardous Energy Lockout/Tagout. Raise platform and remove forks. Refer to Platform for
Locate a shim and push it away to isolate it from the fork removal procedures.
remaining shims. Disconnect battery and chock wheels.
Using a hammer and small chisel, break the shim and
remove from roller stud.
CAUTION
Don't allow any metallic objects to come in contact with
top of the battery before and during the removal and
installation process.
Remove battery from power unit. Refer to Battery and
Control of Hazardous Energy Lockout/Tagout for bat-
tery removal procedures
Using a lifting device, raise the truck, block the power
unit and main frame assembly on both sides of the
truck so the load wheels are just off the floor.
CAUTION
The power unit, if not blocked, will fall to the floor once
the mast assembly is removed. The power unit should
Isolate Shim be blocked so it remains parallel with the floor.
& Remove
Figure 3329-01
Crown 2007 PF15797-9 SP3500 M7.0-7335-009
523
LIFTING MECHANISM
Mast
Attach Strap or Chain

to All Top Braces
(a) Wheel Chock

(b) Hard Wood Blocks (Block Both Sides
of Main Frame and Power Unit)
Figure 17008-01
Attach a strap or chain to all top cross braces so all

mast sections can be lifted at once. Refer to Figure
10587-01.
Attach sufficiently rated lifting device to strap/chain
around all top cross braces on mast sections to be re-
Figure 10587-01
moved. Refer to Figure 10587-01.
Disconnect hydraulic lines to lift cylinders and catch
and clean up all oil spillage. Secure hydraulic lines out
of the way.
Disconnect control cables connected to the distribution
board located in the power unit. Note location and rout-
ing of cables.
Disconnect limit switches from distribution board and
secure out of the way if present on truck.
Secure height sensor on back of platform if present on
truck. Refer to Platform.
Using a lifting device apply tension to the strap/chain
that is connected to the top of the mast assembly.
M7.0-7335-010 SP3500 Crown 2007 PF15797-10
524
LIFTING MECHANISM
Mast
NOTE
Shims may be in place when the main frame is secured
to the power unit. Note location and number of shims
used. These shims must be installed in the same loca-
tion at assembly.
Remove six screws that mount the mast assembly to
the power unit. When installing these screws apply
thread locking adhesive (061004-019) and torque to
325 - 353 Nm (240 - 260 ft lb).
Lift and remove mast assembly from truck.
Mast Assembly
Reverse the above procedures for installing the mast
on the truck.
Crown 2007 PF15797-11 SP3500 M7.0-7335-011
525
Notes:
526
LIFTING MECHANISM
Lift Chains
Lift Chains
Lift chains are highly important components on fork lift
trucks. The chain system on your mast was designed
for efficient, reliable transmission of lifting force from
hydraulic cylinder(s) to the mast, platform (if present)
and forks. Safe, uninterrupted use of your lift truck de-
pends on the proper care and maintenance of the lift
chains.
Most complaints of unsatisfactory chain performance
can be traced directly to inadequate maintenance.
Highly stressed precision chains require periodic main- Roller and Leaf
tenance to deliver maximum service life. Chain Wear Scale
Inspection
After every 100 hours of truck operation, lift chains
should be inspected and lubricated. When used in an
extremely corrosive environment, inspect chains every
50 working hours. During inspection, check for the fol-
lowing:
Wear
As the chain flexes on and off pulleys, the joints gradu- Figure 16844
ally wear.
Chain wear can be measured by using a 106440 wear
The "stretch" a chain develops during usage is due to scale or a steel tape (Refer to Figure 16844). When
material being worn off of pin outside diameter and pin chains have elongated 3%, as represented on scale
hole inside diameter on the inside plates. "A" (19 mm [0.75 in] or 25 mm [1.0 in] pitch chain) or
scale "B" (16 mm [0.625 in] pitch chain) of the wear
scale, they should be discarded. On chain with 19 mm
(0.75 in) between pins, for example, 305 mm (12.0 in)
of chain contains 16 pitches or links. When 16 pitches
measure 314 mm (12.375 in) the chain should be re-
placed. On chain with 16 mm (0.625 in) between pins,
20 pitches or links equal 318 mm (12.5 in). When 20
pitches measure 327 mm (12.875 in) the chain should
be replaced. Crown currently uses 16 mm (0.625 in)
pitch (20 links in 318 mm [12.5 in]), 19 mm (0.75 in)
pitch (16 links in 305 mm [12.0 in]) and 25 mm (1.0 in)
pitch (12 links in 305 mm [12.0 in]) chain. When check-
ing chain wear, be sure to measure a segment of chain
that operates over a pulley. Do not repair chain(s) by
cutting out the worn section and splicing in a new
piece. If part of a chain is worn, replace lift chain(s). If
truck has a matched set of lift chains replace both
chains at same time.
Crown 1984 PF5856-1 Rev. 7/07 SP3500 M7.5-18.0-001

08 Rev. 7/07
527
LIFTING MECHANISM
Lift Chains
Corroded Chain
(with Stress-Corrosion Cracks)
With Forks Lowered Figure 16846

Check Either Front Heavy motor oil serves both as a joint lubricant and
or Rear Pulley for corrosion inhibitor. During inspection, carefully exam-
Chain Wear ine external chain surfaces for the presence of an oily
film. Under certain operating or environmental condi-
tions it may be necessary to oil chains more frequently
than 100 hour intervals. In all cases, the external sur-
face of the chain must be protected with a film of oil.
Corroded chains should be inspected for cracked
plates. Outside plates are particularly susceptible to
stress corrosion cracking. If chains are heavily rusted
Figure 16845
or corroded they should be removed from the mast for
a thorough inspection for cracked plates. If plates are
Rust and Corrosion cracked, both chains on the truck must be replaced. Oil
Chains used on lift trucks are highly stressed precision chains when they are reinstalled on the mast.
components. It is very important that "as-manufac-
tured" ultimate strength and fatigue strength be main- Cracked Plates
tained throughout the chain service life.
The most common cause of plate cracking is fatigue
Corrosion will cause a major reduction in the load-car- failure. Fatigue is a phenomenon that affects most met-
rying capacity of lift chain or roller chain because cor- als and many plastics. After many repeated heavy
rosion causes side plate cracking. loads the plates may crack and the chains will eventu-
It is extremely important to protect lift chains from cor- ally break.
rosion, whether in service or in storage. The initial fac-
tory lubrication on chains is an excellent rust and cor-
rosion inhibitor. Factory lube is applied in a hot dip tank
to insure complete penetration into the joint. Do not
steam clean or degrease new chains. After the chain Fatigue Cracks
has been placed in service, factory lube must be sup-
plemented by a maintenance lubrication program.
Refer to applicable lubrication and adjustment section Figure 16847
for your particular truck series and/or the lubrication in-
formation later in this section. Fatigue cracks are almost always found through the pin
holes perpendicular to the pitch line. (Refer to Figure
16847) Contrast this failure mode to the random fail-
ures caused by stress-corrosion cracking. (Refer to
Figure 16846) If any fatigue cracks are discovered dur-
ing planned maintenance (PM) inspections, both lift
chains should be replaced. Many apparently sound
plates will be on the verge of cracking, making chain
failure very likely.
M7.5-18.0-002 SP3500 Crown 1984 PF5856-2 Rev. 7/07
08 Rev. 7/07
528
LIFTING MECHANISM
Lift Chains
Tight Joints
All joints in lift chain should flex freely. Tight joints resist
flexure, increase internal friction, thus increasing chain
tension required to lift a given load. Increased tension
accelerates wear and fatigue problems. Refer to Figure
16848.
Tight Joints Protruding & Turned Pin
Tight joints in lift chains can be caused by: Chain Side Wear
1. Bent pins or plates,
A continuous wear pattern on pin heads and outside
2. Rusty joints, plates indicates misalignment. Misalignment can be
caused by two different factors: unequal chain tension
3. Peened plate edges.
or nonalignment between pulleys and chain anchors.
Oil rusty chains and replace chains that appear bent or
peened. Peening of plate edges may be caused by • Unequal Chain Tension - When a lift chain is in-
worn pulleys, unusually heavy loads, or chain sliding stalled or adjusted, care should be taken to "load"
past a guide or obstruction in the mast. the chains evenly. When changing fork heel height
or platform height for example, the chain anchors
should be loosened until both forks come in contact
Protruding or Turned Pins
with the floor. At this point both chains should dis-
Heavily loaded chains operating with little lube gener- play the same tension or slack. The chain anchor
ate tremendous friction between pin and plates (pin nuts should be tightened an equal number of revo-
and bushing in roller chain). In extreme cases, the fric- lutions on both chain anchors to put equal tension
tional torque in the joint can actually turn pins in the on chains. When the desired height setting is
press-fit outside plates. achieved the locking nut should be tightened to se-
cure setting.
If chain is allowed to operate in this condition, the pins
slowly work out of the chain, causing chain failure. • Non Alignment of Lifting Components - Non
Turned pins can be quickly spotted because the flats alignment of the pulley and chain due to incorrect
on the "V" heads are no longer in line. Refer to Figure shimming of the mast or bent or damaged mast or
16849, pin has turned 45 degrees. Chains with turned cylinder components can also contribute to chain
or protruding pins should be replaced immediately. side wear. A check for this condition is to place the
Never attempt to repair the chain by driving pins back truck on a level area in your maintenance area. Af-
into the chain. ter supporting the fork carriage, disconnect each
end of the lift chain at the chain anchor and visually
inspect its alignment with the anchor slots.
Crown 1984 PF5856-3 Rev. 7/07 SP3500 M7.5-18.0-003

08 Rev. 7/07
529
LIFTING MECHANISM
Lift Chains
Lift Chain Lubrication tremely severe service, may require more frequent lu-
brication to maintain an oil film on all chain surfaces.
The most important consideration in field maintenance
In dusty operating conditions, lubed chains will gather
of lift chains is LUBRICATION. Hard working, heavily
dust. Even under these conditions wear life will be
loaded chains cannot be expected to give satisfactory
greatly improved by periodic lubrication. Joints may ac-
wear life without scheduled periodic lubrication. Like all
quire a "paste" made up of oil and dirt, but joint wear
bearing surfaces, the precision-manufactured, hard-
will still be much less than if the chain is allowed to run
ened-steel, joint-wearing surfaces require a film of oil
dry with metal-to-metal contact between pins and
between mating parts to prevent rapid wear.
plates.
Maintaining an oil film on all chain surfaces will:
At 100 hour intervals, clean chains to remove accumu-
• Minimize joint wear (chain stretch). lation of dirt-and lubricate immediately. (Do not steam
clean chains.)
• Prevent corrosion.
• Reduce the possibility of pin turning.
• Minimize tight joints in roller chain. Lubricant
• Promote smooth, quiet chain action.
• Lower chain tension by reducing internal friction in

the chain system.
Heavy motor oil is an excellent chain lubricant-even
used motor oil is adequate to lubricate exposed lift
chains.
Laboratory wear tests show SAE 40 oil to have greater
ability to prevent wear than SAE 10 oil. Also, SAE 40
oil is superior to hydraulic fluid or automatic transmis-
sion fluid. Generally, the heaviest (highest viscosity) oil Figure 16850
that will penetrate the joint works best.
Laboratory wear testing shows dry film lubes to be less Lift Chain Replacement
effective in preventing joint wear than fluid petroleum
The first step in chain replacement is to find the chain
based products.
part number in your service manual parts list.
Some aerosol spray lubes, such as Crown part number
An important factor in ordering replacement chain from
063001-009, are effective, more convenient and less
the truck manufacturer is that special chains may be
messy than applying motor oils.
specified for your truck with certified minimum ultimate
Whatever method is used, the oil must penetrate the strength.
chain joint to prevent wear. Applying oil to external sur-
If the unit is equipped with two strands, replace chains
faces will prevent rust, but oil must flow into the live
as a pair. It will be virtually impossible to maintain uni-
bearing surfaces for maximum wear life. (Refer to Fig-
form loading between the strands if a new chain is put
ure 16850).
into service opposite an old chain. The joints in the old
Apply oil to chains with a narrow paint brush. A plastic chain will have worn through the hardest layer of the
liquid detergent bottle makes a handy lube applicator. case-hardened pin. Therefore, the wear rate on the old
Flood the chain with oil over its entire length every chain will be greater than that on the new chain, greatly
lube-inspection period. complicating the problem of maintaining equal chain
tension.
Frequency of lubrication will vary with operating condi-
tions and environment. The best estimate of lube pe- The new chain will wear more slowly, causing it to bear
riod is 100 hours actual operating truck time. Trucks the major portion of the load, resulting in premature
parked outdoors, used in freezers or trucks in ex- wear and fatigue failure.
M7.5-18.0-004 SP3500 Crown 1984 PF5856-4 Rev. 7/07
08 Rev. 7/07
530
LIFTING MECHANISM
Lift Chains
Never steam clean or degrease new chains. The man- 2. A support ring (flatwasher) with an inside diameter
ufacturer's grease is effective in reducing wear and cor- slightly greater than the pin diameter and a height
rosion. If the original factory lube is dried out or wiped equal to the head height of the pin.
off, soak the new chain in heavy engine oil for at least
3. Grinding wheel.
0.5 hour prior to installing on truck.
4. Pin punch with a diameter slightly less than the pin
After the existing chains have been removed from the
diameter, hammer or pressing equipment.
mast, very carefully inspect chain anchors and
sheaves. Broken, cracked, or worn anchors must be
replaced. Replace worn sheaves, and check sheave Disconnect Procedures:
bearings for wear. Do not paint the replacement chain (Refer to Figure 16851)
before or after it has been installed. Paint will help pre-
vent corrosion, but will prevent oil from reaching the pin 1. Grind the top head of the pin flush with the pin link
surface for good joint lubrication. plate. Be careful not to grind or damage the pin link
plate.
Install the new chains, using new anchor pins. Existing
pins may contain invisible fatigue cracks that could 2. Position the support ring over opening of the work
lead to pin failure. After chains have been connected to surface. The support ring serves to support the
the anchors, adjust chain tension to obtain proper fork bottom pin link plate and avoids damage to chain
or platform height. components while driving the pin through the
chain.
Correct chain installation and mast adjustment will in-
crease chain service life. 3. Stand the chain on its side and seat pin in the sup-
port ring.
Chain Anchors and Pulleys 4. Remove the pin from the chain through the top pin
link plate.
An inspection of the chain system should include a
close examination of chain anchors, anchor tension
devices and pulleys.
Check chain anchors for wear, breakage, and radial
misalignment. Anchors with worn or broken fingers
should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain.
When chain is misaligned, the load is not distributed
uniformly between the plates-prolonged operation will
result in premature fatigue failure.
Pulleys with badly worn flanges and outside diameter
should be replaced. Heavy flange wear indicates chain
misalignment. Investigate cause by checking chain
tension and mast shimming. (1) Support Ring
(2) Grind Pin Flush with Link Plate
Leaf Chain Disconnect (3) Grinding Wheel
To minimize the risk of damaging (cracking, etc.) the (4) Pin Link Plate
chain, refer to the following when disconnecting leaf (5) Work Surface Knock Out Aperture
chain.
Tools Required: Figure 16851
1. A sturdy work surface with an opening slightly

greater than the pin diameter, and should be thick
enough to allow the pin to extend beneath the work
surface as it is driven through the bottom pin link
plate.
Crown 1984 PF5856-5 Rev. 7/07 SP3500 M7.5-18.0-005

08 Rev. 7/07
531
Notes:
532
LIFTING MECHANISM
Fork
Fork Blade Measurement

Fork wear calipers have two measuring points or jaws.
The inside jaws measure 10 percent less than the out-
Fork Inspection side jaws. Refer to Figure 9237-01
equipment, damaged materials, bodily injury or loss of
life. At each planned maintenance interval an inspec-
tion and measurement of the forks must be made to
check for wear, overload, fatigue, bends, etc. Outside Jaws Inside Jaws
100% 90%
WARNING
Use the proper fork for how it was designed to be used.
Avoid using fork extensions. Figure 9237-01
Do not modify forks. Only qualified personnel should
To set the outside jaws, use a measuring instrument
make such repairs.
such as a vernier or machinist 152 mm (6.0 in) scale
Inspect forks visually each work day.
and set outside jaws at 51 mm (2.0 in). Refer to Figure
9238-01.
Abrasion
Abrasion gradually reduces the thickness of the fork. them square across the shank or an incorrect reading
Be sure fork thickness is up to standard. Do not allow will result.
forks to rub the floor during normal operation (if forks
do rub floor, check lift chain adjustment). Fork wear at
the heel must not exceed 10 percent of the original
mately 80 percent of rated capacity (refer to Chart 2).
Crown has a fork wear calipers (part no.107330) avail- Set at 51 mm (2.0 in)
able for use or a measuring instrument such as a ver-
nier or machinist 152 mm (6.0 in) scale may be used.
For allowable fork wear thickness refer to Chart 1.
Figure 9238-01
Chart 1 Fork Thickness Once the outside jaws are set, check to see if the inside
jaws of the calipers pass over the fork flanks between
Standard Fork Allowable 10% Wear the two ends of taper or between the end of taper and
Thickness Fork Thickness end of fork depending on how your fork was manufac-
tured (check thickest part of fork). If the inside jaws
mm in mm in pass over the fork flanks, replace fork. Refer to Figures
32.0 1.25 28.5 1.12 9239-01 and 9240-01.
38.0 1.50 35.0 1.38

44.5 1.75 40.0 1.56
51.0 2.00 46.0 1.81
57.0 2.25 51.0 2.00
63.5 2.50 57.0 2.25
If using the fork wear calipers refer to the following:
Crown 1988 PF7392-1 Rev. 8/06 SP3500 M7.8-07.2-001

01 Rev. 8/06
533
LIFTING MECHANISM
Fork
calipers square across the bore or an incorrect reading

will result.
Check Fork Rotate

Wear Here Calipers 180°
Mounting
Support
Check Fork
Wear Here
Figure 9239-01
Figure 9242-01
After the jaws are set, remove caliper and using a

measuring instrument such as a verniers or machinist
152 mm (6.0 in) scale, measure across the outside
jaws. The maximum allowable measurement for the
Fork mounting support bore is 43.7 mm (1.72 in) and
Cross Section 42.7 mm (1.68 in) for the platform bore.
Figure 9240-01
Mounting Support And Platform Bore

Measurement
To check for elongation (wear) of the mounting support
and platform bore, the outside jaws of the fork wear cal-
ipers are used by rotating the legs of the calipers so
that the jaws are on the outside.
Use Outside Jaws

for Bore Measurement
Figure 9241-01
Check the mounting support and platform bore by plac-

ing the outside jaws into the bore and locate the largest
diameter of the bore by rotating the calipers 180 de-
grees. Set the jaws to the feel of the bore by lightly tap-
ping on them with a metal object. Be careful to hold the
M7.8-07.2-002 SP3500 Crown 1988 PF7392-2 Rev. 8/06
01 Rev. 8/06
534
LIFTING MECHANISM
Fork
Wear vs. Capacity

Percentage Reduction in Fork Thickness
Percentage Remaining of Specified Fork Capacity
Figure 9243-01
Overloading Fatigue
Know the capacity of the forks and truck. Fork capacity The entire fork should be visually inspected for fatigue
and load center is stamped on the fork (refer to Figure cracks each work day. Normally, a fatigue crack will
9244-01). Overloading can cause permanent deforma- start in an area about the mounting support of the fork.
tion or serious fatigue conditions. Pay particular attention for cracks that transverse the
fork in an area up to 130 mm (5.0 in) either side of the
mounting support. Fatigue cracks are a sign that an
area of the fork has weakened and the fork needs to be
replaced. If a more accurate inspection is necessary,
dye penetrants can be used or magnaflux fork. Refer to
Figure 9245-01
Location of
Capacity and
Load Center
Rating
Figure 9244-01
Figure 9245-01
Crown 1988 PF7392-3 Rev. 8/06 SP3500 M7.8-07.2-003

01 Rev. 8/06
535
LIFTING MECHANISM
Fork

another is 3% of the fork length. Cord
The maximum deformation from fork straightness shall String
be less than 183 degrees. Any angle greater will re-
quire fork repair or replacement. The fork manufacturer
or technicians with the expertise of equal competence
Cord String
are the only parties that should attempt to make such
repairs. Refer to Figure 9246-01.
Figure 9247-01
Hanger
183 Degrees Check for cracks or damage in the area of fork attach-
Max. ment. Check platform and fork rod for excessive wear
or cracks. Repair or replace parts if necessary.
Figure 9246-01 Bottom View

of Platform
To check the fork for straightness, a cord string, car-
penters chalk line or a straight edge 1220 mm (48.0 in)
or longer can be used. For an example of checking fork
straightness, a cord string will be used here (refer to
Figure 9247-01).
Figure 9248-01
CAUTION
maintenance, etc. beneath the platform, blocks should
be positioned under each side of the platform. Refer to
chapter M9.0 for lifting and blocking procedures.
Measure 610 mm (24.0 in) from both sides of the
center of the mounting support and mark edge of fork.
Hold cord string taunt between these two points being
sure the string at both points is even with the top of fork.
Measure the maximum perpendicular distance from
the cord string to top of fork. If this measurement is
greater than 32 mm (1.25 in), the fork is deformed
more than 183 degrees and should be replaced. Refer
to Figure 9247-01.
M7.8-07.2-004 SP3500 Crown 1988 PF7392-4 Rev. 8/06
01 Rev. 8/06
536
CYLINDERS
537
Notes:
538
CYLINDERS

The mast and free lift cylinders (shown in Figure
17013) are single acting ram type cylinders. When lift
is selected, pressurized oil enters the bottom of the cyl-
inders forcing the ram to extend. When lowering, the
weight of the mast assembly, platform and load forces
the oil out to retract the cylinders.
(a) Mast Cylinders

(b) Free Lift Cylinder
(TT Only)
Figure 17013-01
Located in the bottom of the mast and free lift cylinders

(refer to Figure 18211) are velocity fuses. These de-
vices monitor oil flow. Should a break occur in a hy- (a) O-Ring (1) Wiper Ring
draulic line, excess oil flow from the cylinder will force
(b) Retaining Ring (2) Cap
the velocity fuse piston down blocking oil flow, thereby
locking the ram in place. (c) Poppet (3) Packing Rod
(d) Spring (4) Collar
(e) Cylinder (5) Piston
(f) Bleed Screw (6) Bushing
(g) Seal (7) Screw
Ram (8) Velocity Fuse Cartridge
Figure 18211
Crown 1994 PF10326-1 Rev. 11/07 SP3500 M8.0-7330-001

03 Rev. 11/07
539
CYLINDERS
Inspection Disassembly
Great care and cleanliness should be exercised in the
WARNING disassembly and assembly of any hydraulic cylinder.
Wipe all surfaces clean of dirt and oil before attempting
AVOID HIGH PRESSURE FLUIDS-Escaping fluids un- disassembly.
jury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pres- CAUTION
When cleaning piston, be sure to clean seal seating ar-
eas. Protect eyes and face when using compressed
air.
hand.
Any fluid injected into the skin under high pressure Care should be taken when removing the ram from the
should be considered as a serious medical emergency cylinder tube to prevent damage. After cylinder compo-
despite an initial normal appearance of the skin. There nents are disassembled and seals, o-rings and wipers
is a delayed onset of pain, and serious tissue damage are removed, thoroughly wash all metallic parts in sol-
may occur. Medical attention should be sought imme- vent and blow dry with low air pressure. As the cylinder
diately by a specialist who has had experience with this is repaired, be aware of component part condition. Re-
type of injury. place a worn or damaged part. In addition, correct or
replace a part that may be causing other premature
Before disconnecting the battery and initial cylinder re-
wear. If slight scoring of the tube and/or ram is evident,
pair, a careful inspection should be made of the cylin-
sand with aluminum oxide cloth or honing tool until high
der assembly throughout a complete lift and lower se-
areas are removed. Heavily scored components must
quence. Check yoke area for signs of abnormal wear,
be replaced. After all parts are inspected, wash all cyl-
damage, etc. Check rams for any signs of nicks,
inder components in a good grade solvent and dry with
scratches, surface imperfections, etc. that allow abnor-
low pressure air. Place washed components in a clean
mal leakage; improper cylinder operation can create
container until reassembly.
seal damage. Check wiper rings and cap area for com-
ponent wear and/or leakage that is abnormal.
When an excessive amount of hydraulic oil is evident
on the top of the cylinder where the ram exits from the
cap, the rod packing is probably bad and should be re-
placed. Replacement of the packing can be accom-
plished without removing the ram from the cylinder
tube or truck. Refer to Accessing Rod Packing and Rod
Packing Replacement located in this section.
M8.0-7330-002 SP3500 Crown 1994 PF10326-2 Rev. 11/07
03 Rev. 11/07
540
CYLINDERS
Accessing Mast Cylinder Rod Pack- Accessing Free Lift Cylinder Rod
ing Packing
1. Disconnect battery and chock load wheels. 1. Using a lifting device, raise platform approximately
76 mm (3.0 in), disconnect battery and chock load
2. Remove screw, nut and lockwasher located at the
wheels.
top of the mast cylinder ram. Refer to Figure
13834-01. 2. Securely block both sides of the platform. Refer to
3. Disconnect chains secured to free lift cylinder.
CAUTION
Screw, Nut
& Lockwasher
Figure 13834-01
3. Attach a lifting device to the top cross brace of the

2nd stage mast and raise high enough to have ac-
cess to the cylinder cap. Securely block the mast.
Refer to Control Of Hazardous Energy Lockout/Ta-
gout and Lifting Mechanism for lifting and blocking
procedures.
Crown 1994 PF10326-3 Rev. 11/07 SP3500 M8.0-7330-003

03 Rev. 11/07
541
CYLINDERS
Rod Packing Replacement

1. Remove bleeder screw. Refer to Figure 18213.
2. Remove cylinder cap from the cylinder. Refer to
Figure 18213.
(a) Number 8 Metal Screw (Headless)

4 mm Self-Tapping
(b) Screwdriver
152 mm (6.0 in) Shaft Length (Minimum)
(a) Cylinder Tube 4 mm (0.156 in) Shaft Diameter (Maximum)
(b) Cap (c) Tape
(c) Seal (d) Weld (Grind Off Excess) to a Maximum Di-
(d) Bleed Screw ameter of 4 mm (0.156 in)
3. The rod packing can now be removed. To facilitate 4. Insert tools between ram and the cylinder walls,
packing removal, a pair of special tools can be 180 degrees apart, and screw into the face of the
made. Refer to Figure 18213. To make these tools, packing to be removed. Refer to Figure 18215. Af-
weld or braze a headless 4.0 mm (No. 8) metal ter the threads are sufficiently secured into the
self-tapping screw to the end of a screwdriver. The packing, pull gently on the screwdriver handles un-
screwdriver must have at least a 152 mm (6.0 in) til the packing is removed.
shank length with no larger than a 4.0 mm (0.15 in)
shank diameter. After attaching the screw to the
screwdriver, grind off excess weld to a diameter of
4.0 mm (0.15 in). Wrap the shank with electrical
tape from tip of the screw to the screwdriver han-
dle. This will prevent scratching of the cylinder tube
or ram.
(a) Cylinder Tube

(b) Seal Pulling Tool
(c) Ram
(d) Seal
Figure 18215
M8.0-7330-004 SP3500 Crown 1994 PF10326-4 Rev. 11/07
03 Rev. 11/07
542
CYLINDERS
NOTE
Extreme care should be taken to prevent damage to
cylinder wall and ram assembly.
5. Remove the wiper ring from the cylinder cap since
the packing rod and wiper ring should always be
replaced at the same time. Thoroughly clean
where the seals seat. Any burrs, dirt or seal debris
must be removed before installing replacement
seals.
CAUTION
Close inspection of seal seating critical areas should
be made before replacement seal is installed. Your
seal failure may not have been caused by a worn seal,
but rather by burrs, nicks and dirt located on the seal (a) Cylinder Tube
seating area, causing the seal to deform and loose its (b) Sleeve
sealing ability. (c) Forging Tool
6. Lightly apply clean hydraulic oil to replacement (d) Seal

seals and seal contact areas of cylinder and instal- (e) Critical Seal Seating Area
lation tools. Install rod packing in cylinder "lip" first. (f) Collar
A sleeve should be used to protect the seal from
damage on threads and shoulders, refer to Figure Figure 18216
18216. Tools used to install hydraulic seals should
be of soft metal or suitable plastic, free of burrs and 7. Install wiper ring and assemble cap to cylinder.
sharp edges. Screwdrivers and other similar tools 8. Inspect bleed screw seal and replace if needed.
should not be used. Crown has sleeves (Poly-Pak Apply hydraulic sealant (061004-023) to bleed
Seal Tools) available for installing replacement screw threads and install seal and screw.
seals. Refer to Cylinders for correct Poly-Pak seal
tool. 9. Install yoke and connect lift chains.
10. Cycle cylinder(s) to check operation and leakage.
11. Bleed air from cylinder before placing truck back
into service.
Crown 1994 PF10326-5 Rev. 11/07 SP3500 M8.0-7330-005

03 Rev. 11/07
543
CYLINDERS
Mast Cylinder Removal 3. Attach a lifting device to the top cross brace of the
2nd stage mast and raise mast approximately
1. Disconnect battery and chock load wheels. 1524 mm (60.0 in). Securely block mast. Refer to
2. Remove screw, nut and lockwasher located at top
Lifting Mechanism for lifting and blocking proce-
of the mast cylinder ram. Refer to Figure 13834-01.
dures.
4. Disconnect hydraulic hoses and cylinder screws at
bottom of cylinder, refer to Figure 18217. Be pre-
pared to catch hydraulic oil.
Screw, Nut
& Lockwasher
Figure 13834-01
(a) Part of Mainframe
(b) Remove Hoses and Fittings
WARNING
(c) Remove Screws
glasses, steel-toe shoes, etc. whenever performing Figure 18217
maintenance work. To avoid injury, Do Not place fin-
gers, hands, arms or feet through mast or position 5. Attach a lifting device to cylinder to secure cylinder.
them at pinch points. Remove hose guides.
Make sure lifting device is sufficiently rated to lift vari- 6. Remove cylinder from truck.
ous parts of the mast sections either individually or as
a group. Make sure that the blocking material is strong 7. Reverse the above procedures for reinstalling cyl-
enough to withstand the weight. Never work under or inder on truck.
around a truck that is not securely blocked. Refer to
Control Of Hazardous Energy Lockout/Tagout chapter
for lifting and blocking procedures.
M8.0-7330-006 SP3500 Crown 1994 PF10326-6 Rev. 11/07
03 Rev. 11/07
544
CYLINDERS
Free Lift Cylinder Removal

1. Using a lifting device, raise platform approximately
76 mm (3.0 in). Disconnect battery and chock load
wheels.
2. Securely block both sides of the platform. Refer to
3. Disconnect chains secured to free lift cylinder. Re-
CAUTION
5. Attach a lifting device to cylinder to secure cylinder
and disconnect hydraulic hoses at bottom of cylin-
der.
6. Remove nuts and clamp securing cylinder to 3rd
stage mast. Refer to Figure 18218.
7. Remove cylinder.
(a) Yoke Mounting Screw

(b) Cylinder Mounting Screws
(c) Cylinder Mounting Screw
Figure 18218
Crown 1994 PF10326-7 Rev. 11/07 SP3500 M8.0-7330-007

03 Rev. 11/07
545
CYLINDERS
Mast And Free Lift Cylinder Assem-

bly
Before assembling cylinder, coat all seals, ram, tube,
etc. with clean hydraulic oil. When installing ram into
cylinder tube, never allow ram to come in contact with
any sharp edges. Extreme care must be taken not to
damage seals or the surfaces they operate on. Apply
thread locking adhesive (061004-026) to velocity fuse
cap screws.
Mast And Free Lift Cylinder Installa-

tion
To install cylinder, reverse removal procedures. Apply
thread locking adhesive (061004-019) to lower cylinder
mounting screws.
After the cylinder is installed on the truck, but before the
truck is put back into operation, air must be bled from
the hydraulic system. Without a load on the forks, raise
platform approximately 150 - 305 mm (6.0 - 12.0 in) to
pressurize the cylinder. Loosen bleeder screw, located
at the top of the cylinder until all air escapes and only a
solid stream of oil continues to flow from the screw.
Tighten the screw and completely lower mast and plat-
form to relieve all pressure in cylinder. Loosen bleed
screw 2-3 revolutions. Remove oil from threads with
degreaser and dry with low pressure air. Apply hydrau-
lic sealant (061004-023) to threads and tighten screw.
Verify hydraulic oil level in reservoir and add as
needed.
M8.0-7330-008 SP3500 Crown 1994 PF10326-8 Rev. 11/07
03 Rev. 11/07
546
PLATFORM
547
Notes:
548
PLATFORM
Platform
Platform
Service and/or repair of the platform and components
may be necessary to keep the truck operating properly.
Use the following information as an aid in maintaining
proper platform condition and operation.
Floor Mat Replacement Safety Shield

Remove the worn floor mat and thoroughly clean the
platform floor surface. Apply a thin coat of adhesive
(061001-031) to the back side of mat and platform
floor. Do Not apply adhesive to back side of the mat if
it is a sponge type surface, rather apply a heavier coat Figure 17029
to the platform floor. Allow the adhesive to become
A special tool 103792 will aid in the installation of the
tacky (approximately 10 to 15 minutes). Place mat in
wedge locking strips. To use the tool, the strip must be
position and apply pressure to insure good contact be-
fed through the throat of the tool head (refer to Figure
tween mat and platform floor.
17030), leaving approximately 25 mm (1.0 in) of strip
exposed beneath the head. The tool should then be in-
serted into the "V" slot in the main molding body. Once
started with both the strip and body ends flush, clamp
the end with your thumb and push the tool through the
slot. If the tool seems to push relatively hard, heat can
be applied to the molding which will liquefy the film on
the molding and act as a lubricant.
Floor Mat
Figure 17028
Safety Shield
It may be necessary to remove the safety shield when
performing service to certain areas of the platform. The
safety shield is mounted in rubber molding so that it is
(1) Main Moulding Body
fully suspended. Assemble the molding and safety
shield. Refer to Figure 17030. The wedge locking strip (2) Wedge Locking Strip
must be pressed into the open groove to secure the (3) Wedge Insertion Tool
shield in place. (4) Glass
Figure 17030
Crown 2010 PF17884-1 SP3500 M9.0-7335-001
549
PLATFORM
Platform
Forks Fork Replacement
Fork Inspection WARNING

Visually inspect forks for cracks, deformation, proper
Wear appropriate items, such as safety glasses, when-
mounting, etc. Refer to Forks section of this service
ever performing maintenance work. Do not place fin-
manual for inspection information. The platform needs
gers, hands or arms through mast or position them at
to be raised accordingly to inspect the portion of fork
pinch points.
beneath the platform. Refer to Platform for additional
information.
CAUTION and sling are sufficiently rated to withstand the weight
When performing any type of inspection, adjustment, not properly secured. Refer to truck Data Plate for truck
maintenance, etc. beneath the platform, hardwood weight information.
blocks should be positioned under each side of the It will be necessary to disconnect and remove the bat-
platform along the mast channel. Refer to Control Of tery from the truck, disconnect tilt cylinders from the
Hazardous Energy Lockout/Tagout in this manual and mast, disconnect electrical connections and hydraulic
refer to Figure 17031. lines. "Control of Hazardous Energy" section provides
Raise platform approximately 610 mm (24.0 in) and
securely block. Refer to Control Of Hazardous Energy
Lockout/Tagout in this manual. Wrap a chain as tight as
possible around the platform floor. As the forks pins are
removed this chain will help support the heel of the
fork. Using a sling on the fork to make sure the fork
weight is balanced evenly. Remove retaining ring from
end of fork rod. Using a lifting device to assume the fork
weight, carefully remove fork pin.
NOTE
Shorter tapered fork lengths will tend to be heavier in
the heel area. Care must be taken to handle fork safely
after removal.
Fork installation requires a balance fork hook-up to the
lifting device that allows for the fork to be raised safely
into position. Install fork pin and retaining ring.
Shims are used in the heel area of the fork to obtain the
proper position of the fork tip. Fork tip height should be
Figure 17031 the same as fork height at the rear edge of the platform.
Be sure measurement is taken on a level surface. Ap-
(1) Hardwood Blocks 100 mm x 100 mm (4.0 in x 4.0 in)
ply thread locking adhesive to the screws securing
(2) Operator Platform shims to platform.
(3) Pallet Grab
(4) Fork
M9.0-7335-002 SP3500 Crown 2010 PF17884-2
550
PLATFORM
Platform
After forks have been inspected, replaced, etc. remove Pallet Grab
chain from platform. Raise platform and remove blocks
from under platform. Lower platform completely and (Refer to Figure 17033)
measure fork height from floor. Fork height should be
The pallet grab is located beneath the operator plat-
approximately 75 mm (3.0 in) from top of fork to floor at
form. Mechanical linkage connects the mounting plate
maximum lowered position. If the fork height is not cor-
beneath the platform to the operator release handle lo-
rect, then the lift chains will have to be adjusted.
cated below the control module. The pallet grab is foot
applied and hand released. The platform must be
Fork Height Adjustment blocked before performing any service to the pallet
grab. Reference Control Of Hazardous Energy Lock-
out/Tagout in this manual for lifting and blocking in-
Refer to Figure 17032. On trucks equipped with TL structions.
mast, fork height is adjusted at the chain anchors lo-
cated both sides at the top of the main frame. On trucks Release Handle Adjustment
equipped with TT mast, fork height is adjusted at the
chain anchors located on the free lift cylinder. With the The release handle is in a near horizontal position and
platform completely lowered, adjust the forks so the top should be parallel to the cutout in the console when the
of the forks is a maximum of 75 mm (3.0 in) from the pallet grab is not being used (foot pedal in the "up" po-
floor. Allow for a 6.5 mm (0.25 in) clearance between sition). To maintain this position an adjustment can be
underside of platform and top of outrigger. made to the push rod connecting the handle to the
latch located on the power unit side of the platform. Re-
move pin from the connecting rod and latch. Loosen
"jam" nut securing push rod end to the push rod. Turn
rod end counterclockwise to lengthen push rod and this
will rotate the release handle "down". Turn the rod end
clockwise to shorten push rod and this will rotate han-
dle up.
Foot Pedal Adjustment
CAUTION
service, etc. beneath the platform, hardwood blocks
should be positioned under each side of the platform
along the mast channel. Refer to Control Of Hazardous
Energy Lockout/Tagout in this manual.
The foot pedal has spring tension applied to it con-
stantly during normal release and applied conditions.
When the pedal is "up" or released position, the back-
Figure 17032 side of the pedal is contacting a poly stop. The poly
stop prevents metal to metal contact between the pedal
(1) TL Mast Chain Anchor and the platform. Inspect the poly stop and replace if
(2) TT Mast Chain Anchor needed.
Crown 2010 PF17884-3 SP3500 M9.0-7335-003
551
PLATFORM
Platform
Pallet Grab Removal

Two cables are used with the pallet grab mechanism;
they are referred to as cable "E" and "F". Cable "E" is
the shorter of the two cables (approximately 368 mm
[14.5 in] overall length) and cable "F" is the longer ca-
ble (approximately 1346 mm [53.0 in] overall length).
Should cable "E" or "F", springs, pulleys, etc., need re-
placement the pallet grab can be removed from the
platform by removing two screws near the rear of the
platform. Hold the pallet grab in position until both
screws are removed. The pallet grab can be rotated
down the "L" shaped mounting bracket located under
the platform floor. Be careful the pallet grab does not
slip from this bracket. Remove cotter pin, flatwasher
and cable from point "G". Remove pallet grab from plat-
form and place on workbench for repair.
When reassembling the pallet grab override spring, in
the pallet grab released position should measure
Figure 17033-01 143 mm (5.62 in) overall length. Refer to Figure
17033-01.
1 Horizontal
2 Release Handle Attach cable "F" to the first hole in the end of the re-
tainer. If the cable has stretched slightly or a replace-
3 Release Handle Adjustment
ment cable has been installed, the second or third hole
4 Foot Pedal
can be used to maintain the proper spring length and
5 Foot Pedal Adjustment (Jam Nuts) cable tension. Refer to Figure 17033-01 for cable rout-
6 Pint (G) ing and connection points.
7 Cable (F)
A poly stop is located at the rear of the right pallet grab
8 Poly Stop arm and should be inspected for wear, damage, etc.
9 Cable (F) Anchor Points The stop is secured in position with two screws for sim-
10 Cable (E) Anchor Points ple installation or removal as necessary. Be sure all
11 Poly Stop springs, retainers, rollers, etc. are positioned and work-
ing properly before installing mounting plate with asso-
12 Cable (E)
ciated parts to the underside of platform.
The foot pedal position, in the released position, can be
adjusted to make sure it latches properly. During nor-
mal operation slightly lower, release pedal position
may develop that could make latching impossible. Re-
fer to Figure 17033-01. To adjust pedal height, loosen
the jam nuts and turn nut clockwise until pedal height
and latching are correct. The adjustment must be made
from beneath the floor of the platform. Be sure platform
is securely blocked. If correct pedal height can not be
achieved through this adjustment, then some parts
may need to be replaced to achieve correct pedal
height.
M9.0-7335-004 SP3500 Crown 2010 PF17884-4
552
PLATFORM
Platform
Operator Compartment Gates Spring Replacement

The platform has operator compartment gates that can To replace a weak or broken coil spring on the bottom
rotate "up" to allow easy entry or exit when the platform pivot shaft, left or right side, the following information
is in the lowered position. The truck will not travel or must be used.
raise until both gates are in the "down" position. The Use a spanner wrench (104712) that has two 4.0 mm
sidegate upper pivot shaft activates switches as it is (5/32 in) pins, at a spread of 23.8 mm (0.937 in). Refer
rotated. When raising the sidegates, the lower pivot to Figure 17035.
shaft has a coil spring attached that aids the operator
in raising/lowering the gate. A poly stop, located on the
floor of the platform directly below each gate upright,
acts as rest when the gates are "down".
Spanner Tool
Figure 17035
With the gate in the "down" position, place spanner

wrench on the lower pivot shaft. Using a hammer and
4-5 mm (3/16 in) diameter punch, drive the roll pin par-
tially out (approximately 15 to 19.0 mm (0.50 to
0.75 in). Keep spanner wrench on the shaft, remove
punch and rotate gate to "up" position. Remove roll pin
from shaft making sure spanner wrench is still on shaft.
Using spanner wrench rotate shaft until all spring ten-
sion is relieved. As the roll pin is removed the spring
tension will be transferred to the spanner wrench. You
will have to assume the load when the roll pin is com-
pletely out. Remove shaft and note the position of
Figure 17034
spacers and bearings for correct position at assembly.
(1) Side Gates Down Position Refer to Figure 17036. Position coil spring with outer
(2) Console flange next to small stop welded to platform wall that
(3) Side Gates Upright Position keeps the coil spring from rotating when all parts are
(4) Console Mounting Screws
assembled properly.
To gain access to the sidegate upper pivot shaft and

switches the console must be removed from the plat-
form. Refer to Electrical.
Remove the six console mounting screws. Refer to Fig-
ure 17034. Two additional covers must be removed
that are located on both sides of the platform for trucks
with a 1370 and 1625 mm (54.0 and 64.0 in) wide plat-
forms.
Crown 2010 PF17884-5 SP3500 M9.0-7335-005
553
PLATFORM
Platform
Operator Harness
The operator belt and lanyard must be inspected regu-
larly to insure they are in a safe condition. Operator
belts are available in sizes small, medium, large and
x-large to allow for comfortable fit. Be sure belt is clean
and shows no signs of tearing, stressed areas or frayed
ends. Inspect attachment rings and buckle of belt for
wear or any sign of deterioration. Replace a belt that
has any flaws or deterioration that may affect operator
safety. The lanyard must be checked on a regular basis
for the same signs of wear as the operator belt. Inspect
snap hooks and locks at each end of the lanyard. Be
sure the lanyard connection to the overhead guard is
secure. Replace the lanyard if there are any signs of
wear. If there are any doubts about the lanyard or op-
erator belt, replace it.
Figure 17036
(1) Gate
(2) Apply Spring Force
(3) Release Spring Force
(4) Bushing
(5) Roll Pin
(6) Spring Stop
(7) Torsion Spring
(8) Bushing
Operator Harness
(9) Shaft “V” Slot
(10) Shim
After all parts have been installed and the side gate is
held in the "up" position, use spanner wrench to turn
the pivot shaft to increase spring force until the roll pin Figure 17037
can be installed through the lower gate and pivot shaft.
The pivot shaft will need to be turned approximately 40
to 45 degrees to allow for roll pin installation with the
side gate in the "up" position.
M9.0-7335-006 SP3500 Crown 2010 PF17884-6
554
PLATFORM
Platform
Shim Basics
(TL Platform Not Available On SP3570/80/71/81)
The mast is designed to be at its tightest point when
fully extended and at its loosest when fully lowered.
This allows the mast and platform column rollers to
move freely as the mast extends while providing maxi-
mum stability when fully extended. Each mast is de-
signed to be wider at the bottom than at the top. If the
mast were shimmed so it was tight when fully lowered,
it would not fully extend because of mast to column
roller binding causing detrimental effects to the mast
channel. The mast should only be checked for tight-
ness when near or at full extension.
thick. Refer to Lifting Mechanism for mast shimming
procedures.
Figure 17038
TT Platform
(1) Non-Adjustable Column Rollers
(2) Shim (060030-085) 0.8 mm (0.031 in) Thick AR
Crown 2010 PF17884-7 SP3500 M9.0-7335-007
555
PLATFORM
Platform
Platform Removal & Shimming TL 3. Measure the distance between the channel and
the column roller, 10 mm (0.375 in) from the chan-
Mast nel face. Always measure the side the column
(TL Mast or Platform Not Available On SP3570/80/ roller is canted toward. A clearance of 0 to
71/81) 0.75 mm (0 to 0.030 in) should be obtained. Check
the center and lower platform column rollers since
In order to shim the platform column rollers it is neces- the top column rollers are not adjustable. If the di-
sary to remove the platform from the mast. Refer to mension is greater than 0 to 0.75 mm (0 to
Control Of Hazardous Energy Lockout/Tagout. 0.030 in), another shim will need to be added be-
hind the column roller. It will be necessary to re-
move the platform from the mast to shim the plat-
WARNING form column rollers. If the dimension is zero and it
does not appear to be tight, proceed to check the
Wear appropriate items, such as safety glasses, when-
remaining platform column rollers.
ever performing maintenance work. Do not place fin-
pinch points.
weight information.
1. Raise platform to full extension.
Figure 17039
2. Use a man-up vehicle to get into position to meas-
ure platform column roller clearance. Use a pry bar (1) Adjustable Column Rollers
to shift the platform to one side; this will force the (2) Non-Adjustable Column Rollers
opposite side tight against the mast channel. This
is necessary to seat each platform column roller 4. Lower the second stage mast and block both sides
against the roller stud shoulder to allow for an ac- when it is a minimum of 760 mm (30.0 in) above
curate measurement. Once the platform has the floor. Use hardwood blocks that are 50 x
shifted, retain slight pressure to hold the platform in 100 mm (2.0 x 4.0 in). Refer to Control Of Hazard-
position. ous Energy Lockout/Tagout for lifting and blocking
procedures.
M9.0-7335-008 SP3500 Crown 2010 PF17884-8
556
PLATFORM
Platform

6. Remove platform height sensor if present on truck.
Refer to Platform for height sensor removal, instal-
lation and adjustment procedures.
7. Using a lifting device raise the platform approxi-
mately 75 mm (3.0 in) to allow the mast chains to
become slack. Note that the combined weight of
the platform and forks are approximately 485 to
620 kgs (1070 to 1360 lb).
8. Disconnect mast lift chains from the platform by re-
moving the chain pins and secure with tie straps.
9. Using lifting device, lower platform to floor making
sure that cables, hoses and lift chains do not be-
come tangled with platform to prevent any damage
to them.
10. Place platform away from mast approximately
125 mm (5.0 in) to gain access to platform column
rollers.
11. Remove column rollers and note number of shims
on each roller mounting stud. Remove column roll-
ers carefully, many times the shims will stick to the
back of the column roller and fall off after removal.
12. Shim platform column rollers as needed. Please
note that it is best to shim the platform column roll-
Figure 17040 ers evenly. That is an equal number of shim(s) on
each column roller. However if this is not possible
(1) Block Both Sides of Second Stage Mast a Minimum Height follow the shim procedures. Refer to Lifting Mech-
of 760 mm (30 in)
anism. Example: Two shims on both left side plat-
(2) Use 50 x 100 mm (2.0 x 4.0 in) Hardwood Blocks form column rollers and one shim on both right side
column rollers. Refer to Figure 17041.
Crown 2010 PF17884-9 SP3500 M9.0-7335-009
557
PLATFORM
Platform
13. Install platform back into mast. With lifting device,

extend platform to full height and check for tight
spots. Make sure that all cables, hoses and chains
are not pinched, cut or damaged in any way while
extending the platform up the mast. If any tight
spots are found make corrections to shims as re-
quired.
14. If no tight spots are found, lower platform and reas-
semble chains, hoses etc. in reverse order of re-
moval.
15. Connect battery remove wheel chocks and verify
truck operation.
Figure 17041
Correct Method for Uneven Shimming

(1) One Shim
(2) Two Shims
Incorrect Method for Uneven Shimming
(4) One Shim
(5) Two Shims
(6) One Shim
M9.0-7335-010 SP3500 Crown 2010 PF17884-10
558
PLATFORM
Platform
Platform Removal & Shimming TT 3. Measure the distance between the channel and
the column roller, 10 mm (0.375 in) from the chan-
Mast nel face. Always measure the side the column
In order to shim the platform column rollers it is neces- roller is canted toward. A clearance of 0 to
sary to remove the platform from the mast. Refer to 0.75 mm (0 to 0.030 in) should be obtained. If the
Control Of Hazardous Energy Lockout/Tagout. dimension is greater than 0 to 0.75 mm (0 to
0.030 in), another shim will need to be added be-
hind the column roller. It will be necessary to re-
WARNING move the platform from the mast to shim the plat-
form column rollers. If the dimension is zero and it
Wear appropriate items, such as safety glasses, when- does not appear to be tight, proceed to check the
ever performing maintenance work. Do not place fin- remaining platform column rollers.
4. Raise the mast until the third stage is a minimum of
pinch points.
760 mm (30.0 in) above the floor, the second stage
should be approximately 380 mm (15.0 in) from
the floor. Use hardwood blocks that are 100 x
100 mm (4.0 x 4.0 in) to block the second stage
mast. Refer to Control Of Hazardous Energy Lock-
out/Tagout for lifting and blocking procedures.
weight information.
1. Raise carriage through free lift and stop platform
50 mm (2.0 in) short of spring loaded stops making
contact with stop bar on third stage mast.
2. Use a man-up vehicle to get into position to meas-
ure platform column roller clearance. Use a pry bar
to shift the platform to one side; this will force the
opposite side tight against the mast channel. This
is necessary to seat each platform column roller
against the roller stud shoulder to allow for an ac-
curate measurement. Once the platform has
shifted, retain slight pressure to hold the platform in Figure 17042
position.
(1) Block Both Sides of Second Stage Mast a Minimum Height
of 380 mm (15 in)
(2) Use 100 x 100 mm (4.0 x 4.0 in) Hardwood Blocks
Crown 2010 PF17884-11 SP3500 M9.0-7335-011
559
PLATFORM
Platform
5. Disconnect battery and chock wheels. 12. Shim platform column rollers as needed. Please
note that it is best to shim the platform column roll-
6. Remove platform height sensor if present on truck.
ers evenly. That is an equal number of shim(s) on
Refer to Height Sensor for height sensor removal,
each column roller. However if this is not possible
installation and adjustment procedures.
follow the shim procedures, refer to Lifting Mecha-
7. Using a lifting device, raise the platform approxi- nism. Example: Two shims on both left side plat-
mately 75 mm (3.0 in) to allow the mast chains to form column rollers and one shim on both right side
become slack. Note that the combined weight of column rollers. Refer to Figure 17044.
the platform and forks are approximately 485 to
620 kg (1070 to 1360 lb).
8. Disconnect mast lift chains from the platform by re-
moving the chain pins and secure with tie straps.
Figure 17043
TT Platform
(1) Chain Slack Mechanism
(2) Free Lift Chains
9. Using lifting device, lower platform to floor making

sure that cables, hoses and lift chains do not be-
come tangled with platform to prevent any damage
to them.
10. Place platform away from mast approximately
125 mm (5.0 in) to gain access to platform column
rollers.
11. Remove column rollers and note number of shims
on each roller mounting stud. Remove the column
rollers carefully, many times the shims will stick to
the back of the column roller and fall off after re-
moval.
M9.0-7335-012 SP3500 Crown 2010 PF17884-12
560
PLATFORM
Platform
13. Install platform back into mast. Remove yoke from

free lift cylinder and suspend it from the third stage
mast so that it will be moved toward the power unit
a minimum of 40 mm (1.5 in) to prevent any dam-
age to the yoke assembly while raising or lowering
the platform. Using a lifting device, extend platform
to full height and check for tight spots. Make sure
that all cables, hoses and chains are not pinched,
cut or damaged in any way while raising the plat-
form up the mast. If any tight spots are found make
corrections to shims as required.
14. If no tight spots are found, lower platform and reas-
semble chains, hoses etc. in reverse order of re-
moval.
15. Connect battery remove wheel chocks and verify
truck operation.
Figure 17044
TT Platform
Correct Method for Uneven Shimming
(1) One Shim
(2) Two Shims
Incorrect Method for Uneven Shimming
(3) One Shim
(4) One Shim
(5) Two Shims
(6) One Shim
Crown 2010 PF17884-13 SP3500 M9.0-7335-013
561
Notes:
562
PLATFORM
Platform Height Sensor Height Sensor Encoder Replace-

ment (ECR4)
WARNING Block truck wheels.
Wear appropriate items, such as safety glasses and Raise platform high enough to expose height sensor
steel-toe shoes whenever performing maintenance assembly (ECR4) mounted on bottom of the platform to
work. Do not place fingers, hands or arms through allow removal. Refer to Figure 17711.
mast or position them at pinch points. Disconnect battery and securely block platform. Refer
In this section you may be required to lift and block the to Control of Hazardous Energy Lockout/Tagout and
truck and mast or raise and lower different components Platform for proper procedures to securely block the
for removal and installation. Make sure lifting device platform. Refer to Figure 17711.
being lifted. Never work under or around a truck that is Disconnect height sensor (ECR4) wires from PC317 on
not properly secured. Refer to truck Data Plate for truck bottom of platform.
weight information.
WARNING
Make sure blocking material is strong enough to with-
stand the weight. Never work under or around a truck
that is not properly blocked. Truck must be in an area
with enough clearance to safely raise the platform. Re-
fer to Control of Hazardous Energy Lockout/Tagout
and Platform for proper procedures to securely block
the platform.

Figure 17711
Crown 2007 PF15822-1 Rev. 2/10 SP3500 M9.0-7335-050

01 Rev. 2/10
563
PLATFORM
Disconnect height encoder cable from bottom of main Hold the cable and allow it to slowly rewind onto the
frame. DO NOT release the cable to be quickly re- cable reel until the sleeve makes contact with the outer
tracted into height sensor as the cable could cross housing. Refer to Figure 17713-01.
thread and cause binding of height sensor. Refer to
Figure 17712.
(ECR4) assembly to platform.
ing screws.

on Cable Reel
Figure 17712
(c) Install 3/8 - 16 bolt, 31.75 mm (1.25 in)
Long to Lock Cable Reel
(d) Remove Bearing Block Mounting Screw
(e) Cable Sleeve in Contact with Outer Housing
Figure 17713-01
Install a 3/8-16 bolt, 31.75 mm (1.25 in) long into exist-

ing hole in housing to lock the cable reel. Refer to Fig-
ure 17713-01.
M9.0-7335-051 SP3500 Crown 2007 PF15822-2
564
PLATFORM
Remove ECR4 bearing block by using the two screws Tighten ECR4 mounting screw and make sure it is
in opposite holes on the bearing block. Refer to Figure properly seated in the bearing block.
17714-01.
After ECR4 and bearing block are securely mounted on
outer housing, remove reel stop bolt.
Use Bearing Block Mounting Mount height encoder assembly on platform using ex-
Screws to Remove Encoder isting screws.
from Bearing Block
Connect cable from height encoder to bottom of mast.
Verify cable on the reel did not get cross threaded.
Remove platform blocking material.
Connect battery and lower platform.
Verify height sensor (ECR4) is functional.
WARNING
Figure 17714-01 work. Do not place fingers, hands or arms through
Remove ECR4 from bearing block. mast or position them at pinch points.
Install replacement ECR4 in bearing block with wire truck and mast or raise and lower different components
harness pointing up towards top of height encoder as- for removal and installation. Make sure lifting device
sembly. and sling are sufficiently rated to withstand the weight
NOTE not properly secured. Refer to truck Data Plate for truck
weight information.
Make sure replacement ECR4 is evenly pressed into
the bearing block.
Mount bearing block and ECR4 on housing using exist- mast, disconnect electrical connections and hydraulic
ing screws. lines. "Control of Hazardous Energy" section provides
NOTE with some additional information on other procedures
When tightening mounting screw for ECR4 the cable read and reviewed prior to mast removal, installation
reel will start to unwind. Make sure bolt has been in- and maintenance as outlined in this section.
stalled into housing prior to tightening the mounting
screw. Truck must be in area with enough clearance to safely
raise the platform. Refer to Control of Hazardous En-
ergy Lockout/Tagout and Platform for proper proce-
dures to securely block the platform.
Disconnect height sensor (ECR4) wires from PC317 on
bottom of platform.
Block truck wheels.
Crown 2007 PF15822-3 SP3500 M9.0-7335-052
565
PLATFORM
Raise platform high enough to expose height sensor

assembly (ECR4) mounted on bottom of the platform to WARNING
allow removal. Refer to Figure 17711.
Make sure blocking material used is strong enough to
withstand the weight of the platform. Never work under
or around a truck that is not properly blocked.
Disconnect battery and securely block platform. Refer
to Control of Hazardous Energy Lockout/Tagout and
Platform for proper procedures to securely block the
platform.
Disconnect height encoder cable from bottom of main
frame. DO NOT release the cable to be quickly re-
tracted into height sensor as the cable could cross over
and cause binding of height sensor. Refer to Figure
17712.

Figure 17711

Figure 17712
M9.0-7335-053 SP3500 Crown 2007 PF15822-4
566
PLATFORM
Hold the cable and allow it to slowly rewind onto the Remove ECR4 bearing block by using the two screws
cable reel until the sleeve makes contact with the outer in opposite holes on the bearing block. Refer to Figure
housing. Refer to Figure 17718-01. 17719-01.
assembly to platform.
ing screws.
(a) Remove Height Sensor Mounting

Bracket Screws
(b) Height Sensor Mounting Bracket
(c) Use Bearing Block Screws to Remove
Bearing Block from Housing
Figure 17719-01
Remove mounting bracket from height sensor.

Turn height sensor over to expose front cover.

on Cable Reel
(c) Remove Bearing Block Mounting Screws
(d) Cable Sleeve in Contact with Outer Housing
Figure 17718-01
Crown 2007 PF15822-5 SP3500 M9.0-7335-054
567
PLATFORM
CAUTION WARNING
When last screw is removed in the following step, DO NOT remove spring mounted inside of cable reel.
spring tension will be released through cover rotation. Spring is reverse wound and if not kept restrained, will
Remove screws, cover and spacer. Refer to figures
17720 and 17721.
Turn height sensor so cable reel is face down on a flat
surface.
Unwind cable from reel and leave cable lay flat so it
does not twist or kink.
Place thumbs on shaft and remove outer housing from
Remove Cover Screws cable reel.
Remove bearing from outer housing.
Figure 17720
Install replacement bearing into outer case. Make sure
bearing is evenly pressed into the outer housing.
Inspect cable reel and cable.
Replace as needed.
(a) Cover
(b) Spacer
(c) Reel
(d) Spring
(e) ARbor
Figure 17721
M9.0-7335-055 SP3500 Crown 2007 PF15822-6
568
PLATFORM
Cable Replacement NOTE

To replace cable you will need cable 094422-002 15 m It is easier to wind cable onto reel with cable reel in
(50 ft), two sleeves 107208, swagging tool 107416 and outer housing.
chain and steel cable lubricant, 063001-009.
Make sure cable is evenly wound on reel and cable is
not cross threaded on reel. Refer to Figure 17722.
WARNING
DO NOT remove spring mounted inside of cable reel.
Spring is reverse wound and if not kept restrained, will
Remove existing cable from reel by cutting cable where
sleeve attaches cable to reel.
Install one end of replacement cable in hole on cable
reel. Refer to Figure 17722.
Attach sleeve (107208) and crimp using swagging tool
(107416). Refer to Figure 17722. (a) Wrap Clockwise
Install cable reel into outer housing. (b) Sleeve

(c) Cable (094422-002)
Install bearing block on outer housing. Make sure wires
(d) Cable Should be in Reel Grooves
are pointing up.
and Not Cross Threaded
Place height sensor in a vise.
Turn cable reel and feed cable onto reel. Refer to Fig- Figure 17722
ure 17722. Leave last groove on outside of reel empty.
Secure cable and install outer housing over cable reel.
Lubricate cable and cable reel with 063001-009.
Crown 2007 PF15822-7 SP3500 M9.0-7335-056
569
PLATFORM
Clean and install spacer over cable reel. Refer to Fig- NOTE
ure 17723-01.
Sleeve needs to be placed so it does not go into height
Lubricate spacer with 063001-009. sensor during operation.
Mark one of the mounting holes on height sensor as a Connect cable from height encoder to bottom of mast.
reference point. Refer to Figure 17723-01.
Verify cable on reel did not get cross threaded.
Clean, lubricate (063001-009) and install cover.
Rotate cover nine complete turns clockwise to preload
spring. Using mark placed on the cover as a starting Remove platform blocking material.
point. Refer to Figure 17723-01. Connect battery and lower platform.
After spring has been pre-loaded, secure cover with Verify height sensor (ECR4) is functional.
existing screws. Refer to Figure 17723-01.
Figure 17724
(a) Part of Mast

(b) Sleeve Should be 75 mm (3.0 in) Above Bracket
(c) 75 mm (3.0 in)
Figure 17723-01
(a) Place Mark on Cover, Using Mark as Starting Point, Rotate

Cover Nine Times Clockwise to Pre-load Spring
(b) Install Spacer
(c) Install Cover
(d) Use Existing Screws to Secure Cover
Install mounting bracket onto height sensor using exist-

ing bracket and mounting hardware.
Mount height encoder assembly on platform using ex-
isting screws.
Crimp remaining sleeve (107208) approximately
75 mm (3.0 in) above bracket that secures cable to
main frame. Refer to Figure 17724.
M9.0-7335-057 SP3500 Crown 2007 PF15822-8 Rev. 2/10
01 Rev. 2/10
570
GLOSSARY
571
Notes:
572
GLOSSARY
Glossary
Glossary on the truck such as on platform or in power unit. The

Function column then explains the function or circuit of
Components have been listed in chart form to assist that device. The Diagram column gives the page
the service technician in locating these components on number of the diagram on which the component can be
the Electrical Diagrams and Parts Breakdown forms. found. The callout in parenthesis following the page
number corresponds to the grid callouts on that dia-
The chart is in columns: Component; Location; Func-
gram, locating that component. The Parts Breakdown
tion; Diagram; Parts Breakdown. The Component
column includes the parts breakdown page number on
column contains the abbreviation of the component as
which the component is located along with the index
it appears on the Diagrams in the Maintenance Sec-
number, in parenthesis, if applicable.
tion. The Location column gives the general location
BATTERY
Battery Power Unit Battery Power Supply DIA-7435-002 (B-4)
Compartment DIA-7435-004 (B-4)
DIA-7435-006 (B-4)
CONNECTIONS
CA101 Distribution Panel - Not used DIA-7435-008 (A-3) 04.3-7435-050 (3)
Platform
CA102 Distribution Panel - Overhead Guard Light/Fan DIA-7435-008 (B-3) 04.3-7435-050 (3)
Platform Assemblies
CA103 Distribution Panel - +BV to Platform Modules & DIA-7435-008 (B-2) 04.3-7435-050 (3)
Platform Control Circuit; BNEG from
Alarm 1
CA104 Distribution Panel - Mast Cable #2 DIA-7435-008 (B-2) 04.3-7435-050 (3)
Platform
CA105 Distribution Panel - CAN Communication DIA-7435-008 (B-3) 04.3-7435-050 (3)
Platform
Platform
CA107 Distribution Panel - BNEG Platform Modules & DIA-7435-008 (B-3) 04.3-7435-050 (3)
Platform Control Circuit
CA201 Distribution Panel - +BV to Power Unit Modules DIA-7435-009 (B-3) 04.3-7435-001 (8)
Power Unit & Control Circuit; +BV &
BNEG from Brushwear
Sensors
CA202 Distribution Panel - Lift Power Panel & Brake DIA-7435-009 (B-2) 04.3-7435-001 (8)
Power Unit Power
Power Unit
CA204 Distribution Panel - CAN Communication DIA-7435-009 (B-2) 04.3-7435-001 (8)
Power Unit
Power Unit
Crown 2010 PF17960-1 SP3500 M10-7635-001
573
GLOSSARY
Glossary
CA206 Distribution Panel - +BV & BNEG to Power Unit DIA-7435-009 (B-3) 04.3-7435-001 (8)
Power Unit & Platform Circuits
CA301 Platform InfoLink CAN Access DIA-7435-003 (A-3), Not shown; located
DIA-7435-005 (A-3), near ACCESS 4
DIA-7435-007 (B-3),
DIA-7435-010 (B-1)
CA302 ACCESS 1 ACCESS 1 I/O DIA-7435-010 (B-1) 09.0-7535-009 (8)
CA303 ACCESS 4 ACCESS 4 I/O DIA-7435-010 (B-2) 09.0-7535-009 (19)
CA304 ACCESS 4 ACCESS 4 Power & I/O DIA-7435-010 (B-3) 09.0-7535-009 (19)
CA305 Platform Key Switch DIA-7435-011 (B-1) 04.6-7335-005 (22)
CA308 Platform Switches - Travel, Lift, DIA-7435-011 (B-1) 04.6-7335-005 (60),
Lower, Horn & Key 04.6-7335-050 (11,
68)
CA309 Platform Traction Potentiometer & DIA-7435-011 (B-2) 04.6-7335-005 (41),
Switches - Guidance, Two 04.8-7335-102 (12)
Hand & Override
CA310 Platform BNEG Left Work Light DIA-7435-012 (B-1) 04.8-7335-102
(7-10)
CA311 Platform BNEG Left Spot Light, DIA-7435-012 (A-1) 04.8-7335-102
Dome Light & Optional Fan (7-10)
CA312 Platform BNEG Right Work Light & DIA-7435-012 (B-3) 04.8-7335-102
Dome Light (7-10)
CA313 Platform BNEG Right Spot Light & DIA-7435-012 (B-3) 04.8-7335-102
Operator Fan (7-10)
CA314 Platform +BV Mast Mounted Spot DIA-7435-012 (B-2) 04.9-7332-250 (1)
Lights & Left Spot Light
CA315 Platform +12 V Right Work Light DIA-7435-012 (B-3) 04.8-7335-102
(7-10)
CA316 Platform +12 V Right Dome Light DIA-7435-012 (B-3) 04.8-7335-102
(7-10)
CA317 Platform Height Encoder DIA-7435-010 (A-3) 09.0-7335-200 (21)
CA318 Platform Steer Command Encoders DIA-7435-010 (A-4) 06.0-7335-001 (6)
CA322 Platform Gate Switches DIA-7435-011 (B-4) 09.0-7535-150 (4)
CA323 Platform Display Control Module DIA-7435-010 (B-2) 09.0-7535-009 (16)
Steer Indicator
CA324 Platform Switches - Travel, Lift, DIA-7435-011 (C-2) 04.6-7335-005 (60),
Lower & Horn 04.6-7335-050 (11,
68)
CA330 Platform +BV Travel Alarm Relay DIA-7435-010 (B-3)
Coil
M10-7635-002 SP3500 Crown 2010 PF17960-2
574
GLOSSARY
Glossary
CA331 Platform Chain Break (EU) DIA-7435-010 (B-4)
CA332 Platform Zone Select Switch DIA-7435-011 (B-3) 04.8-7335-102 (11)
CA336 Platform Travel Alarm Harness DIA-7435-010 (B-3)
CA401 ACCESS 3 Module ACCESS 3 I/O DIA-7435-013 (B-1) 04.1-7435-001 (13)
CA402 ACCESS 5 Module Communications DIA-7435-015 (B-1) 04.1-7435-001 (17)
CA403 ACCESS 5 Module ACCESS 5 I/O DIA-7435-015 (B-1) 04.1-7435-001 (17)
CA406 Power Unit Current Sensor DIA-7435-015 (B-3) 04.3-7435-100 (9)
CA407 Power Unit Brake DIA-7435-002 (A-3), 05.3-7335-001 (4)
DIA-7435-004 (A-3),
DIA-7435-006 (B-3),
DIA-7435-015 (B-3)
CA410 Power Unit Steering Feedback En- DIA-7435-015 (B-4) 04.8-7435-200 (3)
coder
CA411 Power Unit Traction Feedback Encoder DIA-7435-015 (B-4) 03.1-7335-001 (16)
CA414 Power Unit Chain Slack DIA-7435-014 (B-4)
CA415 Power Unit Chain Slack DIA-7435-014 (B-4)
CA416 Power Unit Chain Break (EU) DIA-7435-014 (B-4)
CA417 Power Unit Chain Break (EU) DIA-7435-014 (B-4)
CA418 Power Unit Brake/Drive-Tow Switch DIA-7435-009 (B-4) 04.3-7435-001 (8)
CA501 Overhead Guard Lights DIA-7435-012 (B-1) 04.9-7335-050 (16)
CA503 Overhead Guard Lights & Fan DIA-7435-012 (B-3) 04.9-7335-050 (63)
CA601 ACCESS 6 Module (Op- Communications, +BV & DIA-7435-017 (B-1) 04.1-7435-001 (25)
tional) BNEG
CA602 ACCESS 6 Module (Op- I/O DIA-7435-017 (B-1) 04.1-7435-001 (25)
tional)
CA603 Steer Wheel Sensor Bar I/O DIA-7435-017 (A-2)
(Optional)
CA604 Load Wheel Sensor Bar I/O DIA-7435-017 (A-3)
(Optional)
CA607 EAC Sensors I/O DIA-7435-017 (A-1)
CA608 EAC Sensors +12 V & BNEG to EAC DIA-7435-017 (A-1)
Crown 2010 PF17960-3 SP3500 M10-7635-003
575
GLOSSARY
Glossary
CA701 Platform Heaters, Travel Alarm & DIA-7435-018 (B-2), Not shown; located
(Freezer/Condition) Other Options DIA-7435-019 (B-2) near the Platform
Distribution
Panel
CA702 Platform Heaters DIA-7435-018 (C-3) Not shown; located
(Freezer/Condition) behind the Control
Module
CA807 Distribution Board Battery Restraint Switches DIA-7435-018 (B-1) 04.3-7334-250 (1)
(Freezer/Condition) & Rail Guide Switches
Heaters
CA808 Distribution Board Input Power DIA-7435-018 (B-1) 04.3-7334-250 (1)
(Freezer/Condition)
CA809 Power Unit Travel Alarm Relay & Other DIA-7435-018 (B-2), Not shown; located
(Freezer/Condition) Options DIA-7435-019 (B-1) near the Power Unit
Distribution Panel
JC336 Platform Travel Alarm Relay Coil DIA-7435-018 (A-2)
BNEG DIA-7435-019 (A-2)
JC413 Power Unit Drive/Tow DIA-7435-002 (A-3), 4.3-7435-001 (8)
DIA-7435-004 (A-3),
DIA-7435-006 (A-3),
DIA-7435-015 (B-3)
PC306 Platform Customer Accessories DIA-7435-011 (B-1)
PC338 Mast Spot Lights DIA-7435-012 (B-2) 04.9-7332-250 (1)
TB502 Overhead Guard Left Dome Light, Left Spot DIA-7435-012 (B-2) 04.9-7335-050 (14)
Light & Operator Fan
M10-7635-004 SP3500 Crown 2010 PF17960-4
576
SCHEMATIC DIAGRAMS
577
Notes:
578
SCHEMATIC DIAGRAMS
Introduction to Diagram Usage
Introduction to Diagram Usage • The truck has been sectioned with one page cov-
ering each section. When options affect the wiring
in a section, an additional page is added which du-
Schematic plicates wiring that is identical and adds the option
wiring. In this way only one page of the truck sec-
• Power up diagram. Illustrates the circuitry involved tion is required for the applicable truck configura-
in getting the truck system to an operating mode tion.
(Can Interface, Access 1,2,3, Controller, Contac-
tor, ect.). • Wiring that is identified by color rather than number
will typically be a cable or wires with vendor com-
• Circuitry which stands alone and is separate from ponentry.
truck operation is shown in block form with the pic-
torials detailing the circuitry (e.g. light package, dis- • Page titles, listed at the beginning of the electrical
plays, wire guidance, freezer condition). diagrams, indicate the subsystem or section of
truck wiring that is covered by each page.
Pictorials
• Terminal board and connector numbering on the
pictorials are in two classes; power unit and plat-
form. Power unit TB's and CA's are even 100's
(200, 400, 600 etc.) and platform TB's and CA's are
odd 100's (100, 300, 500 etc.). On manup trucks
(SP, TS, TSP etc.), odd and even 100's will be
present on the wiring diagrams. Man-down trucks,
which don't have a platform (stand-up rider, pallet
etc.), only even 100's will be present.
• Wiring starts at a central location (e.g. distribution

board) and wiring connection points are numbered
with the lowest number odd or even. The next wir-
ing connection point from the distribution board are
then numbered with the next group of 100's and so
on for each connection point removed from the
central location.
• Terminal board and connector numbering is se-

quential on each consecutive page. In this way a
wiring address giving a connector number or termi-
nal board number will indicate which direction to
look in the diagrams for the other end of the wire.
When wiring goes to a component and not a termi-
nal board or connector, a reference terminal board
is used and is shown with a dashed line box with
the reference terminal board number in parenthe-
sis. This terminal board will not appear on the truck
and only present as a wiring directory.
• Input/Output arrows may appear at terminal

boards and connectors. These indicate whether
what the wire is carrying is incoming or outgoing.
This is helpful when tracing the origin of the signal
or voltage.
Crown 1991 PF8974-1 Rev. 6/08 SP3500 DIA-ITD-001

02 Rev. 6/08
579
Notes:
580
SCHEMATIC DIAGRAMS

This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Title Page Number Revision

Schematic - Power Unit w/Options DIA-7435-002
Schematic - Platform w/Options DIA-7435-003
Schematic - Power Unit w/Pallet Grab DIA-7435-004
Schematic - Platform w/Pallet Grab DIA-7435-005
Schematic - Power Unit DIA-7435-006
Schematic - Platform DIA-7435-007
Platform Distribution Panel DIA-7435-008
Power Unit Distribution Panel DIA-7435-009
Platform Modules ACCESS 1 & 4 DIA-7435-010
Control Pod And Light Switches DIA-7435-011
Overhead Guard Lights/Fans DIA-7435-012
Overhead Guard Spotlights (Optional) DIA-7435-013
Traction Control Module ACCESS 3 DIA-7435-014
Steering Control Module ACCESS 5 DIA-7435-015
Hydraulics & Optional MMS DIA-7435-016
Guidance Control Module ACCESS 6 (Optional) DIA-7435-017
Travel Alarm & Freezer Conditioning (Optional) DIA-7435-018
Travel Alarm & Pallet Grab DIA-7435-019
Power Cables DIA-7435-020
Wire Harnesses DIA-7435-021
Crown 2009 PF17813-1 SP3500 DIA-7435-001
581
SCHEMATIC DIAGRAMS
142223 H 2 of 4
DIA-7435-002 SP3500 Crown 2009 PF17813-2
582
SCHEMATIC DIAGRAMS
142223 I 1 of 4
Crown 2009 PF17813-3 SP3500 DIA-7435-003
583
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 H 4 of 4
DIA-7435-004 SP3500 Crown 2009 PF17813-4
584
SCHEMATIC DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 I 3 of 4
Crown 2009 PF17813-5 SP3500 DIA-7435-005
585
SCHEMATIC DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 G 2 of 2
DIA-7435-006 SP3500 Crown 2009 PF17813-6
586
SCHEMATIC DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 H 1 of 2
Crown 2009 PF17813-7 SP3500 DIA-7435-007
587
SCHEMATIC DIAGRAMS
142680 D
DIA-7435-008 SP3500 Crown 2009 PF17813-8
588
SCHEMATIC DIAGRAMS
142681 E
Crown 2009 PF17813-9 SP3500 DIA-7435-009
589
SCHEMATIC DIAGRAMS
142682 E
DIA-7435-010 SP3500 Crown 2009 PF17813-10
590
SCHEMATIC DIAGRAMS
142683 D
Crown 2009 PF17813-11 SP3500 DIA-7435-011
591
SCHEMATIC DIAGRAMS
142687 D 1 of 2
DIA-7435-012 SP3500 Crown 2009 PF17813-12
592
SCHEMATIC DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 D 2 of 2
Crown 2009 PF17813-13 SP3500 DIA-7435-013
593
SCHEMATIC DIAGRAMS
142684 B
DIA-7435-014 SP3500 Crown 2009 PF17813-14
594
SCHEMATIC DIAGRAMS
142685 C
Crown 2009 PF17813-15 SP3500 DIA-7435-015
595
SCHEMATIC DIAGRAMS
142686 A
DIA-7435-016 SP3500 Crown 2009 PF17813-16
596
SCHEMATIC DIAGRAMS
142688 A
Crown 2009 PF17813-17 SP3500 DIA-7435-017
597
SCHEMATIC DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 F 1 of 2
DIA-7435-018 SP3500 Crown 2009 PF17813-18
598
SCHEMATIC DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 F 2 of 2
Crown 2009 PF17813-19 SP3500 DIA-7435-019
599
SCHEMATIC DIAGRAMS
Power Cables
Power Cables
146494 D
DIA-7435-020 SP3500 Crown 2009 PF17813-20
600
SCHEMATIC DIAGRAMS
Power Cables
Wire Harnesses
Power Unit
140113 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
143590 CA201, CA202, K15, PC809, HN2

146760 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
147998 Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, RGSL, RGSR, THS2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140170 (b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness

(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2009 PF17813-21 SP3500 DIA-7435-021
601
SCHEMATIC DIAGRAMS
Power Cables
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701

(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7435-022 SP3500 Crown 2009 PF17813-22
602
HYDRAULIC SCHEMATIC
603
Notes:
604
HYDRAULIC SCHEMATIC
Power Unit
Power Unit
To Lift
Cylinder

2 Lift/lower manifold
3 RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi)
4 Lift Pump and motor, P1 & P2 output; 25.4 l/m at 3447.4 kPa (6.7 gal/min
at 500 psi), 17.8 l/m at 12410.6 kPa (4.7 gal/min at 1800 psi)
5 Return line filter, 10 micron nominal
6 Reservoir capacity is approximately 17 liters (4.5 gal)
8 Quick Disconnect (for pressure gauge)
Figure 23117
Crown 2009 PF17848-1 SP3500 HYD-7435-001
605
HYDRAULIC SCHEMATIC
Mast
Mast
Mast Mast
Cylinder Free Lift Cylinder
Cylinder
To Power
Unit
Velocity
Fuse
Velocity Velocity
Fuse Fuse
Figure 23116
HYD-7435-002 SP3500 Crown 2009 PF17848-2
606

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SP 3500 SERIES

Bestell Nummer: 812574-006

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

LUBRICATION & ADJUSTMENT PAGE

HYDRAULIC SYSTEM PAGE

Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

DRIVE UNIT PAGE

ELECTRICAL SYSTEM PAGE

Model - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . 104

Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Event Code 337 .................................... 216

Event Code 411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Event Code 531 .................................... 283

Event Code 597 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

BRAKE SYSTEM PAGE

LIFTING MECHANISM PAGE

Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

SCHEMATIC DIAGRAMS PAGE

HYDRAULIC SCHEMATIC PAGE

General Maintenance Instructions 5. Before starting to operate truck—

WARNING – Apply brake.

Crown 1980 PF6285-1 Rev. 10/06 SP 3500 MA-04.5-001

16. Be sure that any equipment added to the truck (ter-

MA-04.5-002 SP 3500 Crown 1980 PF6285-2 Rev. 10/06

• Do not lay metallic or conductive objects on bat-

Crown 2008 PF17175-1 SP 3500 MA-7535-100

MA-7535-101 SP 3500 Crown 2008 PF17175-2

• Lockout or tagout truck as described in Lockout -

• Chock wheels or make sure truck is secured by

• When towing the truck make sure all operators are

• Insert PC407, to JC413 on harness.

• Move switch DTS1 from the Drive position to the

• Move truck to area intended for maintenance.

• Move DTS1 from the Tow to the Drive position. Dis-

• Disconnect brake from JC413 and connect to orig-

Crown 2008 PF17175-3 SP 3500 MA-7535-102

• Move truck to a secure non-traffic maintenance

• Lockout or tagout truck as described in Lockout -

• Place a minimum 100 ohm, 2 watt resistor between

(a) Battery Positive

MA-7535-103 SP 3500 Crown 2008 PF17175-4

• Move truck to a secure non-traffic maintenance

• Completely lower load engaging means (mast) or,

• Lockout or tagout truck as described in Lockout -

• Open power unit doors and locate the lift manifold.

• Open the manual lower valve to remove hydraulic

Crown 2008 PF17175-5 SP 3500 MA-7535-104

Accumulator Lifting and Blocking

• Move truck to a secure non-traffic maintenance

• Lockout or tagout truck as described in Lockout -

• Hydraulic Jack Capacity: 3620 kg (8000 lb)

• Jack Stand Capacity: 4500 kg (10000 lb)

MA-7535-105 SP 3500 Crown 2008 PF17175-6

(a) Load Wheels

(a) Raise platform 70 - 150 mm (3 - 6 in) from floor

Crown 2008 PF17175-7 SP 3500 MA-7535-106

• Move truck to a secure non-traffic maintenance