WP3000 Service Manual

WP3015/3020 MODELS
MAINTENANCE MANUAL
Order Number: 812601-006

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

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

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

Copyright 2012
Crown Equipment Corporation
TABLE OF CONTENTS
I
Notes:
II
TABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Truck Data Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Truck modifications and additions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lockout/Tagout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Release the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lifting and Blocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cleaning the Truck and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lubricants, Aerosols & Service Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
X10® Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Battery Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Knuckle Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Center, Main, and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Caster Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SAE Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
COMPONENTRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Componentry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Audible Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ALM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
BRK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ACCESS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INFOLINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
InfoLink Module (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ECR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
AC Inlet (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Battery Charger (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hydraulic Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Primary Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
R/T Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
POT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
RV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
HNS1 and HNS2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
HSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
KYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
LMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
LOS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Hydraulic Plumbing and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Freezer Condition Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Bleed the Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Drift Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lift Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Lift Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Suction and Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Lift Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Lift Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
After Lift Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Drive Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Drive Tire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Drive Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Disassemble the Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Assemble the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Wiring Color Codes & Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Curtis Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Handset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Monitor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Faults Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Controller Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Programmer Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Menu Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Monitor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Faults Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Controller Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Programmer Setup Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
X10® Handle (ACCESS 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X10 Handle Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Lower and Upper Shell Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Switch Cap Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
HSS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Hydraulic Printed Circuit Board Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Primary Printed Circuit Board Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
POT, FS, and RS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
SAS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
HNS1 and HNS2 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Hand Grip Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
On Board Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
To set the battery tpye at the On Board Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Battery Pack Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Display Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Operator Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Display Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Hydraulic Pump Motor (M2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Event Code Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
No Event Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Static Return to Off (SRO) Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Event Code 300 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Event Code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Event Code 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Event Code 327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Event Code 331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Event Code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Event Code 335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event Code 336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Event Code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Event Code 339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 373 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 391 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 392 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 853 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 854 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event Code 855 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event Code 856 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event Code 857 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event Code 858 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
No Event Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Description of the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
WP3015/3020 Models
VII
TABLE OF CONTENTS
The Function of the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

The Function of the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Description of the Brake, Override, and Travel Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Tiller is in position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Tiller in position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
To Adjust the Stopping Distance of the Service Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
To adjust the Air Gap of the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
To Release the Parking Brake manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Parking Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Parking Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Parking Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
pParking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Parking Brake, Possible Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Repairing Control Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Return spring pre-tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Replacing the return springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Return spring removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Return spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Roller Bearings Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Roller Bearings Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Tension Bar Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Tension Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Tension Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Lift Cylinder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Lift Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Lift Cylinder Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Introduction to Diagram Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
WP3015/3020 Models
VIII
TABLE OF CONTENTS
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Electrical Schematic - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Electrical Schematic with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Traction/Hydraulic - Standard (ACCESS 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Traction/Hydraulic with Options (ACCESS 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
X10® Handle (ACCESS 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
WP3015/3020 Models
IX
Notes:
X
INTRODUCTION
1
Notes:
2
INTRODUCTION
IMPORTANT INFORMATION
Important Information Manual structure

This maintenance manual applies to the WP3015/ The manual is divided into the following sections:
3020 Models trucks.
Chapter
Service personnel qualification
Index
To maintain the safety and functionality of the
truck, maintenance and repair work must only be Introduction
performed by service engineers who have been au- Safety
thorised by Crown.
Contact Crown if you wish to have your engineers Inspection and Lubrication
trained. Hydraulic System
Ordering spare parts Drive Unit
To order spare parts, use the spare parts catalog sup- Electrical System
plied separately. Always quote the following numbers Brake System
when ordering spare parts:
Steering
• Truck data number (see page 5)
• Serial number Lifting Mechanism
These numbers can be found on the truck data plate. Cylinders
For details of your truck's technical specifications refer
Schematic Diagrams
to the Technical Specifications chapter in the operator
manual. Hydraulic Schematic
Note: Always use original Crown spare parts.
Conventions
Ordering documentation
Text mark-ups in the manual
Parts manuals, operator manuals, specification sheets
etc. can be obtained from: The following symbols and mark-ups are used in the
manual:
1., 2., 3. denote work steps to be taken.
Crown Gabelstapler GmbH & Co. KG
Moosacher Str. 52  This arrow indicates the consequences of an ac-
80809 Munich tion.
Germany  This arrow indicates action to be taken to avoid haz-
ards contained in a warnings.
Tel.: +49 (0)89 / 93 002 -0 (1), (2), (3) etc. indicate text references to item num-
Fax: +49 (0)89 / 93 002 -175 or 133 bers in illustrations.
www.crown.com
• Indicates the first level in a list.
– Indicates the second level in a list.
Note: Where the word "Note" appears before text, this
indicates important additional information.
Crown 2011 PF25499-1 Rev. 7/12 WP3015/3020 Models ITD-2730-001

01 Rev. 7/12
3
INTRODUCTION
TRUCK DATA PLATE
Truck Data Plate • Serial number

• Maximum grade
The data plate is on the top of the power unit cover and
includes this information: • Hour rate
• Capacity with a load • Maximum ampere hour rate
• Truck weight with a maximum battery • DC voltage
• Truck weight less battery • Battery type
• Battery weight • Load tire tread width
• Truck data number • Truck type.
• Model number
Fig. 1 (26034)
ITD-2730-002 WP3015/3020 Models Crown 2011 PF25499-2 Rev. 7/12
01 Rev. 7/12
4
INTRODUCTION
TRUCK DATA NUMBER
Truck Data Number 16 = 1450 mm

17 = 1500 mm
The truck data number is located on the data plate. It 18 = 1550 mm
contains important information concerning the truck's 19 = 1600 mm
features at the time of delivery. 20 = 1650 mm
21 = 1700 mm
22 = 1750 mm
23 = 1800 mm
1 2 3 4 5 6 7 24 = 1850 mm
25 = 1900 mm
1.6 WP 3015 - 4 - 3 - 02 - S 26 = 1950 mm

27 = 2000 mm
28 = 2050 mm
Fig. 2 Example of a truck data number 29 = 2100 mm
30 = 2150 mm
1 Capacity (1.6 = 1600 kg)
31 = 2200 mm
2 Model description 32 = 2250 mm
3 Model number 33 = 2300 mm
34 = 2350 mm
4 Battery box size:
35 = 2400 mm
1 = 150 Ah (146x660x604 mm)
s = special fork length
2 = 250Ah Liftout (212x624x627 mm)
3 = 375Ah Liftout 284x624x627 mm 7 Load wheels:
4 = 250Ah Rollout, 212x624x627 mm S = single
5 = 375Ah Rollout 284x624x627 mm T = tandem
6 = Liftout 146x660x683 mm
7 = Rollout 212x624x627 mm
5 Fork spread:
1 = 520 mm
2 = 540 mm
3 =670 mm
s = special fork spread
6 Fork length:
01 = 800 mm
02 = 850 mm
03 = 900 mm
04 = 950 mm
05 = 1000 mm
06 = 1050 mm
07 = 1100 mm
08 = 1125 mm
09 = 1150 mm
10 = 1200 mm
11 = 1210 mm
12 = 1250 mm
13 = 1300 mm
14 = 1350 mm
15 = 1400 mm
Crown 2011 PF25499-3 Rev. 7/12 WP3015/3020 Models ITD-2730-002

01 Rev. 7/12
5
Notes:
6
SAFETY
7
Notes:
8
SAFETY
SAFETY NOTICES
Safety Notices
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:
DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death will result.
 Follow all instructions indicated by this symbol in or-
der to avoid injury or death.
WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death may result.
der to avoid injury or death.
CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury may result.
der to avoid injury.
CAUTION
This signal word without a symbol warns of mate-
rial damage.
Damage to the truck, tools and mechanisms may re-
sult.
 Follow all instructions indicated by this signal word
in order to avoid damage.
WP3015/3020 Models Rev.2 08/2010
9
SAFETY
BASIC SAFETY NOTICES
Basic Safety Notices • When carrying out work on the hydraulic system,
e.g. bleeding the system, wear suitable protective
clothing such as safety gloves, goggles or a face
Organisational measures mask.
• Maintenance work must only be carried out by ser- • When handling batteries wear acid protective cloth-
vice engineers approved by Crown. ing such as safety gloves, goggles and an apron.
• Work on electrical equipment must only be carried • Long hair, loose clothing and jewellery are prohib-
out by specialist electricians in accordance with ited. They could get caught or drawn in, resulting in
electrical regulations. injury. Do not wear jewellery especially when work-
• Note the basic and action-specific safety notices in ing on electrical systems, as a short circuit could
the respective chapters of this manual. Refer also cause burning.
to the truck operator manual, in particular the Safety • Always use insulated tools when working on electri-
chapter. cal systems.
• Service personnel must also observe statutory and
other binding accident and environmental protec- Protecting the hazardous area
tion regulations. • When carrying out repair work that could be hazard-
• The legal minimum age for performing repair work ous to yourself and other people, seal off a large
must be observed. part of the hazardous area with suitable marker
• Service personnel must be trained and authorised tape.
to operate industrial trucks and must be able to • Before carrying out repair work, service personnel
demonstrate their competence. must ensure that there is no one in the hazardous
area.
Truck modifications and additions • Service personnel must stop work immediately if
• Modifications or additions to the truck may only be any unauthorised persons enter the hazardous
performed with Crown’s prior written approval. In area. These persons must be removed immedi-
such cases the data plate must be changed if nec- ately.
essary.
• If at a later time Crown is no longer in business or is Hazards from stored energy
not operating your country and there is no succes- • High pressure hydraulic oil can cause severe inju-
sor in the interest to the business, modifications and ries. Depressurise the hydraulic system before
alterations may only be performed if the following opening any sections of it.
conditions are met: • A 15 minute discharge time must be observed for
– Design, test(s) and implementation to be carried the electrical energy stored in the capacitors and
out only by an expert in industrial trucks and their coils. Alternatively, these components can undergo
safety a controlled discharge through an electrical resistor.
– Permanent records of the design, test(s) and im- • When carrying out work near the battery, always
plementation to be maintained cover the battery terminals with a suitable insulating
– Modifications must be incorporated into the truck material (e.g. plywood board) to prevent short cir-
labelling and documentation (operator, service cuits.
and parts manuals) • Before carrying out work underneath and on raised
– A permanent and readily visible label to be af- components (e.g. fork carriages, extended mast
fixed to the truck stating the manner in which the stages, the truck itself), attach suitable safety de-
truck has been modified or altered, the date and vices and supports with sufficient capacity.
name and address of the organisation responsi- • Springs and gas pressure dampers must be
ble checked and slowly discharged before removing
them.
Personal safety equipment
• Always wear safety equipment such as safety
shoes and goggles when carrying out maintenance
and repairs. Depending on requirements you may
also need to wear safety gloves and ear muffs.
Rev.1 04/2009 WP3015/3020 Models
10
SAFETY
Repair work Cleaning work

• Always carry out repair work in accordance with the Particular care is required when cleaning the truck and
test and maintenance schedule contained in this components that have been removed. See page 21.
manual and any applicable service bulletins.
• Before carrying out repair work prepare the truck as Handling batteries
follows: • Batteries may only be charged, serviced or re-
– Park the truck on a level surface placed by trained personnel. Observe the instruc-
– Lower the forks to the ground tions contained in the operator manual, as well as
the instructions of the battery and charger manufac-
– Switch off the truck and prevent it from being turers.
switched on again
• The charger must be appropriate to the battery volt-
– Disconnect the battery and prevent the connector age and capacity. First connect the battery, then
from being attached by unauthorised personnel. switch the charger on.
• When carrying out work that requires battery sup- • When handling batteries wear acid protective cloth-
ply, jack up the truck until the drive wheel is clear of ing such as safety gloves, goggles and an apron.
the ground.
• Do not use a naked flame and do not smoke when
• Do not use a naked flame near the truck or to check handling batteries.
fluid levels or for leaks.
• Do not touch battery terminals with metal objects.
• Always have suitable fire protection equipment to Cover the battery terminals with a
hand when carrying out work. suitable insulation (such as a plywood board) if you
• Keep the truck clean; this makes it easier to find have to work in this area.
loose or missing components. • Always charge batteries in designated charging ar-
• Welding work must only be carried out after prior eas and make sure the area is well ventilated.
consultation with Crown. • Remove battery acid stained clothing immediately.
• Keep the work area clean and well lit. An untidy or • If acid comes into contact with the skin, rinse imme-
poorly lit work area can lead to accidents. diately with plenty of clean water. If it comes into
• Only use original Crown spare parts and accesso- contact with the eyes, rinse immediately with clean
ries. water for several minutes and then seek medical at-
• Never install or commission damaged components. tention.
• Immediately neutralize and thoroughly rinse any
Restoring the truck to service after spilled battery fluid.
repair work
Warning and instruction decals on
• After carrying out repairs refit any safety mecha-
nisms that have been removed and make sure they the truck
are working correctly. • In accordance with the test and maintenance inter-
• The truck may only be restored to service after re- vals check that the warning and instruction decals
pair work once all the truck functions have been on the truck are complete and legible.
successfully tested, in particular on the following • Clean any dirty decals and replace any damaged or
components: missing ones.
– Brakes Note: The spare parts manual gives details of the la-
– Speed control belling and position of the warning and instruction de-
– Direction switches cals on the truck.
– Steering Lifting gear and slings
– Lifting mechanism
• Always use suitable hoist devices and lifting gear
– Warning devices (horn, warning indicator) with sufficient capacity.
• To avoid endangering other people, always test the • Attach lifting gear to the designated strap points
truck in an open area where there are no other peo- and prevent it from slipping. Make sure the lifting
ple or obstacles. gear cannot touch other components during lifting.
WP3015/3020 Models Rev.1 04/2009
11
SAFETY
• Do not stand under a swinging load.

• Repair work can only be performed under a raised
truck if the truck has been protected against acci-
dental lowering.
• Work may only be performed on the chassis, fork
carriage or mast if they have also been protected
against accidental lowering.
• Lifting gear such as load slings routed around sharp
edges must be protected from cuts.
Environmental protection
• Any work that involves environmentally hazardous
substances being released must only be performed
in designated areas, to allow hazardous chemicals
and oils to be separated.
• All substances released during maintenance and
repair work must be collected in the proper manner
and disposed of in accordance with national regula-
tions. Oil filters and dehumidifying inserts must be
treated as special waste.
• Always act responsibly when carrying out repairs to
avoid damaging the environment.
Rev.1 04/2009 WP3015/3020 Models
12
SAFETY
CONTROL OF HAZARDOUS ENERGY
Control of Hazardous Energy • If you spill the battery acid on the floor or on a dif-
ferent surface, use a Battery Spill Kit (300035) to
make the battery acid neutral and clean it up. Fol-
Lockout/Tagout low the manufacturer directions to use the kit.
• For safety and to obey OSHA Regulations, (Stand- • Keep the vent plugs tightly in position at all times,
ards - 29 CFR), control of hazardous energy (Lock- but not when you add distilled water or use a hy-
out/Tagout) - 1910.147, Crown has instructions for drometer.
the correct energy control when you do the mainte-
• Do not let flames or sparks near the battery. Gas
nance on the truck. Before you do the maintenance
made while the battery charges is very explosive.
on the truck, look at the applicable sections in this
This gas stays in the cells after you charge the bat-
manual for procedures to follow.
tery.
• Also, Crown recommends that all technicians wear
• Do not put metal or conductive objects on the bat-
applicable protective items when they do the servic-
tery because they can cause a short circuit.
ing on Crown equipment. Some examples of these
protective items are: • Do not let contamination, solution, or other un-
wanted material into the cells. The contamination
– Safety glasses
makes the battery acid neutral and lowers the avail-
– Work gloves able battery charge.
– Steel-toed shoes. • If you must repair the battery, follow the battery
manufacturer instructions for the applicable repair
Battery procedures.
Safety Procedures Battery Maintenance
• Wear protective items when you do the mainte-
nance on the batteries. Some examples of these
protective items are: WARNING
– A rubber apron
Risk of burns by short circuits and high current.
– Gloves
Unapproved handling of tools on batteries can cause
– Boots severe injury to you and damage the truck.
– A full-face shield. • Do maintenance and repair on batteries only if you
are approved for this work.
CAUTION • Make sure that the battery charger you use has the
same voltage and amperage as the truck battery.
Risk of burns by sulphuric acid.
This voltage is on the truck data plate.
The battery contains sulphuric acid which could cause
burns when you come in touch with it. • Before you connect or disconnect a battery to a bat-
tery charger, make sure that the battery charger is
• Do not let the sulphuric acid touch your eyes, skin,
OFF. If you do this and the battery charger is ON,
or clothing.
an injury could occur to you, the battery, and the
• If you come in touch with the sulphuric acid, flush battery charger.
the area immediately and fully with clean water and
• Make sure that the battery you use has the same
get medical aid.
weight, dimension, amperage, and voltage specifi-
cations as the truck (refer to the truck data plate).
• Do not let the battery acid touch the eyes, skin, Do not operate a truck without the correct battery.
clothing, or floor. If the battery acid touches the
eyes, you must flush them immediately with distilled
water and get medical aid immediately.
• If the battery acid touches the skin, you must clean
it immediately with distilled water and soap.
Crown 2011 PF25382-1 Rev. 9/12 WP3015/3020 Models MA-2730-100
13
SAFETY
Battery Charging
CAUTION
Risk of tip over.
WARNING
Wrong battery weight and dimensions can make the
Risk of gas explosion. truck unstable.
Battery gases are explosive. Severe injury or death • Install the same battery or a battery of equal weight
may result if the battery gas explodes. and dimension in the truck.
• Do not smoke, use an open flame, or make an arc • Refer to the data plate for the minimum battery
or sparks around the battery. weight and dimension.
• Make sure the area where you charge the battery is
well vented. Use designated areas for charging bat-
teries if they are available.
• Consult the battery charger manual or refer to

ELECTRICAL SYSTEM > Battery > Battery
Charger for instructions on operation and mainte-
nance.
Battery Removal and Installation
WARNING
Conductive objects which touch the connectors of
the battery cells cause a short circuit.
• Use an insulator (such as plywood) as a cover on
the top of the battery before and during removal and
installation.
WARNING
Crushing hazard.
If you pull the battery from the truck without a battery
roller stand in position, the battery can tip over and
cause a severe injury.
• Put the battery roller stand in position before you
move the battery.
MA-2730-101 WP3015/3020 Models Crown 2011 PF25382-2 Rev. 9/12
14
SAFETY
• For industrial battery removal and installation pro-

cedures, refer to ELECTRICAL SYSTEM > Battery
> Industrial Battery Removal and Installation. For
battery pack removal and installation procedures,
refer to ELECTRICAL SYSTEM > Battery > Battery
Pack Removal and Installation.
Fig. 3 (25801-01) Fig. 4 (25802)

1 Wet or dry cell battery To do maintenance on the truck (with the battery in
2 Maintenance free battery the truck)
1. Disconnect the battery.
Lockout/Tagout Procedures
2. Remove the primary power fuses.
Lockout/tagout procedures for the truck 3. Install a lockout device on the battery connector.
Note: A lockout/tagout kit (300037) is available. Refer
To do maintenance on the truck (with the battery
to the One Source Catalog.
out of the truck)
Note: These procedures let the other personnel know
1. Remove the primary power fuses.
that the truck is not available for operation.
2. If it is possible, install a lockout device on the truck
1. Turn the truck OFF.
battery connector. Or, install a tag with a cable tie
2. Remove the key. on the truck battery connector.
3. Apply a tag to the twist grip with a cable tie. The tag
gives a warning that the truck is not available for Capacitance
operation.
WARNING
A charged capacitor could be dangerous.
Uncontrolled discharge of stored electrical energy in
some control modules can cause injury or damage the
truck.
 When you do the truck maintenance around the bus
bars and related power cables, discharge the ca-
pacitors.
 Refer to the SAFETY > Control of Hazardous En-
ergy > Capacitance section for procedures to dis-
charge the capacitors.
15
SAFETY
Lockout/tagout the truck Release the Park Brake

1. Move the truck to a maintenance area with a level
floor.
2. Lower the forks fully. WARNING
Crushing hazard.
When you manually release the brake on the truck, the
5. Put the chocks against the wheels to prevent the park brake is out of order. If the truck is not chocked,
movement of the truck. Refer to SAFETY > Control the truck can move unintended.
of Hazardous Energy > Lifting and Blocking.
• Remove load on the forks before you release the
6. Complete the lockout/tagout procedures for the brake.
truck. Refer to SAFETY > Control of Hazardous
• Refer to SAFETY > Control of Hazardous Energy >
Energy > Lockout/Tagout Procedures.
Lockout/Tagout Procedures to fully prepare the
 The truck is disconncted from the power source.
truck for maintenance.
To discharge the capacitor
1. Insert the key switch. To release the park brake manually
2. Turn the key switch to the start position and hold a The park brake (1) is spring-applied and electrically re-
minimum of 10 seconds. leased. When the truck is de-energized, the park brake
3. To make sure that the capacitors discharge, put a applies. Refer to Figure 6.
digital volt-ohm multimeter (DVOM) across the • To move the truck while it is de-energized, the park
positive (1) and negative terminals (2) of brake has two screws (2) that you must manually
ACCESS 3 (3). The voltage must be less than 1 V. loosen to release the park brake. Refer to Figure 6.
4. Turn the key switch OFF and remove the key.
2
2
Fig. 6 (26016-01)
Fig. 5 (25803-01)
MA-2730-103 WP3015/3020 Models Crown 2011 PF25382-4 Rev. 9/12
16
SAFETY
Hydraulic
To release the pressure from the hydraulic system
1. Refer to SAFETY > Control of Hazardous Energy
> Lockout/Tagout Procedures to fully prepare the 6
truck for maintenance.
2. Lift and lower the forks to release all hydraulic
pressure.
Lifting and Blocking 5

Special Tools and Equipment:
• Hydraulic Jack: Capacity 3620 kg (8000 lb)
– Crown part number: 122599 3
– Collapsed height minimum: 60 mm (2.25 in)
– Lift height maximum: 400 mm (16 in) 3
• Jack Stand: Capacity 4500 kg (10000 lb)
7
• Lift Straps: Capacity 900 kg (2000 lb)
3
To lift and block the truck
1
1. Refer to SAFETY > Control of Hazardous Energy
> Lockout/Tagout Procedures to fully prepare the 2
truck for maintenance. 6
2. Remove the battery. Refer to SAFETY > Control of
Hazardous Energy > Battery Removal and Installa-
tion.
3. Lift the power unit end (1) with a hydraulic jack (2)
5
and put two hardwood blocks (3) or two jack stands
(4) below the truck skirt. Make sure that you set the
hydraulic jack to the applicable height, which is no
more than 400 mm (16 in).
4. Lift the forks (5) with a lift device (6). If you use
hardwood blocks (3), put one below the forks and
one below the center of the battery compartment 4
(7). If you use jack stands (4), put two below the
forks and two below each side of the battery com- 7
partment.
4
1
2
Fig. 7 (25805-01)
17
Notes:
18
INSPECTION AND LUBRICATION
19
Notes:
20
ELECTRICAL SYSTEM
CLEANING THE TRUCK AND COMPONENTS
Cleaning the Truck and Cleaning the entire truck

Components 1. Park the truck in an area with an oil separator.
2. Switch off the truck, disconnect and remove the
battery.
CAUTION
CAUTION
Health risk
Cleaning agents, lubricants and consumables can Incorrect cleaning procedures can damage the
damage your health. truck
 Observe the manufacturer’s safety instructions Incorrect cleaning can damage electric components as
when handling solvents and lubricants. well as bearings and lift chains.
 When wet-cleaning the truck, do not aim the water
hose or high pressure cleaner at electrical compo-
Effects of incorrect cleaning nents, bearings or lift chains.
 Make sure that no water can penetrate electrical
Electrical components components.
Electrical components such as connectors, contacts,  Use only cleaning petroleum and cleaning petrol to
distributor boards, controllers and wiring can be dam- clean lift chains, and then apply new type H chain
aged by water, cleaning agents and solvents. oil.
Mineral and chemical residue that automatically re-
main on or in components after cleaning, are a cause
of corrosion. This corrosion results in malfunctions and Cleaning the truck surface
premature failure. 3. It is preferable to dry clean the truck using a cloth,
soft brushes or weak, dry compressed air.
Roller and slide bearings 4. If you have to wet-clean the truck, do not aim the
Steam cleaning and solvents damage the lubricant film water hose or high pressure cleaner at electrical
on bearing surfaces. This results in dry running and components, bearings or lift chains. Avoid using
rapid damage to the bearing elements. cleaning agents where possible. If grease needs to
be removed, use a mild neutral cleaning agent.
Corrosion-protected surfaces
Note: High pressure cleaning can remove anti-corro-
The brake lines, screw connections and shiny metal sion agent and paint from surfaces.
surfaces in particular on cold store trucks are factory-
treated with an anti-corrosive agent 5. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
(Anticorit BW 366®). This protection can be washed off
by solvents and steam cleaning. The above-mentioned 6. Leave the cleaned truck to dry thoroughly.
components will corrode as a result. Cleaning electrical components
7. Clean electrical components only with weak, dry
Environmental protection compressed air and a dry cloth.
Cleaning must only be performed in specially desig-
nated areas to enable hazardous chemicals and oils to Interior cleaning
be separated. 8. Clean detachable rubber mats with water and a
Collect any waste (such as oily cleaning cloths) and neutral cleaning agent.
dispose of them in accordance with local regulations. 9. Allow the rubber mats to dry out fully before return-
ing them to the truck.
10. Damp-wipe plastic parts with a neutral cleaner.
Note: If necessary use a standard commercial plastic
cleaning agent to remove obstinate dirt.
After cleaning the truck
11. Wipe down the truck.
12. Remove any paint damage.
WP3015/3020 Models Rev.2 08/2010
21
ELECTRICAL SYSTEM
CLEANING THE TRUCK AND COMPONENTS
13. Add anti-corrosion agent if necessary. Note: Cleaned components must be dry and free of
cleaning agent residue before being refitted, lubricated
Returning the truck to operation after cleaning
or painted.
Normally no special measures are required.
5. Re-lubricate, paint or apply anti-corrosion agent to
If however there is a possibility that damp may have the components as required.
penetrated electrical components, proceed as follows:
6. Refit the components.
1. Clean the truck with weak, dry compressed air and
a cloth. 7. For cold store trucks apply Anticorit BW 366® as
an anti-corrosion agent for screw connections and
2. Leave the truck to stand for at least 30 minutes in
shiny metal surfaces.
a dry environment.
3. Insert the battery but do not connect it yet.
4. Jack up the truck so that the drive wheel is clear of
the ground (see page 17).
5. Connect the battery.
6. Switch on the truck.
 If a function automatically starts, apply the
Emergency Disconnect immediately.
Note: If possible, apply compressed air to the respec-
tive switch or connector. Repeat steps 1 to 6.
 Is the starting pattern is normal, proceed to
step 7.
7. Check all functions.
Cleaning removed components

Cleaning other mechanical components
With the exception of lift chains, components that have
been removed can be pressure- or wet-cleaned under
certain conditions.
CAUTION
Steam-cleaning can damage electrical compo-
nents and bearings.
 Mechanical components may only be pressure- or
wet-cleaned if no electrical components or bearings
are affected.
1. Components that have been removed should be

cleaned by hand, ideally with warm water and a
mild neutral cleaning agent.
2. If high pressure cleaning cannot be avoided, it
should be done without a cleaning agent. If grease
needs to be removed, use a mild neutral cleaning
agent.
Note: High pressure cleaning can remove anti-corro-
sion agent and paint from surfaces.
3. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
4. Leave the cleaned components to dry thoroughly.
Rev.2 08/2010 WP3015/3020 Models
22
LUBRICANTS, AEROSOLS & SERVICE SUPPLIES
Lubricants, Aerosols & Service recommended list of lubricants, aerosols and service
supplies to use when you do planned maintenance on
Supplies Crown Lift Trucks.
Refer to the Lubrication Identification Chart or the Alter-
nate Lubricants & Fluids Chart in this section for the
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity

363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
363514-001 1 Quart
AAAA Synthetic Gear Oil 75W-90
363514-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
063002-025 14.5 oz Cartridge
BBBB Grease (Multi-Purpose) Premium
063002-026 5 Gallon
C Oil (SAE 40)
363500-001 1 Quart
Engine Oil (10W30)
363500-012 (12) 1 Quart
CC
063041-001 1 Quart
JD Turf Guard (10W30)
063041-012 (12) 1 Quart Cans
363504-101 1 Gallon
D (1) Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon
DDD (2) Hydraulic Oil - Mobil DTE24 063001-021 1 Gallon
DDDD (3) Hydraulic Oil - Mobil Univis HVI 13 063001-035 5 Gallon

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

063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
Crown 2011 PF25240-1 Rev. 4/12 WP3015/3020 Models M1.0-04.0-050

01 Rev. 4/12
23
363143-001 10.5 oz Can

EE Channel Slide Lubricant
363143-012 (12) 10.5 oz Cans
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
063002-039 1 lb
I Grease (Lift Pump Coupling)
127801S 1 oz
063004-002 12 oz
J Brake Fluid - Dot 5
063004-003 1 Gallon
063002-034 14.5 oz Cartridge
K Grease (Wheel Bearing)
063002-045 (40) 14.5 oz Cartridges
L Metal Assembly Spray 063002-021 11 oz Spray
LL Sprayon 500727 PTFE Freezer Lube 063002-059 9 oz. Can
M Silicone Grease (Clear) 063002-020 5.3 oz Tube
363102-001 14 oz Can
Brake & Parts Cleaner
363102-012 (12) 14 oz Cans
363103-001 14 oz Can
N Low VOC Brake & Parts Cleaner
363103-012 (12) 14 oz Cans
363116-001 19 oz Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 19 oz Cans
363104-001 20 oz Can
O Penetrating Lubricant
363104-012 (12) 20 oz Cans
363108-001 11 oz Can
P Premium Formula Multi-Purpose Grease
363108-012 (12) 11 oz Cans
363110-001 11 oz Can
Q White Lithium Grease
363110-012 (12) 11 oz Cans
363109-001 15 oz Can
R Choke & Carburetor Cleaner
363109-012 (12) 16 oz Cans
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
M1.0-04.0-051 WP3015/3020 Models Crown 2011 PF25240-2 Rev. 4/12
01 Rev. 4/12
24
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

01 Rev. 4/12
25
Alternate Lubricants & Fluids Chart
Manufacturer/ Distribu-
Type of Lubricant Product Name
tor
A Gear Lube 80W-90 (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
AAA Universal Hydraulic & Transmission Fluid Crown Crown
AAAA Synthetic Gear Oil 75W-90 Crown Crown
Mobilgrease XHP 222 Special Mobil
Union Unoba EP No 2 Union 76 Co.
B Grease (Multi-Purpose) Retinax A (1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease (Low Temp) (2) Alvania RA (1) Shell
Helveum O (1) Burmah Castrol
BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
Mobilux EP2 64127-4 Mobil
Retinax AM 71119 Shell
BBBB Grease (Multi-Purpose) Premium
Chevron RPM Heavy Duty LC Chevron
Grease EP
C Oil (SAE 40)
D (2) Hydraulic Oil Crown Crown

DD Hydraulic Oil (Low Temp) Crown Crown
DDD (3)(5) Hydraulic Oil - Mobil DTE24 Mobil DTE 24 Mobil
DDDD (4) Hydraulic Oil - Mobil Univis HVI 13 Mobil Univis AVI 13 Mobil
E Channel Grease Factran #2 Standard Oil Co.
EE Channel Slide Lubricant Crown Crown
F Gear, Channel & Shaft Grease Molykote BR-2 Plus Dow Corning
Chain & Cable Lube Crown Crown
G
Premium Chain & Cable Lube Crown Crown
H Final Finish - Rubber & Vinyl Dressing Crown Crown
NOTE: Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
(1) Denotes allowable substitutes, contact factory if unavailable.
(2) Normal operation (temperatures of 0 °C and above)
(3) Standard temperature freezers (-18°C to 4°C)
(4) Low temperature freezers (-40°C to -12°C) Do not blend with any other oil.
(5) Premium antiwear hydraulic oil used in blending with low temp oil.
01 Rev. 4/12
26
Alternate Lubricants & Fluids Chart
Manufacturer/ Distribu-
Type of Lubricant Product Name
tor
I Grease (Lift Pump Coupling) Nyogel 774F-MS NYE Lubricants
J Brake Fluid - Dot 5 Q2-1141 Silicon Brake Fluid Dow Corning
Mobilgrease XHP 222 Special Mobil
K Grease (Wheel Bearing) Unirex EP-2 Exxon
Lubriplate No. 1242 (1) Fiske Bros. Refining Co.
L Metal Assembly Spray Dow Corning Dow Corning
LL Sprayon 500727 PTFE Freezer Lube Sprayon 500727 Sherwin Williams
M Silicon Grease (Clear) Dow Corning 111 Compound Dow Corning
Brake & Parts Cleaner Crown Crown
N Low VOC Brake & Parts Cleaner Crown Crown
Non-Flammable Brake & Parts Cleaner Crown Crown
O Penetrating Lubricant Crown Crown
P Premium Formula Multi-Purpose Grease Crown Crown
Q White Lithium Grease Crown Crown
R Choke & Carburetor Cleaner Crown Crown
S Contact Cleaner Crown Crown
Electrical Connector Oxidation &
T Nye Grease NYE Lubricants
Corrosion Inhibitor
U Battery Cleaner Crown Crown
V Battery Protector Crown Crown
W Food Grade Machinery Lubricant Crown Crown
X Food Grade Silicone Spray Crown Crown
Y Extended Life Coolant
(1) Denotes allowable substitutes, contact factory if unavailable.

01 Rev. 4/12
27
PLANNED MAINTENANCE
Planned Maintenance 9. Look for unwanted material in or around the truck

components.
To make sure that your truck continues to move mate-
10. Look for damaged components.
rials safely and quickly, you must do regular mainte-
nance on your truck. 11. Look for loose or missing fasteners.
12. Look for damaged electrical wires or connectors.
Do the planned maintenance
WARNING 1. Use the applicable interval chart in this section to
do the planned maintenance.
Injury or material damage can occur.
If you operate a truck for which repair is necessary or • 12 Months/1000 Hours
that is not in a safe condition, it can cause injury or ma- • 36 Months/3000 Hours
terial damage. Note: You must change the lubrication and inspection
If repair is necessary on the truck, or the truck is not in intervals to decrease corrosion and wear on parts for
a safe condition: trucks operated in environments with low tempera-
 Do not operate the truck until it is safe. tures, moisture, or other conditions that can cause con-
 Immediately make a report of the condition to the tamination or corrosion.
applicable authority. Note:
 Do not make repairs or adjustments to the truck un- • Use the applicable Planned Maintenance Inspec-
less you are approved to do them. tion Report (PF11827) to record maintenance.
• Consult your Crown dealer for Planned Mainte-
nance Inspection Reports.
• Figure 1 gives an example of PF11827. It is possi-
WARNING ble that it is not the newest report.
If you do not correctly prepare the truck for mainte-
nance, it can cause injury or material damage. o Com-
plete all lockout/tagout procedures. Refer to SAFETY >
Control of Hazardous Energy.
 Obey all safety instructions. Refer to SAFETY.
Do a visual inspection of the truck

1. Complete the Operators Daily Checklist. Refer to
INSPECTION AND LUBRICATION > Operator's
Daily Checklist.
floor.
5. Put the chocks against the wheels to prevent the
movement of the truck. Refer to SAFETY > Control
6. Complete the lockout/tagout procedures for the
7. Release the capacitance voltage in ACCESS 3.
Refer to SAFETY > Control of Hazardous Energy.
8. Blow off the truck with low pressure air.
M1.0-2730-001 WP3015/3020 Models Crown 2011 PF25470-1 Rev. 7/12
01 Rev. 7/12
28
PLANNED MAINTENANCE
Fig. 8 (27359)
Crown 2011 PF25470-2 Rev. 7/12 WP3015/3020 Models M1.0-2730-002

01 Rev. 7/12
29
PLANNED MAINTENANCE
Component Access
Fig. 9 (25991-01)
1 X10® handle
2 Top cover
3 Battery cover
4 Knuckle cover
5 Center cover
6 Main cover
01 Rev. 7/12
30
PLANNED MAINTENANCE
X10® Handle • Travel alarm (ALM).

Remove the covers on the X10® handle to get access
to these components:
Lubrication
• Forward switch (FS) The information that follows gives the correct intervals
for lubrication. Use high-grade lubricants and fluids.
• High speed switch (HSS)
Refer to the Lubrication Charts for the applicable lubri-
• Horn switches (HNS1 and HNS2) cants.
• Lower switch (LOS) Note: You must change the lubrication and inspection
• Raise switch (RAS) intervals to decrease corrosion and wear on parts for
• Reverse switch (RS) trucks that operate in environments with low tempera-
tures, moisture, or that can cause contamination or cor-
• Safety reverse switch (SAS)
rosion.
• Traction accelerator potentiometer (POT)
• Apply rust preventative (078882) to all fasteners,
• X10® handle PC boards. washers, nuts, roll pins, retaining rings, and other
components to prevent corrosion.
Battery Cover
Remove the battery cover to get access to the battery.
Knuckle Cover
Remove the knuckle cover to get access to the brake
switch (BRS) and the override switch (ORS).
Center, Main, and Top Covers

Remove the center, main, and top covers to get access
to these components:
• AC inlet
• Park brake (BRK)
• Control circuit fuses (FU2 and FU3)
• Display gauge (TT)
• Drive/tow switch (DTS) Fig. 10 (25865)
1 100% Standard Hydraulic Oil (063001-001)
• Freezer condition fuse (FU4)
2 50/50 Mixture of 50% Low Temperature Hydraulic Oil
• Horn (HN) (063001-006) and 50% Standard Hydraulic Oil
• Impact sensor (063001-021)
• Key switch (KYS)

• Lift cylinders
• Lift limit switch (LMS)
• Lift pump
• Lift pump motor (M2)
• Line contactor (L)
• Pump contactor (P)
• Relief valve (RV)
• Solenoid valve (SV)
• Traction control module (ACCESS 3)
• Traction motor (M1)
• Traction motor temperature sensor (TS1)
• Traction power fuse (FU1)
• Traction speed encoder (ECR)

01 Rev. 7/12
31
PLANNED MAINTENANCE
L-1
L-1
L-2
1
L-3
1 The X10® handle springs are in

the bottom of the handle between
the knuckle
2 The return pipe and suction pipe
are in the reservoir
L-4 L-5
2
Fig. 11 (25992-01)
01 Rev. 7/12
32
PLANNED MAINTENANCE
Chart 1 - Planned Maintenance Lubrication
12 Months 36 Months
Index Component Lube Type Quantity
1000 Hours 3000 Hours
Lift Cylinder Attachments (Top and
L-1 B As Necessary Check
Bottom)
L-2 X10® Handle Springs B As Necessary Check
L-3 Steer Bearings B As Necessary Check
L-4 Drive Unit Oil A 0.75 L 1st Change Change
Hydraulic Reservoir
L-5 • Hydraulic Oil D 0.75 L 1st Change Change
• Return Pipe and Suction Pipe 1 each 1st Change Change
Refer to INSPECTION AND LUBRICATION > Lubricants, Aerosols & Service Supplies for more lubricant type information. You
must change your lubrication schedule for environments with high levels of contamination or moisture.
Freezer condition trucks: you must change your lubrication schedule for freezer condition trucks to decrease wear on shafts and
parts.

01 Rev. 7/12
33
PLANNED MAINTENANCE
Fig. 12 (25993)
01 Rev. 7/12
34
PLANNED MAINTENANCE
Chart 2 - Planned Maintenance Lubrication
12 Months
Index Component Lube Type Quantity
1000 Hours
L-1 Ball Bearings in the Load Wheel B As Necessary Check
L-2 Risers B As Necessary Check
L-3 Lubrication Fittings in the Lift Linkage B As Necessary Check
Refer to INSPECTION AND LUBRICATION > Lubricants, Aerosols & Service Supplies for more lubricant type information. You
must change your lubrication schedule for environments with high levels of contamination or moisture.
Freezer condition trucks: you must change your lubrication schedule for freezer condition trucks to decrease wear on shafts and
parts.

01 Rev. 7/12
35
PLANNED MAINTENANCE
Fig. 13 (25994)
01 Rev. 7/12
36
PLANNED MAINTENANCE
Chart 3 - Planned Maintenance Inspection
12 Months
Index Component
1000 Hours
Travel Controls (Forward Switch, Reverse Switch, and Traction Accelerator Po-
I-1 Check
tentiometer)
I-2 Lift Cylinder Check
I-3 Battery Charger Check
I-4 Hydraulic Connections, Hoses, and Lines Check
I-5 Drive Tire Check
Refer to the applicable section of the service manual for more adjustment information.

01 Rev. 7/12
37
PLANNED MAINTENANCE
Fig. 14 (25995)
01 Rev. 7/12
38
PLANNED MAINTENANCE
12 Months
Index Component
1000 Hours
I-1 Battery Disconnect Check
I-2 Battery and Battery Connections Check
I-3 Lift Limit Switch Check
I-4 ACCESS 3 Check
I-5 Line Contactor Tips Check
I-6 Caster Wheels and Bearings Check

01 Rev. 7/12
39
PLANNED MAINTENANCE
Fig. 15 (25996)
01 Rev. 7/12
40
PLANNED MAINTENANCE
12 Months
Index Component
1000 Hours
I-1 Load Wheels and Ball Bearings Check
I-2 Risers Check
I-3 Lift Linkage and Tension Bars Check

01 Rev. 7/12
41
PLANNED MAINTENANCE
Fig. 16 (25997)
01 Rev. 7/12
42
PLANNED MAINTENANCE
12 Months
Index Component
1000 Hours
I-1 X10® Handle Operation Check
I-2 Fork Height Check
I-3 Brake Switch and Override Switch Check
I-4 Traction Motor and Traction Speed Encoder Check
I-5 Electrical Connections Check

01 Rev. 7/12
43
PLANNED MAINTENANCE
Fig. 17 (25998)
01 Rev. 7/12
44
PLANNED MAINTENANCE
12 Months 36 Months
Index Component
1000 Hours 3000 Hours
I-1 End Head on the Lift Pump Motor Check
I-2 Travel Alarm or Drive/Tow Switch Check
I-3 Park Brake Adjustment, Installation, and Operation Check
I-4 Friction Plate and Rotors on the Park Brake Check
I-5 Park Brake Hub Check Change
I-6 Brushes in the Lift Pump Motor Check
I-7 Horn Check

01 Rev. 7/12
45
CASTER
Caster Adjust the casters

Refer to Figure 18.
The brake and caster systems are adjusted at the fac-
tory to supply nominal brake and stable performance 8. Remove the jam nut (2) from the caster.
for level, smooth, and dry floors, and standard tire and 9. Remove the adjustment screw (1) from the caster.
load conditions. After you install the casters, make sure 10. With your hand, tighten the adjustment screw (1)
that the truck brake and performance are stable. It into the caster. Continue to tighten the adjustment
could be necessary to change the factory adjustments screw 1/2 turn with a wrench.
for the applicable operation conditions. When a truck
11. Fully remove the adjustment screw (1) from the
operates in many conditions, it is not possible to adjust
caster again.
the brakes and casters to operate best for all of the
conditions. 12. With your hand, tighten the adjustment screw (1)
into the caster again. Continue to tighten the ad-
Caster Adjustment justment screw three 3/4 turn with a wrench.
To make sure that the truck brake and performance are 13. Tighten the jam nut (2).
stable, you must adjust the caster for tire wear and tire
replacement. Refer to the Caster Adjustment Chart.
WARNING
A truck that is not stable can cause an injury.
Wrong adjustment of the casters has a negative effect
on the performance of the truck.
 Obey the adjustment procedures for the casters.
 Make sure the floor conditions in the set up area
agree with the floor conditions in the operating area.
Note: If you increase the caster load, you decrease the

load on the drive tire and decrease the truck brake and
traction operation.
1
If you decrease the caster load, you decrease how sta- 2
ble the truck is.
Drive tire wear or replacement and floor conditions
have an effect on how the truck operates.
Prepare the truck for maintenance

Refer to Figure 18.
floor.
2. Turn the caster to get access to the adjustment
screw (1).
3. Lower the forks fully.
Fig. 18 (25657-01)
02 Rev. 7/12
46
CASTER
Prepare the truck for operation 16. Connect the battery.

14. Remove the wheel chocks. 17. Turn the truck ON and make sure that the adjust-
ment is correct. The force of each caster must be
15. Remove the lockout/tagout tag to operate the
approximately 489 N, the equivalent of a 50 kg
truck.
load.
Caster Adjustment Chart
Caster Adjust- Caster Load Drive Tire Load Traction and How Stable the Truck Steer Force
ment Brake Perfor- is and How the Truck
mance Controls
Up Decreases Increases Increases Decreases Increases
Down Increases Decreases Decreases Increases Decreases

02 Rev. 7/12
47
METRIC TORQUE VALUES
Metric Torque Values torque values in the maintenance and parts sections of
this manual override the standard torque values in this
It is important to tighten fasteners to the correct torque section.
value. This section shows the standard torque values
for the screws and bolts used in Crown trucks. Special Grade
Grade Identification Bolt and Screw

Specification Size (mm)
(on Head)
5.8 Class 5.8 M5 through M36
NOTE: .Even though a bolt head is unmarked, Crown uses nothing less than class 8.8
in all of its bolted assemblies. Instances do occur when class 8.8 bolts are manufac-
tured unmarked. When a fastener is replaced that is unmarked, replace the fastener
with a class 8.8.
Figure 15048-01
04 Rev. 7/12
48
Torque Chart - Metric Hex Head Cap Screws and Nuts
Thread Diameter & Torque Nm

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

M5 x 0.80 4-7 5-8 7 - 10
M6 x 1.00 7 - 10 9 - 12 11 - 14
M8 x 1.25 16 - 19 23 - 26 27 - 30
M10 x 1.50 31 - 34 45 - 49 54 - 58
M12 x 1.75 56 - 60 79 - 84 94 - 102
M14 x 2.00
M16 x 2.00 124 - 146 190 - 206 228 - 247
M20 x 2.50 259 - 281 363 - 395 437 - 473
M24 x 3.00 416 - 451 586 - 635 702 - 762
M30 x 3.50

04 Rev. 7/12
49
Torque Chart - Metric Socket Head Cap Screws

M5 x 0.80 5-8 7-9 8 - 11
M6 x 1.00 9 - 12 12 - 15 15 - 18
M8 x 1.25 22 - 24 30 - 33 35 - 38
M10 x 1.50 42 - 45 58 - 64 71 - 76
M12 x 1.75 72 - 77 102 - 110 122 - 132
M14 x 2.00 115 - 125 161 - 175 194 - 210
M16 x 2.00 179 - 194 251 - 273 301 - 327
M20 x 2.50 348 - 377 489 - 530 588 - 637
M24 x 3.00 601 - 651 846 - 915 1014 - 1098
M30 x 3.50 1196 - 1296 1681 - 1822 2017 - 2187
Torque Chart - Metric Flanged Hex Head Cap Screws and Nuts

M5 x 0.80 5-8 8 - 11 9 - 12
M6 x 1.00 9 - 12 14 - 16 16 - 19
M8 x 1.25 22 - 24 31 - 34 38 - 41
M10 x 1.50 44 - 48 62 - 68 75 - 81
M12 x 1.75 77 - 83 108 - 117 130 - 141
M14 x 2.00 123 - 134 174 - 187 209 - 225
M16 x 2.00 193 - 210 273 - 294 327 - 354
04 Rev. 7/12
50
SAE TORQUE VALUES
SAE Torque Values torque values in the maintenance and parts sections of
this manual override the standard torque values in this
It is important to tighten fasteners to the correct torque section.
value. This section shows the standard torque values
for the screws and bolts used in Crown trucks. Special Grade
Grade Identifica- Bolt and Screw

Specification
tion(on Head) Size (Inches)
SAE - Grade 2 1/4 thru 1-1/2
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted
assemblies. Instances do occur when Grad 5 bolts are manufactured unmarked. When a fastener is re-
placed that is unmarked, replace the fastener with a Grade 5.
Fig. 19 (14916-01)
Torque Chart
Torque Chart
Mounting bolt torque re-
Grade 5 Grade 8 quirements involving hy-
draulic valves.
Dry Torque Requirement
13 ± 2
Nm Nm
24 ± 2
12 ± 4 17.5 ± 5.5
39 ± 2
24.5 ± 7 34 ± 7
NOTE: Torque values called out in the maintenance
43.5 ± 7 65 ± 13.5
section of this manual will take precedence over
67.5 ± 13.5 102 ± 13.5 torque values found on this page.
101.5 ± 13.5 152 ± 20.5
149 ± 20.5 221 ± 27
203.5 ± 27 305 ± 41
359 ± 47.5 542 ± 68
569 ± 81 868 ± 108
868 ± 109 1300 ± 156
1085 ± 136
1356 ± 163
1630 ± 203
2034 ± 271

05 Rev. 6/12
51
Notes:
52
COMPONENTRY
53
Notes:
54
COMPONENTRY
COMPONENTRY
Componentry
Introduction
The components in this section help the technician with
data for each component:
• The component designator (for example, ALM1)
that is on the electrical diagram and parts pages.
• The description of the component.
• The location of the component on the truck.
• The function of the component.
• The data of the component.
• The applicable adjustments.
• The electrical diagrams that the component is on.
Two numbers immediately follow the page number.
The first number (in parentheses) is the grid coordi-
nate and the second number (in parentheses) is the
manual page number (for example, DIA-2730-012
(C-2) (223).

01 Rev. 7/12
55
COMPONENTRY
AUDIBLE INDICATORS
Audible Indicators
ALM
Travel Alarm (Optional)
Location: above the battery charger
Function: gives an audible indication of the movement
of the truck
Data: receives +BV from the line contactor (L) and
BNEG from ACCESS 3. See the ACCESS 3 output to
ALM from the ALM-TRAVEL ALARM DRIVER menu in
the DRIVER OUTPUTS menu.
Adjustment: turn ALM ON or OFF in the FORWARD
TRAVEL ALARM ENABLE and REVERSE TRAVEL
ALARM ENABLE menus in the TRAVEL ALARM menu
Diagrams: DIA-2730-011 (A-2)(222)
DIA-2730-013 (B-2)(224)
HN
Horn
Location: the power unit near the drive unit
Function: lets the operator give an audible indication
of the truck location
Data: receives +BV from the brake (BRK) and BNEG
from ACCESS 3. See the ACCESS 3 output to HN
from the HN-HORN DRIVER PWM menu in the
DRIVER OUTPUTS menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (A-3)(221)
DIA-2730-011 (A-3)(222)
DIA-2730-012 (A-1)
DIA-2730-013 (A-1)
01 Rev. 7/12
56
COMPONENTRY
BATTERY
Battery
BATT
Battery
Location: behind the power unit
Function: supplies power to the truck and its compo-
nents
Data: 24 V (four 6 V batteries). See the battery settings
in the BATTERY menu.
Adjustment: adjust the battery settings in the BAT-
TERY menu in the PROGRAM menu
Diagrams: DIA-2730-010 (B-4)(221)
DIA-2730-011 (B-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-4)(224)
DIA-2730-015 (A-1)(226)

01 Rev. 7/12
57
COMPONENTRY
BRAKES
Brakes
BRK
Brake
Location: the drive unit, on the traction motor (M1)
Function: supplies brake force to the traction motor
(M1) to stop the truck and prevents the movement of a
parked truck
Data: ACCESS 3 controls BRK and supplies positive
and negative to BRK. See the ACCESS 3 output to
BRK in the BRK-EM BRAKE PWM menu in the
Adjustment: adjust the BRK settings in the BRAKE
RATE and BRAKE OVERRIDE menus in the PRO-
GRAM menu. Also, refer to BRAKE SYSTEM > Brake.
Diagrams: DIA-2730-010 (B-2)(221)
DIA-2730-011 (B-2)(222)
DIA-2730-012 (A-1)(223)
DIA-2730-013 (A-1)(224)
01 Rev. 7/12
58
COMPONENTRY
BRAKES
Fig. 20 (26000)

01 Rev. 7/12
59
COMPONENTRY
CONTACTORS
Contactors
L
Line Contactor
Location: above the lift pump motor (M2)
Function: supplies +BV to the ACCESS 3 power cir-
cuit
Data: ACCESS 3 controls the line contactor and sup-
plies 24 V and negative to the line contactor coil. See
the ACCESS 3 output to the line contactor in the L-
MAIN CONTACTOR PWM menu in the DRIVER OUT-
PUTS menu. See the line contactor condition in the
MAIN STATE menu in the CONTROLLER menu.
Adjustment: N/A
Diagrams:
Coil: DIA-2730-010 (A-2)(221)
DIA-2730-011 (A-2)(222)
DIA-2730-012 (A-1)(223)
DIA-2730-013 (B-1)(224)
DIA-2730-015 (C-2)(226)
Contacts: DIA-2730-010 (A-4)(221)
DIA-2730-011 (A-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-3)(224)
DIA-2730-015 (C-2)(226)
P
Pump Contactor
Location: above the lift pump motor (M2)
Function: supplies +BV to the lift pump motor (M2)
Data: ACCESS 3 controls the pump contactor and
supplies 24 V and negative to the pump contactor coil.
See the ACCESS 3 output to the pump contactor in the
P-PUMP CONTACTOR PWM menu in the DRIVER
OUTPUTS menu.
Adjustment: N/A
Diagrams:
Coil: DIA-2730-010 (A-2)(221)
DIA-2730-011 (A-2)(222)
DIA-2730-012 (A-1)(223)
DIA-2730-013 (B-1)(224)
DIA-2730-015 (C-2)(226)
Contacts: DIA-2730-010 (B-4)(221)
DIA-2730-011 (B-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (C-3)(224)
DIA-2730-015 (C-2)(226)
01 Rev. 7/12
60
COMPONENTRY
CONTACTORS
Fig. 21 (26001)

01 Rev. 7/12
61
COMPONENTRY
CONTROL MODULES
Control Modules • The lower switch (LOS)

• The traction accelerator potentiometer (POT)
ACCESS 3 • The raise switch (RAS)
• The reverse switch (RS)
Traction Control Module
• The safety reverse switch (SAS)
Location: above the lift contactor (L) and pump con-
tactor (P) • The display gauge (TT).
Function: controls the operation of the traction motor, Adjustment: if you replace a module, calibrate the
the lift pump motor (M2), and the brake (BRK) truck to prevent event codes. If the replacement mod-
ule includes the newest software, do a software update
Data: receives an input from these components:
in the other modules to make sure that all software is
• ACCESS 8 compatible.
• The brake switch (BRS) Diagrams: DIA-2730-010 (B-1)(221)
• The traction speed encoder (ECR) DIA-2730-011 (B-1)(222)
• The key switch (KYS) DIA-2730-014 (B-2)(225)
• The lift limit switch (LMS)
INFOLINK
• The override switch (ORS)
• The traction motor temperature sensor (TS) InfoLink Module (Optional)
• The display gauge (TT). Location: on the top of the power unit
Adjustment: if you replace a module, calibrate the Function: monitors the truck operation and impacts. If
truck to prevent event codes. If the replacement mod- your truck has a proximity reader, you must use a pass-
ule includes the newest software, do a software update word before you operate the truck.
in the other modules to make sure that all software is
Data: N/A
compatible.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-3)(221)
DIA-2730-011 (B-3)(222) Diagrams: DIA-2730-011 (B-1)(222)
DIA-2730-012 (B-2)(223) DIA-2730-013 (A-3)(224)
DIA-2730-013 (B-2)(224)
DIA-2730-015 (C-2)(226)
ACCESS 8
X10® Handle
Location: above the drive unit
Function: controls the operator inputs. The operator
inputs include:
• High speed
• Horn
• Lower
• Raise
• Safety reverse
• Steer
• Truck travel.
Data: receives an input from these components:
• ACCESS 3
• The forward switch (FS)
• The horn switches (HNS1 and HNS2)
• The high speed switch (HSS)
01 Rev. 7/12
62
COMPONENTRY
CYLINDERS
Cylinders
Lift Cylinders
Location: the two sides of the power unit
Function: raises the forks
Data: N/A
Adjustment: N/A
Diagrams: HYD-2720-001 (1)(231)

01 Rev. 7/12
63
COMPONENTRY
ENCODERS
Encoders
ECR
Traction Speed Encoder
Location: the drive unit, on the traction motor (M1)
Function: supplies traction motor (M1) speed and di-
rection to ACCESS 3
Data: ACCESS 3 supplies 5 V and BNEG to ECR.
ECR has two outputs (A and B) that give feedback to
ACCESS 3 to show truck speed and direction.
ACCESS 3 examines if it receives A or B input first
(goes "high" first) to find the truck travel direction.
ACCESS 3 then examines the speed at which A and B
change condition to find the truck speed. See the rpm
of A and B from the MOTORSPEED A and MOTOR-
SPEED B menus in the MONITOR menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (C-3)(221)
DIA-2730-011 (C-3)(222)
DIA-2730-012 (C-2)(223)
DIA-2730-013 (C-2)(224)
01 Rev. 7/12
64
COMPONENTRY
FUSES
Fuses Function: prevents the freezer condition components

and applicable circuits from too much current
FU1 Data: 4 A
Adjustment: N/A
Traction Power Fuse
Diagrams: DIA-2730-011 (B-4)(222)
Location: above ACCESS 3 DIA-2730-013 (B-3)(224)
Function: prevents ACCESS 3, the traction motor
(M1), the lift pump motor (M2), and applicable circuits
from too much current
Data: 125 A
Adjustment: N/A
Diagrams: DIA-2730-010 (A-4)(221)
DIA-2730-011 (B-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-4)(224)
DIA-2730-015 (C-1)(226)
FU2
Control Circuit Fuse
Location: the instrument bracket by the display gauge
(TT)
Function: prevents the control circuits from too much
current
Data: 10 A
Adjustment: N/A
Diagrams: DIA-2730-010 (B-4)(221)
DIA-2730-011 (B-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-4)(224)
FU3
Control Circuit Fuse
Location: the instrument bracket below the key switch
(KYS)
Function: prevents the control circuits from too much
current
Data: 4 A
Adjustment: N/A
Diagrams: DIA-2730-010 (A-4)(221)
DIA-2730-011 (A-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-3)(224)
FU4
Freezer Condition Fuse (Optional)
Location: the instrument bracket above the key switch
(KYS)

01 Rev. 7/12
65
COMPONENTRY
FUSES
1 Lift Cylinders
Fig. 22 (26003)
01 Rev. 7/12
66
COMPONENTRY
MISCELLANEOUS
Miscellaneous Adjustment: the board and its components are not

serviceable and you must replace them
AC Inlet (Optional) Diagrams: DIA-2730-014 (B-2)(225)
Location: the instrument bracket between the display TT

gauge (TT) and key switch (KYS)
Function: charges the batteries with them in the truck Display Gauge
Data: 125 V, 15 A Location: the instrument bracket by the AC inlet
Adjustment: N/A Function: shows the battery, hour meter, and event
code data
Diagrams: DIA-2730-013 (C-4)(224)
Data: the temperature of operation is -40 to 65 °C
Battery Charger (Optional) Adjustment: refer to ELECTRICAL SYSTEM > Dis-
play Gauge
Location: by the drive unit
Diagrams: DIA-2730-010 (B-2)(221)
Function: charges the batteries with them in the truck
DIA-2730-011 (B-2)(222)
Data: 24 V DIA-2730-014 (B-1)(225)
Adjustment: refer to ELECTRICAL SYSTEM > Bat-
tery
Diagrams: DIA-2730-011 (A-4)(222)
DIA-2730-013 (B-4)(224)
Hydraulic Printed Circuit Board

Location: in ACCESS 8 (the X10® handle)
Function: mechanically controls and electrically con-
nects the lower switch (LOS), the raise switch (RAS),
and the freezer condition resistors (RES2 and RES3)
Data: N/A
Adjustment: the board and its components are not ser-
viceable and you must replace them
Diagrams: DIA-2730-014 (B-3)(225)
Primary Printed Circuit Board

nects the horn switches (HNS1 and HNS2), the safety
reverse switch (SAS), and the traction accelerator po-
tentiometer (POT)
Data: N/A
Adjustment: the board and its components are not
serviceable and you must replace them
Diagrams: DIA-2730-014 (B-2)(225)
R/T Printed Circuit Board

nects the high speed switch (HSS) and the freezer con-
dition resistor (RES1)
Data: N/A

01 Rev. 7/12
67
COMPONENTRY
MISCELLANEOUS
2 FU4 FU3
1 Battery Charger
2 AC Inlet
Fig. 23 (26004-01)
01 Rev. 7/12
68
COMPONENTRY
MOTORS
Motors
M1
Traction Motor
Location: the drive unit
Function: operates with the drive unit to supply the
truck traction (speed and direction)
Data: ACCESS 8 (the X10® handle) supplies speed
and direction control by the forward switch (FS), the re-
verse switch (RS), and the traction accelerator potenti-
ometer (POT). ACCESS 3 supplies AC voltage to M1,
which causes ACCESS 3 to operate the truck at the
necessary speed. ACCESS 3 then holds M1 at that
speed by input from the traction speed encoder (ECR)
until the command or conditions change. See the M1
settings in the MOTOR menu in the MONITOR menu.
See the total M1 hours in the H1 TRACTION HOURS
menu in the HOUR METERS menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (C-3)(221)
DIA-2730-011 (C-3)(222)
DIA-2730-012 (C-3)(223)
DIA-2730-013 (C-2)(224)
DIA-2730-015 (B-3)(226)
M2
Lift Pump Motor
Location: by the drive unit, below the line contactor (L)
and pump contactor (P)
Function: operates with the lift pump to supply hydrau-
lic oil flow to raise the forks
Data: the line contactor (L) supplies +BV and the pump
contactor (P) supplies BNEG. See the total M2 hours in
the H2 PUMP HOURS menu in the HOUR METERS
menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-4)(221)
DIA-2730-011 (B-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-3)(224)
DIA-2730-015 (C-3)(226)
HYD-2720-001 (5)(231)

01 Rev. 7/12
69
COMPONENTRY
POTENTIOMETERS
Potentiometers
POT
Traction Accelerator Potentiometer
Function: supplies input to ACCESS 8 for travel
speed
Data: ACCESS 8 supplies 10 V and BNEG to POT.
See the POT counts in the TILLER THROTTLE menu
in the MONITOR menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-2)(221)
DIA-2730-011 (B-2)(222)
DIA-2730-014 (C-1)(225)
Pumps
Lift Pump
Location: by the drive unit, below the line contactor (L)
and pump contactor (P)
Function: operates with the lift pump motor (M2) to
supply hydraulic oil flow to raise the forks
Data: N/A
Adjustment: N/A
Diagrams: HYD-2720-001 (6)(231)
01 Rev. 7/12
70
COMPONENTRY
POTENTIOMETERS
M2
POT
1 The lift pump is in the

reservoir
M1
Fig. 24 (26006-01)

01 Rev. 7/12
71
COMPONENTRY
SENSORS
Sensors
Impact Sensor (Optional)
Location: on the power unit, by the battery charger
Function: supplies the truck impact data to the Info-
Link® module
Data: receives 5 V and negative from the InfoLink®
module
Adjustment: N/A
Diagrams: DIA-2730-013 (A-3)(224)
TS
Traction Motor Temperature Sensor
Location: in the traction motor (M1)
Function: monitors the M1 temperature and sends
that data to ACCESS 3
Data: see the M1 temperature in the TEMPERATURE
menu in the DRIVER OUTPUTS menu
Adjustment: N/A
Diagrams: DIA-2730-010 (C-3)(221)
DIA-2730-011 (C-3)(222)
DIA-2730-012 (C-2)(223)
DIA-2730-013 (C-2)(224)
01 Rev. 7/12
72
COMPONENTRY
SOLENOIDS
Solenoids
CV
Check Valve
Location: the lift pump manifold
Function: lets hydraulic oil flow in one direction only
Data: N/A
Adjustment: N/A
Diagrams: HYD-2720-001 (4)(231)
RV
Relief Valve
Function: puts a limit on the pressure in the lift circuit
Data: N/A
Adjustment: set to 145 bar on 1.6 t capacity or
165 bar on 2.0 t capacity
Diagrams: HYD-2720-001 (11)(231)
SV
Solenoid Valve
Function: moves to let hydraulic oil flow to the reser-
voir. This lowers the forks.
Data: the coil receives positive and negative from
ACCESS 3. See the ACCESS 3 output to the solenoid
valve in the SVL-LOWER VALVE PWM menu in the
Adjustment: N/A
Diagrams: DIA-2730-010 (A-3)(221)
DIA-2730-011 (A-3)(222)
DIA-2730-012 (A-1)(223)
DIA-2730-013 (B-1)(224)

01 Rev. 7/12
73
COMPONENTRY
SOLENOIDS
CV
SV
1 Impact sensor
2 TS is in M1
2
RV
Fig. 25 (26007-01)
01 Rev. 7/12
74
COMPONENTRY
SWITCHES
Switches Function: operates the horn (HN)

Data: momentary switch that is normally open. HNS1
BRS and HNS 2 supply a positive input signal to HN when
closed (you push HNS1 or HNS2). See the HNS1 or
Brake Switch HNS2 inputs in the HN-HORN SWITCH menu in the
Location: on the knuckle above the drive unit SWITCH INPUTS menu.
Function: supplies a brake command input to Adjustment: N/A
ACCESS 3 Diagrams: DIA-2730-010 (B-1)(221)
Data: momentary switch that is normally open. BRS DIA-2730-011 (B-1)(222)
supplies a positive input signal to ACCESS 3 when DIA-2730-014 (C-2)(225)
closed (the brake [BRK] coil energizes and BRK re-
leases). See the BRS inputs in the BRS-BRAKE
SWITCH menu in the SWITCH INPUTS menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (A-3)(221)
DIA-2730-011 (B-3)(222)
DIA-2730-014 (C-3)(225)
DTS
Drive/Tow Switch (Optional)
Location: above the battery charger
Function: releases the brake (BRK) to tow the truck
Data: fully maintained switch that is normally open.
When you put DTS in the tow position, the BRK coil
energizes and BRK releases.
Adjustment: N/A
Diagrams: DIA-2730-013 (A-1)(224)
FS
Forward Switch
Location: in ACCESS 8 (the X10® handle) as part of
the traction accelerator potentiometer (POT) assembly
Function: supplies a forward travel command input to
ACCESS 8
Data: momentary switch that is normally open. FS sup-
plies a positive input signal to ACCESS 8 when closed
(the thumbwheel is away from the operator). See the
FS inputs in the FS-FORWARD SWITCH menu in the
SWITCH INPUTS menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-1)(221)
DIA-2730-011 (B-1)(222)
DIA-2730-014 (C-2)(225)
HNS1 and HNS2

Horn Switches 1 and 2
Location: ACCESS 8 (the X10® handle) in the two
hand grips

01 Rev. 7/12
75
COMPONENTRY
SWITCHES
Fig. 26 (26008)
01 Rev. 7/12
76
COMPONENTRY
SWITCHES
HSS held closed (LMS is in operation). See the LMS inputs

from the LMS-LIFT LIMIT SWITCH menu in the
High Speed Switch SWITCH INPUTS menu.
Location: in ACCESS 8 (the X10® handle) Adjustment: N/A
Function: lets the truck travel in turtle speed or rabbit Diagrams: DIA-2730-010 (B-3)(221)
speed DIA-2730-011 (B-3)(222)
Data: momentary switch that is normally open. HSS DIA-2730-014 (B-4)(225)
supplies a positive input signal to ACCESS 8 when
closed (HSS is set to rabbit speed). See the HSS in- LOS
puts in the HSS-RABBIT SWITCH menu in the
Lower Switch
SWITCH INPUTS menu.
Location: in ACCESS 8 (X10® handle) on the hydrau-
Adjustment: N/A
lic printed circuit board
Diagrams: DIA-2730-010 (B-1)(221)
Function: supplies a lower command input to
DIA-2730-011 (B-1)(222)
ACCESS 8
DIA-2730-014 (B-2)(225)
Data: momentary switch that is normally open. LOS
KYS supplies a positive input signal to ACCESS 8 when
closed (LOS is in operation). See the LOS inputs in the
Key Switch LOWER SWITCH menu in the SWITCH INPUTS
Location: the instrument bracket by the AC inlet menu.
Function: lets you turn the truck ON and turn the truck Adjustment: N/A
OFF Diagrams: DIA-2730-010 (B-1)(221)
Data: momentary switch that is normally closed. KYS DIA-2730-011 (B-1)(222)
supplies a positive input signal to these components DIA-2730-014 (C-3)(225)
when it is open (KYS is ON):
• ACCESS 3
• ACCESS 8 (the X10® handle)
• The override switch (ORS)
• The brake switch (BRS)
• The lift limit switch (LMS)
• The display gauge (TT)
• The InfoLink® module.
See the KYS voltage in the KEYSWITCH VOLTAGE
menu in the BATTERY menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-4)(221)
DIA-2730-011 (B-4)(222)
DIA-2730-012 (B-4)(223)
DIA-2730-013 (B-4)(224)
LMS
Lift Limit Switch
Location: by the drive unit and below the instrument
bracket
Function: cuts out lift when the forks are at their max-
imum lift height
Data: momentary switch that is normally open. LMS

01 Rev. 7/12
77
COMPONENTRY
SWITCHES
Fig. 27 (26009)
M1.91-2730-021 WP3015/3020 Models

01 Rev. 7/12
78
COMPONENTRY
SWITCHES
ORS SAS
Override Switch Safety Reverse Switch
Location: on the knuckle above the drive unit Location: in ACCESS 8 (the X10® handle)
Function: sends a signal of a slow travel range to Function: operates the truck in reverse safely away
ACCESS 3 from the operator
Data: momentary switch that is normally open. ORS Data: momentary switch that is normally closed. SAS
supplies a positive input signal to ACCESS 3 when supplies 10 V to ACCESS 8 when held open (SAS is in
closed (ORS is in operation). See the ORS inputs from operation). SAS is not available if ACCESS 8 is not in
the ORS-BRAKE OVERRIDE SWITCH menu in the the power unit first direction. See the SAS inputs in the
SWITCH INPUTS menu. SAS-EMERGENCY REVERSE CAN and SAS-EMER-
Adjustment: N/A GENCY REVERSE REDUNDANT menus in the
SWITCH INPUTS menu.
Diagrams: DIA-2730-010 (A-3)(221)
DIA-2730-011 (B-3)(222) Adjustment: N/A
DIA-2730-014 (C-4)(225) Diagrams: DIA-2730-010 (B-1)(221)
DIA-2730-011 (B-1)(222)
RAS DIA-2730-014 (C-2)(225)
Raise Switch
Location: in ACCESS 8 (X10® handle) on the hydrau-
lic printed circuit board
Function: supplies a raise command input to
ACCESS 8
Data: momentary switch that is normally open. RAS
closed (RAS is in operation). See the RAS inputs in the
RAS-LIFT SWITCH menu in the SWITCH INPUTS
menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-1)(221)
DIA-2730-011 (B-1)(222)
DIA-2730-014 (B-3)(225)
RS
Reverse Switch
Location: in ACCESS 8 (the X10® handle) as part of
the traction accelerator potentiometer (POT) assembly
Function: supplies a reverse travel command input to
ACCESS 8
Data: momentary switch that is normally open. RS sup-
plies a positive input signal to ACCESS 8 when closed
(the hand grip is toward the operator). See the RS in-
puts in the RS-REVERSE SWITCH menu in the
SWITCH INPUTS menu.
Adjustment: N/A
Diagrams: DIA-2730-010 (B-1)(221)
DIA-2730-011 (B-1)(222)
DIA-2730-014 (C-2)(225)
WP3015/3020 Models M1.91-2730-022

01 Rev. 7/12
79
COMPONENTRY
SWITCHES
1 RS
SAS
1 SAS is below the button
ORS
RAS
Fig. 28 (26010-01)
M1.91-2730-023 WP3015/3020 Models

01 Rev. 7/12
80
HYDRAULIC SYSTEM
81
Notes:
82
HYDRAULIC SCHEMATIC SYMBOLS
Hydraulic Schematic Symbols
VENTED RESERVOIR
ELECTRIC MOTOR
with the lines above the fluid M
level operates in one direction and speed
ELECTRIC MOTOR
VENTED RESERVOIR M operates in one direction in a speed
with the lines below the fluid that changes
level
ELECTRIC MOTOR
M operates in two opposite directions in
FILTER or STRAINER a speed that changes
HYDRAULIC PLUMBING HYDRAULIC PUMP

with full flow (this includes tubes, fixed displacement, operates in one
hoses, and the flow paths in the direction
manifolds)
HYDRAULIC PUMP-MOTOR
fixed displacement, operates in two
PILOT or DRAIN LINE opposite directions in a speed that
limited flow changes
LINES CROSSING
HYDRAULIC MOTOR
operates in two opposite directions
LINES CONNECTED
GAUGE
pressure
QUICK DISCONNECT
(disconnected)
GAUGE
temperature
PLUGGED PORT
(test port)
ACCUMULATOR
gas charged, diaphragm type
FLOW METER
Fig. 29 (3559-05)

07 Rev. 6/12
83
PRESSURE SWITCH ACTUATOR MANUAL
CYLINDER
double-acting cylinder, SPRING
unequal area (spring-bias in the
de-energized position)
CYLINDER
double acting cylinder, equal area
(steer) (two end) SOLENOID
one coil or winding
CYLINDER
single-acting cylinder with spring return
(the rod end has a vent)
HYDRAULIC PILOT
OPERATED
CYLINDER
single-acting cylinder, ram type
SOLENOID
pilot operated
CYLINDER
single-acting cylinder, with cushion
SOLENOID DUAL
COMPONENT ENCLOSURE
manifold block SOLENOID PROPORTIONAL
ACTUATOR MANUAL LEVER

VALVE PILOT CHECK
(pilot to open)
Fig. 30 (3560-05)
07 Rev. 6/12
84
ORIFICE THROTTLE
VALVE SHUTTLE
fixed
ORIFICE THROTTLE
adjustable
VALVE
SINGLE COUNTERBALANCE
FLOW CONTROL in manifold
PRESSURE COMPENSATED
fixed
FLOW CONTROL
PRESSURE COMPENSATED
fixed with reverse flow bypass
FLOW DIVIDER/COMBINER
FUSE VELOCITY
BYPASS FLOW CONTROL
controlled flow, pressure
adjusted
VALVE RELIEF
VALVE MANUAL SHUTOFF
fixed
P TORQUE GENERATOR
VALVE RELIEF T
adjustable
STEER UNIT
T L hydrostatic
VALVE CHECK P R
Fig. 31 (3561-05)

07 Rev. 6/12
85
VALVE
VALVE
two-way valve with two positions
three-way valve with two positions
spring-bias, solenoid control
VALVE
three-way valve with two positions
VALVE
four-way valve with three positions
two spring centered, manual lever
VALVE control
four-way valve with two positions
VALVE
four-way valve with three positions
NOTE: The type of valve is the

number of spools found in the
component (the three spool
VALVE valve is above)
two-way valve with all positions
VALVE
four-way valve with all positions
Fig. 32 (3562-04)
07 Rev. 6/12
86
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Hydraulic System
Circuit Operation
Lift 1
Push the lift button to energize the lift pump motor (M2),
which operates the lift pump. The lift pump collects oil
through a filter in the lift pump and lift pump motor and
sends pressurized oil through an internal check valve
(CV) to the lift cylinders. When the lift cylinders are fully
extended, the lift limit switch (LMS) operates and turns •
M2 off. The relief valve (RV) puts a limit on the maxi-
14
mum pressure. Refer to Figure 33. 2
•
4 3
12
5
• 11
¡E
M2
6 10
8 13 9
Fig. 33 (25862-01)
1 Lift cylinders
2 Lowering solenoid valve SV
3 Return filter
4 Check valve CV
5 Lift pump motor M2
6 Lift pump
7 Reservoir
8 Suction filter
9 Return filter
10 Vent cap
11 Relief valve RV (145 or 165 bar)
12 Flow control
13 Suction
14 Pressure

01 Rev. 7/12
87
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Lower
Push the lower button to energize the solenoid valve
(SV), which moves the spool. This lets oil flow from the
lift cylinders, through the flow control and return filter,
and to the reservoir. Refer to Figure 34. 1
•
13
2
•
4 3
12
5
• 11
•
M2
6
10
8 9
Fig. 34 (25863-01)
1 Lift cylinders
2 Solenoid valve SV
3 Pressure filter
4 Check valve CV
5 Lift pump motor M2
6 Lift pump
7 Reservoir
8 Suction filter
9 Return filter
10 Vent cap
11 Relief valve RV(145 or 165 bar)
12 Flow control
13 Return
01 Rev. 7/12
88
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Reservoir Hydraulic Plumbing and Fittings

With the lift cylinders in the retracted position (and after
you bleed all air from the hydraulic system), the oil level
in the reservoir (1) must be approximately 20 mm be- WARNING
low the bottom of the vent cap (2). The capacity of the
reservoir is approximately 0.75 L. Refer to Figure 35. High pressure hydraulic system.
There is a risk of injury from high pressure hydraulic oil.
 Before you open a section of the hydraulic system,
release the pressure.
 Before you pressurize the hydraulic system, tighten
all hydraulic connections.
 Keep your hands and body away from pin holes
which eject high pressure hydraulic oils.
 Use a piece of paper or cardboard to do a leak
check. Do not use your hand or body.
 High pressure fluid that goes into the skin is a med-
ical emergency although the skin can look usual at
first.
 There is a delayed start of pain and severe tissue
damage can occur.
2
 Get medical aid from a specialist who has experi-
ence with this type of injury.
• Blow air through all hoses and tubes to remove

loose particles.
• Replace a tube or hose with wire-braid inner con-
struction that collapses or that has kinks. It is possi-
ble that you will not see the damage externally.
1 • Replace a flexible hose if it collapses in its usual
position for operation.
• Hoses and tubes must be away from surfaces or
edges that cause wear or cuts.
Fig. 35 (25864-01)
• Hoses and tubes must be away from surfaces or
Oil Change edges on which they can become caught.
The reservoir does not have an oil drain plug. You must • All connections must be free from leaks.
remove the used oil from the oil reservoir. Discard the
• Put the suction hoses in the correct position to keep
used oil in compliance with applicable laws for the re-
them at full volume flow. This prevents the collapse
moval of hazardous waste.
of the suction hoses.

01 Rev. 7/12
89
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Freezer Condition Lubrication Bleed the Hydraulic System

• It could be necessary for Crown trucks to use a mix- Bleed the hydraulic system
ture of low temperature hydraulic oil (063001-006)
Note: Air in the hydraulic system could cause oil to
with standard hydraulic oil (063001-021) in a
spill. Make sure that you catch the oil that spills.
freezer or cooler.
1. Raise and lower the forks (this operates the lift cyl-
Note: 100% low temperature oil is too thin for cold stor-
inders) many times.
age operations and could decrease the life of the lift
cylinder packings and lift pump in higher temperatures. 2. Wait for approximately ten minutes.
 This removes the air bubbles from the oil.
• For trucks that operate in temperatures at or more
than 0 °C, use 100% standard hydraulic oil 3. Do a check of the oil level after the air bubbles are
(063001-001). out of the oil.
• For trucks that operate in temperatures at or less Drift Test
than 0 °C, use a 50/50 mixture: 50% low tempera-
ture hydraulic oil (063001-006) and 50% standard Do a drift test of the lift cylinders
hydraulic oil (063001-021). Note: Do the drift test with a load of maximum capacity
load. Refer to the data plate for the truck capacity.
1. Fully raise the forks with a capacity load.
50 120 2. Turn the truck OFF.
40 100 3. Record the lift measurement from the tip of the fork
30 80 to the floor.
1
20 60 4. Wait five minutes.
10
40 5. Record the lift measurement from the tip of the fork
0
20 to the floor.
10
20 0 2  If there is a drift, correct it.
30 20  If the load did not drift down, the test was o.k.
40 40
Correct lift cylinder drift
C F
1. Make sure that there are no leaks in the hoses or
hydraulic connections.
Fig. 36 (25865-01)
2. Do a check for leaks at the check valve and sole-
1 100% standard hydraulic oil (063001-001)
noid valve.
2 50/50 Mixture of 50% low temperature hydraulic oil
(063001-006) and 50% Standard hydraulic oil (063001-021) 3. If there are leaks in the valves, raise and lower the
fork carriage two to three times to flush the contam-
ination out of the valve seats.
01 Rev. 7/12
90
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Hydraulic Pump
WARNING
Avoid high pressure fluids.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
 Relieve pressure before disconnecting hydraulic
lines.
 Tighten all connections before applying pressure.
 Keep hands and body away from pinholes which
eject fluids under high-pressure.
 Use a piece of cardboard or paper to search for
leaks. Do not use your hand.
Consider any fluid injected into the skin under high-
pressure as a serious medical emergency despite an
initial normal appearance of the skin. There is a de-
layed onset of pain, and serious tissue damage may
occur. Seek medical attention immediately by a spe-
cialist who has experience with this type of injury.
Hydraulic Pump Removal

1. Move the truck to a secure non-traffic maintenance
area with a level floor.
2. Lower the forks completely and turn the truck OFF.
3. Disconnect the battery. Lockout/Tagout the truck
as described in Lockout/Tagout in the Control of Figure 25810
Hazardous Energy section.

4. Chock the drive tire.
5. Remove the power unit covers.
Note: For steps 6 - 10, refer to Figure 25810.
6. Be prepared to catch hydraulic oil by placing a
catch pan, cardboard, etc. under the truck and on
the work surface if the hydraulic pump (1) and hy-
draulic pump motor (M2) (2) will be disassembled.
7. Disconnect the solenoid valve (SV) leads (3).
8. Disconnect the M2 power cables (4).
9. Disconnect the hydraulic pump output connection
(5).
10. Support the hydraulic pump (1) and M2 (2) and re-
move the assembly by removing the two mounting
screws (6) from the power unit.
Crown 2011 PF25411-1 WP3015/3020 Models M2.1-2730-001
91
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Filters the pressure port, ensure the check valve (CV) ball (2)
is not lost. Refer to Figure 25811.
Pressure Filter
The pressure filter (150 micron) (1) is integrated within
the hydraulic pump output connection. When removing
Figure 25811
Suction and Return Filters Hydraulic Pump Inspection

To access the suction (3) and return filters (450 micron) To access the hydraulic pump (10), remove the reser-
(4), the reservoir (5) must be removed from the pump voir (5) as described in Suction and Return Filters in
support (6) by removing the four flatwashers (7) and this section. The hydraulic pump is not a serviceable
screws (8) from the flange (9). The suction filter is at- part and can only be replaced as an assembly. Remove
tached to the hydraulic pump (10), while the return filter the hydraulic pump components (11) as necessary and
is attached to the flow restrictor (13). Refer to Figure ensure they are clean and lubricated with the hydraulic
25811. oil to be used prior to replacement. Assess their suita-
bility for reuse as well. Inspect the hydraulic pump body
to ensure there is no superficial damage which may ad-
versely affect performance or seating. Pay particular
attention to the port threads. Refer to Figure 25811.
Hydraulic Pump Replacement

1. Ensure the o-rings (12) are properly lubricated be-
fore seating them. Refer to Figure 25811.
M2.1-2730-002 WP3015/3020 Models Crown 2011 PF25411-2
92
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Note: Position the flange (9) over the elbow (14) on the After Hydraulic Pump Replacement
reservoir (5) before installing it.
• Use clean, filtered (10 micron minimum) oil to re-
2. Install the hydraulic pump (10), reservoir (5) and plenish the reservoir.
flange (9) to the pump support (6) using four flat-
• Start the hydraulic pump without a load on the forks
washers (7) and screws (8). Refer to Figure 25811.
and let it run for a few seconds without pressure to
3. Install the hydraulic pump (1, Fig. 25810) and M2 ensure sufficient lubrication.
(2) assembly to the power unit using the two • Never let the hydraulic pump run without oil.
mounting screws (6).
• If oil is still foaming after approximately 20 seconds,
4. Connect the hydraulic pump output connection (5). check the hydraulic system. Refer to Chart 1 - Hy-
draulic Pump Troubleshooting.
5. Connect the M2 power cables (4).
• When the hydraulic system has reached operating
6. Connect the SV leads (3). temperature, check to ensure the connections are
sealed.
Chart 1 - Hydraulic Pump Troubleshooting
Issue Probable Cause Remedy

• Low oil supply • Check the reservoir
• Oil is too heavy (i.e., viscous) • Check for proper oil viscosity
Noisy hydraulic pump
• Air leak on the inlet hose • Check the plumbing
• Partially blocked suction hose • Check for a foreign object and clean
• Hydraulic pump cavitation • Check the reservoir
• Water is in the oil • Check for proper oil viscosity
Foaming hydraulic oil
• Check the plumbing
• Clean and fill the reservoir
• Oil supply is too thin • Drain and fill with proper oil
• Oil is contaminated • Drain, clean and fill with clean oil
Hydraulic pump or oil over-
• Hydraulic pump cavitation • Check the reservoir and refer to the
heating
• System relief valve is bypassing remedy for foaming hydraulic oil
• Check the relief valve
• Hydraulic pump cavitation • Check the reservoir and refer to the
• Foaming hydraulic oil remedy for foaming hydraulic oil
• Relief valve is leaking or set too low • Check for proper oil viscosity
Low flow • Oil is too hot • Check the relief valve
• Check the temperature and refer to
the remedy for hydraulic pump or oil
overheating
• Defective relief valve • Check the relief valve
Failure to build pressure
• Low oil supply • Fill the reservoir
93
Notes:
94
DRIVE UNIT
95
Notes:
96
DRIVE UNIT
DRIVE UNIT
Drive Unit
WARNING
Injury can occur.
Injury can occur if you do not wear the applicable pro-
tective equipment when you do maintenance on lift
trucks.
 Wear eye protection.
 Wear work gloves.
 Wear steel-toed shoes.
1
WARNING
Injury or damage can occur.
Injury to you or damage to your truck can occur if the
lift and block devices are not sufficient for your truck.
 Do not do maintenance below or around a truck that
is not correctly blocked and safe.
2
 Read and follow all applicable safety procedures in
SAFETY > Control of Hazardous Energy.
Drive Unit Inspection

Refer to Figure 37.
• A torque wrench.
3
Do an inspection of the drive unit
• Examine the drive unit (1) for leaks.
• Examine the drive unit (1) for the correct level of oil.
• Examine the drive tire (2) for cuts, gouges, and
wear.
• Make sure that the torque of the drive tire bolts (3) Fig. 37 (25978-01)
is 122–135 Nm.

01 Rev. 7/12
97
DRIVE UNIT
DRIVE UNIT
Drive Unit Lubrication

Refer to Figure 38.
Special Tools and Equipment: 3
• A catch pan
• 80W90 gear oil (063002-028)
• DTE 24 hydraulic oil (063001-020 - freezer condi-
tion trucks only).
floor.
1
2. Fully lower the forks.
3. Turn the drive unit until you get access to the
check, drain, and fill plugs.
4
8. Remove the power unit cover, knuckle cover, and
center cover. 2
Change the drive unit oil
9. Put a catch pan below the drive unit (1).
Fig. 38 (25979-01)
10. Remove the drain plug (2) to drain the drive unit
(1). Prepare the truck for operation
11. Remove the fill plug (3). 19. Install the center cover, knuckle cover, and power
unit cover.
12. Examine the seals on the drain plug (2) and the fill
plug (3). If the seals are damaged, replace them. 20. Remove the wheel chocks.
13. After you drain the oil, install the drain plug (2). 21. Remove the lockout/tagout tag to operate the
truck.
14. To fill the drive unit (1), remove the check plug (4).
15. Examine the seal on the check plug (4). If the seal
is damaged, replace it. 23. Turn the truck ON and make sure that the truck op-
erates correctly.
16. Fill the drive unit (1) with 80W90 gear oil or DTE 24
hydraulic oil at the fill plug hole until oil starts to flow
from the check plug hole.
17. Install the fill plug (3) and the check plug (4).
18. Examine the drive unit (1) for leaks.
01 Rev. 7/12
98
DRIVE UNIT
DRIVE UNIT
Drive Tire Replacement

• A hydraulic press
• A lift device
• A torque wrench
• Hardwood blocks.
Drive Tire Removal

3
Prepare the truck
floor.
3. Turn the drive unit until you get access to the wheel 1
bolts.
of Hazardous Energy > Lifting and Blocking. 2
truck. Refer to SAFETY > Control of Hazardous Fig. 39 (25981-01)
Energy > Lockout/Tagout Procedures. 11. Put the new drive tire (1) on a flat and stable plate
8. Lift the power unit until the drive tire is off the floor. (2). Refer to Figure 39.
Put hardwood blocks below the power unit. Refer Note: The plate must not bend when you push the hub
to SAFETY > Control of Hazardous Energy > Lift- into the drive tire. If the plate bends, the hub tilts in the
ing and Blocking. drive tire.
Remove the drive tire from the truck 12. Align the hub (3) on the drive tire (1).
9. Remove the wheel bolts and the drive tire. Note: For steps 13–15, refer to Figure 39.
Remove the drive tire from the hub 13. Apply a thin layer of oil to the outer surface of the
hub (3).
10. Remove the drive tire from the hub.
14. Push the hub (1) slowly into the drive tire (2).
Note: Examine the hub for damage. Replace a dam-
aged hub. If the hub has paint on the seats of the wheel
bolts and truck axle, remove it.
WARNING
Truck accidents and injury can be caused by incor-
rect tire compound or tire dimension.
An incorrect tire type can have an unwanted effect on
how the truck can stop or steer. It can also have an
unwanted effect on the truck capacity.
 Use only a tire with the correct compound and di-
mension.

01 Rev. 7/12
99
DRIVE UNIT
DRIVE UNIT
1
3
Fig. 41 (25983)
Prepare the truck for operation
Fig. 40 (25982-01)
3. Remove the hardwood blocks from below the
power unit and lower the power unit until the drive
 The outer face (3, Fig. 41) of the hub must be flush tire is on the floor.
with the outer edge (4Fig. 41) of the drive tire. 4. Remove the wheel chocks.
Drive Tire Installation 5. Remove the lockout/tagout tag to operate the
Special Tools and Equipment: truck.
• A torque wrench. 6. Connect the battery.
7. Turn the truck ON and make sure that the drive tire
Install the drive tire operates correctly.
1. Install the drive tire on the truck and tighten the
wheel bolts by hand. Drive Unit Removal
• A lift device
CAUTION
• A strap
Torque that is too high can cause cracks in the • Hardwood blocks.
wheel studs.
If the torque value of the wheel bolts is too high, the Prepare the truck for maintenance
wheel studs could get cracks. 1. Move the truck to a maintenance area with a level
 Make sure that you torque the wheel bolts to the floor.
specifications that follow. 2. Fully lower the forks.
2. Torque the wheel bolts to 122–135 Nm. Refer to 4. Disconnect the battery.
the sequence in Figure 41. 5. Put the chocks against the wheels to prevent the
01 Rev. 7/12
100
DRIVE UNIT
DRIVE UNIT

8
7. Lift the power unit until the drive tire is off the floor. 4
Put hardwood blocks below the power unit. Refer
to SAFETY > Control of Hazardous Energy > Lift-
ing and Blocking. 5
center cover. 7
6
WARNING
A truck that falls can cause injury or death.
If the capacity of the lift device, strap, or hardwood
blocks cannot hold the truck, the truck could fall.
 Make sure that the lift device, strap, and hardwood
blocks can safely hold the weight (A WP 3000 truck
weighs as much as 2040 kg).
 Use equipment with sufficient capacity to connect
the strap safely.
9. Attach a strap to the drive unit and to a lift device.

Remove the drive unit
Refer to Figure 42.
10. Disconnect these components:
– The three power cables from the traction motor
(M1) (1).
3
– The parking brake (BRK) connector (2). 2
– The traction speed encoder (ECR) connector
(CA209) (3).
11. Remove the two screws (4) and damper sheet (5)
from the knuckle (6). 1
Note: It is not necessary to remove the steer tiller (7)
from the knuckle (6) during this procedure. 9
12. Remove the six screws (8) and knuckle (6) from
the power unit.
10
13. Lift the knuckle (6) and all applicable wires away 11
from the drive unit (9). Make sure that the knuckle
and all applicable wires are secure before you con-
tinue. Fig. 42 (27362)
14. Use the lift device to lower and remove the drive
unit (9) from the truck.
 When you lower the drive unit (9), the lower bear-
ing could loosen and fall out.

01 Rev. 7/12
101
DRIVE UNIT
DRIVE UNIT
Disassemble the Drive Unit Wheel shaft disassembly

1. Remove these components from the drive unit (1)
Refer to Figure 43.
in the sequence below:
M1 disassembly – The retaining ring (44)
1. Remove the four cap screws (17 and 31) and the – The two shims (42 and 43)
two flatwashers (18) to remove M1 (24) from the
– The 2nd reduction gear (41)
drive unit (1).
– The wheel shaft (29)
2. Remove the remaining components from M1 (24)
in the sequence below: – The retaining ring (40)
– The retaining ring (35) – The ball bearing (39)
– The 1st reduction pinion (34) – The oil seal (30)
– The bearing holder (28) – The roller bearing (36)
– The oil seal (32) – The retaining ring (37)
– The ball bearing (25) – The spacer (38).
– The spring washer (26)
– The O-ring (27)
– The two keys (23)
– The ring (33).
2nd reduction pinion disassembly
1. Remove the ten cap screws (15) to remove the
drive unit cover (19) and the impact cover (16) from
the drive unit (1).
2. Remove the remaining components from the drive
unit (1) in the sequence below:
– The retaining ring (11)
– The flatwasher (10)
– The 1st reduction gear (9)
– The retaining ring (8)
– The plug (4)
– The 2nd reduction pinion (6)
– The key (12)
– The two ball bearings (5 and 7).
01 Rev. 7/12
102
DRIVE UNIT
DRIVE UNIT
20
21
23
22
6
7 9
5
24
23 25 12
10
1
27 8
26 28
14
2 11
2
29
31 3
30
34
33
35
13
32
1
39
40 19
3 41
2
37
42 17
36
38 44
18
43
16
15
3
Fig. 43 (25980-01)
1 Torque to 122–135 Nm)
2 Torque to 10 Nm
3 Torque to 25 Nm

01 Rev. 7/12
103
DRIVE UNIT
DRIVE UNIT
Assemble the Drive Unit M1 installation

1. Install the two keys (23).
Refer to Figure 43.
2. Push the ball bearing (25) onto the M1 (24) shaft
while you hold the shaft end on the BRK (20) side.
• A lift device
3. Apply some thread-locking adhesive (061004-001)
• A strap to the ring (33).
• A torque wrench 4. Apply some multi-purpose lubricant (063002-026)
• 80W90 gear oil (063002-028) to the O-ring (27).
• DTE 24 hydraulic oil (063001-020 - freezer condi- 5. Install the O-ring (27) in the bearing holder (28).
tion trucks only) 6. Push the oil seal (32) into the bearing holder (28)
• Multi-purpose lubricant (063002-026) and install the spring washer (26).
• Thread-locking adhesive (061004-001) 7. Install the bearing holder (28) on the M1 (24) shaft.
• Thread-locking adhesive (061004-006) 8. Install the retaining ring (35).
• Thread-locking adhesive (061004-031). 9. Install M1 (24) in the drive unit (1) with two flat-
washers (18) and four cap screws (17 and 31).
Wheel shaft installation
Torque the cap screws to 10 Nm.
1. Install the oil seal (30) in the drive unit (1).
Drive unit cover installation
2. Push the roller bearing (36) into the drive unit (1)
and keep it in position with the retaining ring (37). 1. Clean the drive unit cover (19) and drive unit (1)
surfaces.
3. Carefully install the wheel shaft (29) on the oil seal
(30) side while you install the spacer (38). 2. Apply some thread-locking adhesive (061004-031)
to the drive unit cover (19) and drive unit (1) sur-
4. Push the ball bearing (39) into the drive unit (1) and
faces. Let the thread-locking adhesive dry for two
keep it in position with the retaining ring (40).
hours.
5. Apply some 80W90 gear oil (063002-028) or some
3. Apply some thread-locking adhesive (061004-006)
DTE 24 hydraulic oil (063001-020) for freezer con-
to the ten cap screws (15).
dition trucks to the 2nd reduction gear (41).
4. Install the drive unit cover (19) and the impact
6. Install the 2nd reduction gear (41) on the spline
cover (16) with the ten cap screws (15). Torque the
end of the wheel shaft (29).
cap screws to 25 Nm.
7. Keep the 2nd reduction gear (41) in position with
the two shims (42 and 43) and the retaining ring Drive unit installation
(44). Refer to Figure 44.
2nd reduction pinion installation 1. Attach a strap to the drive unit (9) and to a lift de-
vice.
1. Push the ball bearing (5) into the drive unit (1).
2. Use the lift device to lift and install the drive unit (9)
2. Push the ball bearing (7) into the drive unit (1) and
keep it in position with the retaining ring (8). onto the power unit.
3. Install the 2nd reduction pinion (6) while you hold  Use the lift device to keep the drive unit (9) secure
the ball bearing (7). until you install the knuckle (6).
4. Apply some 80W90 gear oil (063002-028) or some  The drive tire (10) must align with the X10® handle
DTE 24 hydraulic oil (063001-020) for freezer con- and the drive unit cover (11) must point to the right
dition trucks to the 1st reduction gear (9). side.
5. Install the key (12) in the 2nd reduction pinion (6) 3. Route the applicable wires for the knuckle (6) as
shaft and push the 1st reduction gear (9) on. they were before the removal of the drive unit.
6. Keep the flatwasher (10) in position with the retain- 4. Install the knuckle (6) onto the power unit with the
ing ring (11). six screws (8).
7. Apply some thread-locking adhesive (061004-031)  This will secure the drive unit (9) to the power unit.
to the plug (4). 5. Install the damper sheet (5) onto the knuckle (6)
8. Install the plug (4) on the 2nd reduction pinion (6) with the two screws (4).
shaft. 6. Connect these components:
01 Rev. 7/12
104
DRIVE UNIT
DRIVE UNIT
– The three power cables to M1 (1). Prepare the truck for operation
– The BRK connector (2). 8. Install the center cover, knuckle cover, and power
– The ECR connector (CA209) (3). unit cover.
7. Remove the strap from the drive unit (9) and the lift 9. Remove the hardwood blocks from below the
device. power unit and lower the power unit until the drive
tire is on the floor.
10. Remove the wheel chocks.
8 11. Remove the lockout/tagout tag to operate the
4 truck.
5 13. Turn the truck ON and make sure that the truck op-
erates correctly.
7
6
2 3
10
11
Fig. 44 (27362)

01 Rev. 7/12
105
Notes:
106
ELECTRICAL SYSTEM
107
Notes:
108
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
Electrical System Wiring Color Codes

Wire colors are generally limited to the colors shown in
Wiring Color Codes & Schematic the chart below. The function of the circuit determines
Symbols the wire color. A three or four digit number is assigned
to each wire. The first one or two digits identify the color
The following is an explanation of wiring color codes of the lead. The last two digits number the lead from
and symbols which are standard on Crown wiring dia- one through ninety-nine. Exceptions to this may be
grams. component leads supplied by vendors. A wiring picto-
rial identifies each wire by number. Refer to the DIA
section for wiring pictorials and diagrams.
Wiring Color Codes Chart
Number Color Function
0xx Black Digital Signal (1)

1xx Brown Analog Signal (1)
2xx Red Primary positive that has not gone through a switch (2)
3xx Orange 12 V Non-Battery Positive (3)
4xx Yellow Non-Battery Positive (3)
5xx Green Primary negative that has not gone through a switch (2)
6xx Blue Isolated Negative (4)
7xx Violet 5 V Non-Battery Positive (3)
8xx Gray Non-Battery Positive (3)
9xx White Miscellaneous
29xx Red/White Primary positive that has gone through a switch (2)
59xx Green Primary negative that has gone through a switch (2)
(1) Signal - A conductor that provides an intentional fluctuating or variable potential.
(2) Primary- A conductor which provides battery positive potential or battery negative potential.
(3) Non-Battery Positive - A conductor which provides a non-battery positive potential from the output of a regu-
lated DC-to-DC converter.
(4) Isolated Negative - A conductor that provides a negative potential that is electrically isolated from battery
negative.
109
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
Power Cables
Except WP trucks, power cables are designated using
one of the following abbreviations, followed by a dash
number. Fig. 47 (8117-01)
or
An example of such a cable is PC # 1/0 - 10. The part
number for this cable is 084572-010.
Power Cables Abbreviations Chart

Fig. 48 (8118-01)
Abbreviation Part Numbers Number of Terminals
PC#1 084571 • All terminals are shown even if not wired.
PC#2 084570 Momentary or Maintained Contact
PC#4 084569 • Momentary contact is a shaded triangle.
PC#6 084568
PC#8 124474
PC#10 090963 Fig. 49 (8119-01)
or
PC#1/0 084572
PC#2/0 084573
PC#3/0 086749
Fig. 50 (8120-01)
PC#4/0 137636 • Maintained is an open circle (an open circle also de-
notes the common terminal).
Switches
Switch symbols convey:
14. Type of switch.
Fig. 51 (8115-01)
15. Number of terminals. or
16. Momentary or maintained contact.
17. How the switch is held and wired.
18. How the switch is activated. Fig. 52 (8117-01)
19. Application.
Type of Switch
• With common
Fig. 45 (8115-01)
or
Fig. 46 (8116-01)
• Without common
110
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
How the Switch is Held and Wired switches include the markings present on the actual
To determine how the switch is held and wired, look switch.
closely at the contact symbols. An open circle denotes Example:
a maintained contact so therefore it is the normally
closed terminal. A shaded triangle denotes a momen-
tary contact, therefore it is the normally open terminal.
Switches having more than one maintained contact do
not have a normally open or normally closed terminal, Fig. 53 (8121-01)
although they may have a common. Symbols for these
Examples (All Momentary)
With Common (Transfer) Without Common (Double Break)

Wired normally
open, held open
Figure 8119-01 Figure 8120-01
Wired normally
open, held closed Figure 8122
Figure 8123
Wired normally
closed, held open
Figure 8115-01 Figure 8117-01
Wired normally
closed, held closed Figure 8124 Figure 8125
How the Switch is Activated

If it is necessary 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
An abbreviation, called a component designator, con-
veys the switch application. For example, FS = For-
ward Switch. Refer to the Componentry section for
more information on the applicable component desig-
nators for your truck.
Notes:
• In a schematic, the condition of a circuit is defined
using a note (example: vehicle shown fully lowered
with no operator on vehicle).
• Positive action switches are marked with the follow-
ing symbol:
Fig. 54 (8126-02)
111
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
Fig. 55 (8100-01)
112
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
113
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
Specialty Switches
Pressure Switch
Fig. 56 (8127)
Reed Switch
Fig. 57 (8128)
Temperature Switch
Fig. 58 (8129)
Brake Fluid Switch
Fig. 59 (8130)
Three Position Key Switch
Start
Off
Fig. 60 (8131-01)
114
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
Fig. 61 (8132-02)
115
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,
Amplifier/Com-
DC
parator
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
Fig. 62 (8133-02)
116
ELECTRICAL SYSTEM
MENUS
Menus startup screens do not reach the Main Menu screen,

your handset software is incompatible.Contact your lo-
cal Crown dealer.
Curtis Handset
This handset (Crown part number 130475) allows the
user to input calibration settings, monitor inputs and
outputs and is a diagnostic aid for troubleshooting.
Handset Operation
Before using the handset (1), turn the truck OFF, con-
nect the connector (2) into JC202 (3), then turn the
truck ON to power it up. Refer to Figure 63.
Fig. 64 (25633)
The handset includes the following features:
• Display Screen (1) - An LCD screen capable of dis-
playing up to seven lines of text and graphics simul-
taneously.
• Menu Navigation Key (2) - The up or down arrows
scroll through menu choices, the right arrow enters
a submenu and the left arrow exits a submenu.
• Data Increase/Decrease Key (3) - The plus or mi-
nus signs increase or decrease the values indi-
cated by the cursor, or turn a setting ON or OFF.
• Bookmark Keys (4) - Allow the user to quickly go
Fig. 63 (25632)
back to favorite selections without having to navi-
Once the truck is turned ON, the handset displays the gate through the menus.
handset model number (1) and software version (2) be- Refer to Figure 65.
fore preparing the data for display (3). Following these,
the handset displays the Main Menu (4), which is the
starting point for all basic programmer functions and
the first time user input is required. Refer to Figure 64.
Note: If your handset startup screens do not resemble
the ones shown in Figure 25633, or if your handset

01 Rev. 2/12
117
ELECTRICAL SYSTEM
MENUS
From this submenu, use the right arrow to enter an-

other submenu (1). This submenu contains the current
value (2), which is changed by using the plus or minus
signs. Other submenus contain minimum and maxi-
mum values (3), the current value (4), and a bar graph
(5) indicator and also use the plus or minus signs to
change the values. Refer to Figure 67.
Fig. 67 (25636)
Use the left arrow to exit the submenus and return to
the Main Menu. Any changes you make are automati-
cally saved when you exit the submenus.
To bookmark a position in the menu, press and hold a
bookmark key for three seconds until the Bookmark
Fig. 65 (25634) Set screen is displayed. After the bookmark is set, use
The blinking square (1) on the display screen indicates the appropriate bookmark key to jump to the wanted
the location of the cursor. From the Main Menu, use the bookmark position. The bookmarks are not perma-
up or down arrows to scroll through the six Main Menu nently stored and are cleared when the handset is dis-
choices (Program, Monitor, Faults, Functions, Control- connected.
ler Information and Programmer Setup). Use the right
arrow to enter a submenu (2), which is indented to the
right and displayed in a second column. Refer to
Figure 66.
Fig. 66 (25635)
01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
Main Menu Functions Menu

There are six Main Menu choices. The Main Menu is The Functions Menu contains a submenu that allows
the starting point and all basic functions are accessed the copying of data between ACCESS 3 modules, writ-
from here. ing data, resetting data, etc.
Program Menu Controller Information Menu

The Program Menu contains several submenus, some The Controller Information Menu contains several non-
with adjustable values. The truck is adjusted to specific adjustable submenus that provide a quick overview of
operating conditions using the values in this menu. ACCESS 3 settings.
Monitor Menu Programmer Setup Menu

The Monitor Menu contains a list of all the variables The Programmer Setup Menu contains handset setup
that can be read and displayed. All of the submenus in submenus and information.
the Monitor Menu are adjustable.
Menu Key
Faults Menu The shaded areas on the menu navigation key and
The Faults Menu contains the present status and ac- data increase/decrease key show what to press on the
cess to fault history. handset to navigate through the menus and submenus
and change the values. Refer to Figure 68.
Fig. 68 (26710)
Menu Layout
The Menu Layout shows an overview of the menu
structure. The ± symbol next to the values indicates
that the values can be increased, decreased, turned
ON, or turned OFF using the data increase/decrease
key on the handset. Refer to Figures 69 and 70.

01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
Fig. 69 (26708)
01 Rev. 2/12
120
ELECTRICAL SYSTEM
MENUS
Fig. 70 (26709)

01 Rev. 2/12
121
ELECTRICAL SYSTEM
MENUS
)
Program Menu
Default value is 77%
Default value is 1.5 Seconds
Default value is 3 Seconds

continued on page -008 continued on page -007 continued on
page -007
Fig. 71 (26711)
01 Rev. 2/12
122
ELECTRICAL SYSTEM
MENUS
continued from
page -006 continued from page -006
Fig. 72 (26712)

01 Rev. 2/12
123
ELECTRICAL SYSTEM
MENUS
continued from page -006
Default value is OFF
Default value is ON
Default value is 2.09 Volt
Default value is 2.04 Volt
Default value is 1.90 V for Maintenance Free Bat-

continued on teries For Dry and Wet Cell Batteries, adjust to
page -009 1.73 V.
Fig. 73 (26713)
01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
Default value is 4500 RPM
Default value is 4500 RPM
Default value is 22
Default value is 100
Default value is 150
Fig. 74 (26714)

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ELECTRICAL SYSTEM
MENUS
Monitor Menu
continued on page -011 continued on page -011
Fig. 75 (26715)
01 Rev. 2/12
126
ELECTRICAL SYSTEM
MENUS
continued from
continued on page -012 continued on page -012
Fig. 76 (26716)

01 Rev. 2/12
127
ELECTRICAL SYSTEM
MENUS
continued from
continued on page -013

Fig. 77 (26717)
01 Rev. 2/12
128
ELECTRICAL SYSTEM
MENUS
continued from
Fig. 78 (26718)

01 Rev. 2/12
129
ELECTRICAL SYSTEM
MENUS
continued from
page -013
continued from page -015 continued on page -015
Fig. 79 (26719)
01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
continued from
continued from page -014 page -014
Fig. 80 (26720)

01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
Fig. 81 (26721)
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132
ELECTRICAL SYSTEM
MENUS
Faults and Functions Menus
1 If faults are present, use the top and bottom arrows to scroll through them
and the right arrow to view them on a different screen
2 Displays the fault name (i.e., SRO Fault, Tiller Comm Loss, and so on)
Fig. 82 (26722)

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ELECTRICAL SYSTEM
MENUS
Controller Information Menu
Fig. 83 (26723)
01 Rev. 2/12
134
ELECTRICAL SYSTEM
MENUS
Fig. 84 (26724)

01 Rev. 2/12
135
ELECTRICAL SYSTEM
MENUS
Fig. 85 (26725)
01 Rev. 2/12
136
ELECTRICAL SYSTEM
MENUS
Fig. 86 (26726)

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ELECTRICAL SYSTEM
MENUS
Program Menu • Decel Rate - Adjusts the rabbit mode deceleration

rate (time it takes for the truck to decelerate from
SRO Enable - Turns static return to off messages ON top speed to a complete stop). Range is 0.1 sec-
or OFF. These messages alert the operator that an im- onds for the shortest deceleration time to
proper operator sequence was performed. 30.0 seconds for the longest deceleration time. The
Traction Performance - Adjusts speed, acceleration, default value is 3 seconds.
deceleration and brake rate settings. • Brake Rate - Adjusts the rabbit mode braking rate.
Slow Speed (Turtle) Range is 0.1 seconds for the shortest braking time
• PUF Max Speed - Adjusts the turtle mode maxi- to 30.0 seconds for the longest braking time. The
mum speed in the power unit first direction. Range default value is 0.8 seconds.
is 0 to 90%. The default value is 77%. Brake Override
• FF Max Speed - Adjusts the turtle mode maximum • Max Speed - Adjusts the brake override maximum
speed in the forks first direction. Range is 0 to 90%. speed. Range is 12 to 50%. The default value is
The default value is 77%. 20%.
• Accel Rate - Adjusts the turtle mode acceleration • Accel Rate - Adjusts the brake override accelera-
rate (time it takes for the truck to accelerate to top tion rate (time it takes for the truck to accelerate to
speed from a complete stop). Range is 0.1 seconds top speed from a complete stop). Range is 0.1 sec-
for the shortest acceleration time to 30.0 seconds onds for the shortest acceleration time to 30.0 sec-
for the longest acceleration time. The default value onds for the longest acceleration time. The default
is 1.5 seconds. value is 3.5 seconds.
• Decel Rate - Adjusts the turtle mode deceleration • Decel Rate - Adjusts the brake override decelera-
rate (time it takes for the truck to decelerate from tion rate (time it takes for the truck to decelerate
top speed to a complete stop). Range is 0.1 sec- from top speed to a complete stop). Range is
onds for the shortest deceleration time to 30.0 sec- 0.1 seconds for the shortest deceleration time to
onds for the longest deceleration time. The default 30.0 seconds for the longest deceleration time. The
value is 3 seconds. default value is 2.5 seconds.
• Brake Rate - Adjusts the turtle mode braking rate. • Brake Rate - Adjusts the brake override braking
Range is 0.1 seconds for the shortest braking time rate. Range is 0.1 seconds for the shortest braking
to 30.0 seconds for the longest braking time. The time to 30.0 seconds for the longest braking time.
default value is 0.8 seconds. The default value is 2 seconds.
High Speed (Rabbit) Travel Alarm
• PUF Max Speed - Adjusts the rabbit mode maxi- • Forward Travel Alarm Enable - Turns ALM ON or
mum speed in the power unit first direction. Range OFF while traveling in the forward direction. The de-
is 0 to 100%. The default value is 94%. fault value is OFF.
• FF Max Speed - Adjusts the rabbit mode maximum • Reverse Travel Alarm Enable - Turns ALM ON or
speed in the forks first direction. Range is 0 to OFF while traveling in the reverse direction. The de-
100%. The default value is 94%. fault value is OFF.
• Accel Rate - Adjusts the rabbit mode acceleration Hydraulic Functions
rate (time it takes for the truck to accelerate to top • Lift Lockout Enable - Turns lift lockout ON or OFF.
speed from a complete stop). Range is 0.1 seconds The default value is ON.
for the shortest acceleration time to 30.0 seconds
for the longest acceleration time. The default value • Lift Lockout BDI - Adjusts the percentage of bat-
tery charge at which lift lockout is activated. Range
is 1.2 seconds.
is 0 to 30%. The default value is 20%.
01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
Battery • Capture Distance 2 - Records the time it takes M1

to go from 0 revolutions per minute to a second pro-
grammed capture distance. This result is stored
CAUTION and can be viewed in the Monitor Menu submenu
Allowing the battery to go deeper into discharge will Time to Dist 2. Range is 1 to 1320. The default
permanently damage the battery and possibly the value is 100.
truck’s electrical components. • Capture Distance 3 - Records the time it takes M1
to go from 0 revolutions per minute to a third pro-
grammed capture distance. This result is stored
Note: Reset Volts Per Cell should always be set higher
and can be viewed in the Monitor Menu submenu
than Full Volts Per Cell.
Time to Dist 3. Range is 1 to 1320. The default
• Reset Volts Per Cell - Adjusts the reset voltage value is 150.
level and is checked only once (when the truck is
turned ON). This determines at what voltage the Monitor Menu
battery is reset to 100% state of charge. Range is
1.5 to 3.0 volt. The default value is 2.09 volt. Tiller Throttle
• Full Volts Per Cell - Adjusts the full voltage level. • Raw Tiller Throttle - Displays the raw tiller throttle
This determines at what voltage the battery is at counts when POT is applied. Range is 0 (the throt-
100% state of charge. When a battery is under load tle is in the neutral position) to 255 (the throttle is in
and drops below this voltage, it begins to lose the full forward position).
charge. Range is 1.5 to 3.0 volt. The default value • Mapped Tiller Throttle - Displays the percentage
is 2.04 volt. of raw tiller throttle counts when POT is applied.
Note: Empty Volts Per Cell setting of 1.90 volt is used Range is -100 (forks first direction) to 100% (power
for sealed batteries. 1.73 volt is used for wet cell batter- unit first direction), 100% being equal to 255 counts.
ies. Check the truck's battery type before adjusting this Switch Inputs
submenu. Note: All switches are normally OFF and stay ON
• Empty Volts Per Cell - Adjusts the empty voltage when they are activated.
level. This determines at what voltage the battery is • BRS-Brake Switch - Displays if BRS is actuating
at 0% state of charge. Range is 1.5 to 3.0 volt. The when applied. Indicated by ON or OFF.
default value is 1.90 volt.
• ORS-Brake Override Switch - Displays if ORS is
Vehicle actuating when applied. Indicated by ON or OFF.
• Metric Units - Turns metric units ON or OFF. The • SAS-Emergency Reverse CAN - Displays if SAS
default value is OFF. When OFF, SAE units are dis- is actuating when applied. Indicated by ON or OFF.
played.
• SAS-Emergency Reverse Redundant - Displays
• Capture Speed 1 - Records the time it takes the if SAS is actuating when applied. Indicated by ON
traction motor (M1) to go from 0 revolutions per or OFF.
minute to the programmed capture speed. This re-
• HSS-Rabbit Switch - Displays if HSS is actuating
sult is stored and can be viewed in the Monitor
when applied. Indicated by ON or OFF.
Menu submenu Time to Speed 1. Range is 0 to
8000 RPM. The default value is 4500 RPM. • HN-Horn Switch - Displays if HN is actuating when
applied. Indicated by ON or OFF.
• Capture Speed 2 - Records the time it takes M1 to
go from 0 revolutions per minute to a second pro- • RS-Reverse Switch - Displays if RS is actuating
grammed capture speed. This result is stored and when applied. Indicated by ON or OFF.
can be viewed in the Monitor Menu submenu Time • FS-Forward Switch - Displays if FS is actuating
to Speed 2. Range is 0 to 8000 RPM. The default when applied. Indicated by ON or OFF.
value is 4500 RPM. • RAS-Lift Switch - Displays if RAS is actuating
• Capture Distance 1 - Records the time it takes M1 when applied. Indicated by ON or OFF.
to go from 0 revolutions per minute to the pro- • Lower Switch - Displays if LOS is actuating when
grammed capture distance. This result is stored applied. Indicated by ON or OFF.
and can be viewed in the Monitor Menu submenu
• LMS-Lift Limit Switch - Displays if LMS is actuat-
Time to Dist 1. Range is 1 to 1320. The default
ing when applied. Indicated by ON or OFF.
value is 22.

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ELECTRICAL SYSTEM
MENUS
Driver Outputs 105.0 V. The voltage for a normally functioning

• L-Main Contactor PWM - Displays if the main con- truck is 24.6 V.
tactor is energizing. Range is 0 (fully OFF) to 100% Motor
(fully ON). • Motor RPM - Displays M1's revolutions per minute.
• BRK-EM Brake PWM - Displays if BRK is energiz- Range is -12000 to 12000 RPM.
ing. Range is 0 (fully OFF) to 100% (fully ON). • Temperature - Displays M1's temperature in de-
• P-Pump Contactor PWM - Displays if the pump grees Celsius. Range is -100 to 300 °C.
contactor is energizing. Range is 0 (fully OFF) to • MotorSpeed A - Displays the revolutions per min-
100% (fully ON). ute of channel A in ECR. Range is -12000 to 12000
• HN-Horn Driver PWM - Displays if HN is energiz- RPM.
ing. Range is 0 (fully OFF) to 100% (fully ON). • MotorSpeed B - Displays the revolutions per min-
• SVL-Lower Valve PWM - Displays if SVL is ener- ute of channel B in ECR. Range is -12000 to
gizing. Range is 0 (fully OFF) to 100% (fully ON). 12000 RPM.
• ALM-Travel Alarm Driver - Displays if ALM is en- Controller
ergizing. Indicated by ON or OFF. • Current (RMS) - Displays ACCESS 3's mean
Hour Meters (RMS = root mean square) current (all three
• H1 Traction Hours - Displays the total accumu- phases). Range is 0.0 to 1000.0 A.
lated M1 hours. Range is 0.0 to 119304.6 hours. • Modulation Depth - Displays the percentage of
• H2 Pump Hours - Displays the total accumulated available voltage being used. Range is 0.0 to
lift pump motor (M2) hours. Range is 0.0 to 100.0%.
119304.6 hours. • Frequency - Displays ACCESS 3's electrical fre-
Outputs quency. Range is -300.0 to 300.0 Hz.
• 5 Volts - Displays the voltage at the 5 V output • Temperature - Displays ACCESS 3's internal tem-
(CA201-26 on ACCESS 3). Range is 0.00 to 12 perature in degrees Celsius. Range is -100 to
volt. The expected voltage for a normally function- 300 °C.
ing truck is 4.88 V. • Main State - Displays the main contactor state.
• 12 Volts - Displays the voltage at the 12 V output Range is 0-10; 0 = open, 1 = precharge, 2 = weld
(CA201-25 on ACCESS 3). Range is 0.00 to 6.25 check, 3 = closing delay, 4 = missing check, 5 =
volt. The expected voltage for a normally function- closed, 6 = delay, 7 = arc check, 8 = open delay, 9
ing truck is 12.04 V. = fault and 10 = closed.
• Ext Supply Current - Displays the combined cur- • Regen - Displays if regenerative braking is ON or
rent of the external 5 V (CA201-26 on ACCESS 3) OFF.
and 12 V (CA201-25 on ACCESS 3) supplies. • VCL Error Module - Displays additional informa-
Range is 0 to 200 mA. The expected current for a tion about the cause of a vehicle control language
normally functioning truck is 52 mA.. runtime error. Refer to Event Code 368 in the Event
• Pot Low - This output is not applicable to the Codes section for more information.
WP 3000. • VCL Error - Displays vehicle control language error
Battery module and error variables. Compare these values
to Event Code 368 and event codes listed in
• BDI - Displays the battery percent of remaining
ACCESS 3's OS SysInfo file to help pinpoint the ve-
charge. Range is 0 to 100%.
hicle control language error that caused the specific
• Capacitor Voltage - Displays the capacitor voltage event code.
of ACCESS 3's internal capacitor bank at the B+
• Cutbacks
terminal. Range is 0.0 to 105.0 V. When the capac-
itor is idle, the voltage is 1.4 V. When you pull the – Motor Temp Cutback - Displays the current
handle down and the capacitor is charged, the volt- available as a result of the M1 temperature cut-
age is 24.8 V. back function. Range is 0 to 100%, 100% indicat-
ing no cutback in the current.
• Keyswitch Voltage - Displays the key switch volt-
age when the truck is turned ON. Range is 0.0 to – Controller Temp Cutback - Displays the current
available as a result of the ACCESS 3 tempera-
01 Rev. 2/12
140
ELECTRICAL SYSTEM
MENUS
ture cutback function. Range is 0 to 100%, 100% • Distance Fine - Displays the truck's net measured
indicating no cutback in the current. distance in the forward and reverse directions. For
– Undervoltage Cutback - Displays the current example, if the truck travels 200 cm in the forward
available as a result of the under voltage cutback direction, then 200 cm in the reverse direction, the
function. Range is 0 to 100%, 100% indicating no net measured distance is 0. The distance will stop
cutback in the current. and restart when the value exceeds the range limit.
Range is 0.0 to 4000000.0.
– Overvoltage Cutback - Displays the current
available as a result of the over voltage cutback
function. Range is 0 to 100%, 100% indicating no
Faults Menu
cutback in the current. System Faults - Displays the current system faults. If
Vehicle no faults exist, “Currently no faults” is displayed.
• Vehicle Speed - Displays the truck's speed. Range Fault History - Displays the truck's fault history. If no
is -3276.8 to 3276.7. fault history exists, "History is empty" is displayed.
• Vehicle Acceleration - Displays the truck's accel- Clear Fault History - Clears the truck's fault history.
eration, which is measured in g's (units of gravita-
tional acceleration). Range is 0.000 to 10.000 g's.
Functions Menu
• Time to Speed 1 - Displays the time it takes M1 to Settings
go from 0 revolutions per minute to the pro- • Get Settings From Controller - Copies the exist-
grammed capture speed. Range is 0.00 to 128.00 ing settings from ACCESS 3.
seconds. • Write Settings to Controller - Copies the existing
• Time to Speed 2 - Displays the time it takes M1 to settings to ACCESS 3.
go from 0 revolutions per minute to a second pro- • Reset All Settings - Resets the existing settings to
grammed capture speed. Range is 0.00 to 128.00 their original values.
seconds.
• Time Between Speeds - Displays the time it takes Controller Information Menu
M1 to go from programmed capture speed 1 to pro- Model Number - Displays the truck's model number.
grammed capture speed 2. Range is 0.00 to 128.00
seconds. Protocol Version - Displays ACCESS 3's protocol ver-
sion.
• Time to Dist 1 - Displays the time it takes M1 to go
from 0 revolutions per minute to the programmed Model Number - Displays ACCESS 3's model num-
capture distance. Range is 0.00 to 128.00 seconds. ber. For example, if the model number on ACCESS 3
is 1232-0001, the model number displayed is
• Time to Dist 2 - Displays the time it takes M1 to go 12320001.
from 0 revolutions per minute to a second pro-
grammed capture distance. Range is 0.00 to Serial Number - Displays ACCESS 3's serial number.
128.00 seconds. For example, if the serial number on ACCESS 3 is
10022C.1078, the serial number displayed is 1078.
• Time to Dist 3 - Displays the time it takes M1 to go This value is sequential.
from 0 revolutions per minute to a third pro-
grammed capture distance. Range is 0.00 to Mfg Date Code - Displays ACCESS 3's manufacturing
128.00 seconds. date. The first two digits indicate the year, while the last
three digits indicate the day. For example, if the serial
• Braking Distance Captured - Displays the truck's number on ACCESS 3 is 10022C.1078, the manufac-
measured braking distance. The measurement turing date displayed is 10022 (22nd day of 2010).
starts when BRK is applied and ends when M1's
revolutions per minute = 0. Range is 0.0 to Hardware Version - Displays ACCESS 3's hardware
1000000.0. version. This value distinguishes the group of elec-
tronic assemblies used in ACCESS 3.
• Distance Since Stop - Displays the truck's dis-
tance traveled when starting from a stop. For exam- OS Version - Displays ACCESS 3's operating system
ple, if the truck travels 200 m in the forward software version. Use the right arrow to enter the sub-
direction, then 200 m in the reverse direction, the menu and view the value.
distance traveled is 400 m. The distance will stop Build Number - Displays ACCESS 3's operating sys-
and restart when M1's revolutions per minute = 0. tem software build number.
Range is 0.0 to 1000000.0.

01 Rev. 2/12
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ELECTRICAL SYSTEM
MENUS
SM Version - Displays ACCESS 3's start manager

software version.
Param Blk Version - Displays ACCESS 3's parameter
block version.
VCL App Version - Displays ACCESS 3's vehicle con-
trol language application software version.
Programmer Setup Menu

Program
• LCD Contrast - Displays the LCD screen's contrast
level for viewing. Range is -150 to 150, 150 being
the brightest level.
• Language - Displays the handset's language.
• Set Security Code - Sets a security code that must
be entered before operating the truck.
Information
• OEM Info - Displays original equipment manufac-
turer information.
• Model Number - Displays the handset's model
number.
• Serial Number - Displays the handset's serial num-
ber.
Manufacturing Date - Displays the handset's manu-
facturing date. The first two digits indicate the year,
while the last three digits indicate the day. For example,
if the manufacturing date displayed is 05338, the hand-
set was manufactured in 2005 on the 338th day.
• Software Version - Displays the handset's soft-
ware version.
• Hardware Version - Displays the handset's hard-
ware version. This value distinguishes the group of
electronic assemblies used in the handset.
• MC-Protocol Ver. - Displays the handset's MC pro-
tocol version.
• ES-Protocol Ver. - Displays the handset's ES pro-
tocol version.
• S-Protocol Ver. - Displays the handset's S protocol
version.
• Device Type - Displays the handset's device type.
01 Rev. 2/12
142
ELECTRICAL SYSTEM
CONTACTOR
Contactor adjustments are tampered with or otherwise changed,

the checks contained in the following information may
be made.
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.
Fig. 87 (10554-01) • Resistance reading of the coil should be between
The purpose of this information is to instruct the techni- 15 - 19 Ω.
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
Risk of unintended truck movement.
Inspection, adjustments, servicing, parts replacement
or any other act requiring physical contact with the
electrical working components or wiring of these con-
tactors can cause unintended truck movement if the
battery is not disconnected or the drive wheels are not
clear of the floor.
 Disconnect the battery,
 Raise the 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

04 Rev. 7/07
143
ELECTRICAL SYSTEM
CONTACTOR
Component Replacement Coil Replacement

Refer to Figure 88 and parts breakdown in Parts Man- 1. Disconnect all electrical wiring.
ual 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.
Fig. 88 (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.
04 Rev. 7/07
144
ELECTRICAL SYSTEM
X10® HANDLE (ACCESS 8)
X10® Handle (ACCESS 8)
1
3
Fig. 89 (25847-01)
1 Steer tiller
2 Upper shell
3 Switch cap
4 Lower shell
5 Hand grips
X10 Handle Component Removal

and Installation
• Torx® screwdrivers (different sizes: T6, T10, T25,
and T40)
• A small, flat screwdriver.

01 Rev. 7/12
145
ELECTRICAL SYSTEM
Remove the lower and upper shell

CAUTION 7. Remove the four Torx® screws (1). Refer to
Figure 90.
If you operate a truck for which repair is necessary or
that is not in a safe condition, it can cause injury or ma-
terial damage.
If repair is necessary on the truck, or the truck is not in
a safe condition:
 Do not operate the truck until it is safe.
 Immediately make a report of the condition to the
applicable authority.
 Do not make repairs or adjustments to the truck un-
less you are approved to do them.
CAUTION
If you do not correctly prepare the truck for mainte-
nance, it can cause injury or material damage.
 Complete all lockout/tagout procedures. Refer to
SAFETY > Control of Hazardous Energy. 1
 Obey all safety instructions. Refer to SAFETY.
Fig. 90 (25848-01)
8. Push on the arrows (1) or carefully pull on the
thumbwheels (2) to move the switch cap (3) up and
out of the lower shell (4). Refer to Figure 91.
CAUTION
9. Disconnect these harnesses from the switch cap
Injury or material damage can occur. (3) and refer to Figure 91:
If you cause damage to the wires during installation, it • The steer tiller harness from CA410 on the primary
can cause injury or material damage. printed circuit board (5).
• The horn harness from CA413 on the primary
Lower and Upper Shell Removal and printed circuit board (5).
• The CAN analog harness from CA414 on the R/T
Installation printed circuit board (6), CA415 on the hydraulic
Prepare the truck for maintenance printed circuit board (7), and CA418 on the primary
printed circuit board (5).
floor.
01 Rev. 7/12
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ELECTRICAL SYSTEM
1
2
3
3
1
5 2
6
Fig. 92 (25850-01)
Fig. 91 (25849-01)
10. Use a small, flat screwdriver (1) to remove the
ends (2) from each hand grip (3). Refer to
Figure 92.

01 Rev. 7/12
147
ELECTRICAL SYSTEM
Note: The horn switches (HNS1 and HNS2) for the left
and right hand grips are different. If you install HNS1 or
HNS2 on the incorrect side, the horn symbol direction
3
is incorrect.
11. Push the horn buttons (1) and pull HNS1 and
HNS2 (2) out of the hand grips (3). Refer to
Figure 93. 2
12. Disconnect the horn harness from CA417 and
CA419 on HNS1 and HNS2 (2). Refer to Figure 93.
1
2 3
1
CA417
Fig. 94 (25852-01)
14. Remove these components to remove the lower
3 shell (1) and upper shell (2) from the steer tiller (3)
and refer to Figure 95:
– The eight Torx® screws (4)
– The washers (5)
– The U-nut retainers (6).
CA419
2
1
Fig. 93 (25851-01)
13. Remove the two Torx® screws (1) and pull the
hand grips (2) from the lower and upper shell (3).
Refer to Figure 94.
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ELECTRICAL SYSTEM
Switch Cap Removal and Installa-

tion
The switch cap contains these components:
• Forward and reverse switches (FS and RS)
• High speed switch (HSS)
2
• Hydraulic printed circuit board
• Primary printed circuit board
• Traction accelerator potentiometer (POT)
• Raise and lower switches (RAS and LOS)
• Safety reverse switch (SAS).
4 Note: You must disassemble the switch cap to replace
4 these components.
Remove the switch cap
1. Follow steps 7–9 in the Lower and Upper Shell Re-
moval and Installation section to remove the switch
cap.
6 Install the switch cap
3
2. To install the switch cap, do the opposite of the re-
moval procedures.
4
5 6
4
Fig. 95 (25853-01)
Install the lower and upper shell
15. To install the lower and upper shells, do the oppo-
site of the removal procedures.

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ELECTRICAL SYSTEM
HSS Removal and Installation

Note: There are no parts in HSS that you can repair.
You must replace HSS. 1
Remove HSS
2
moval and Installation section to remove the switch
cap.
2. Remove the two Torx® screws (1) and HSS (2)
from the switch cap (3). Refer to Figure 96.
1
Fig. 97 (25855-01)
Fig. 96 (25854-01) Install the hydraulic printed circuit board
Install HSS 3. To install the hydraulic printed circuit board, do the
3. To install HSS, do the opposite of the removal pro- opposite of the removal procedures.
cedures.
Primary Printed Circuit Board Re-
Hydraulic Printed Circuit Board Re- moval and Installation
moval and Installation Note: There are no parts on the primary printed circuit
Note: There are no parts on the hydraulic printed cir- board that you can repair. You must replace the primary
cuit board that you can repair. You must replace the printed circuit board.
hydraulic printed circuit board. Remove the primary printed circuit board
Remove the hydraulic printed circuit board 1. Follow steps 7–9 in the Lower and Upper Shell Re-
1. Follow steps 7–9 in the Lower and Upper Shell Re- moval and Installation section to remove the switch
moval and Installation section to remove the switch cap.
cap. Note: For steps 2–4, refer to Figure 98.
2. Remove the two Torx® screws (1) from the hy- 2. Disconnect the POT, FS, and RS connector
draulic printed circuit board (2) (the primary printed (CA411) from the primary printed circuit board (1).
circuit board [3] is larger) and remove the hydraulic 3. Disconnect the SAS connector (CA412) from the
printed circuit board. Refer to Figure 97. primary printed circuit board (1).
01 Rev. 7/12
150
ELECTRICAL SYSTEM
4. Remove the two Torx® screws (2) from the primary

printed circuit board (1) (the hydraulic printed cir-
cuit board [3] is smaller) and remove the primary
1
printed circuit board.
1 6
3
2
5
Fig. 98 (25856-01) 1
Install the primary printed circuit board
5. To install the primary printed circuit board, do the Fig. 99 (25857-01)
opposite of the removal procedures. 4. Remove the four Torx® screws (1) and the switch
cap (2) from the switch cap cover (3). Refer to
POT, FS, and RS Removal and Instal- Figure 100.
lation
Note: There are no parts in POT, FS, or RS that you
can repair. You must replace POT, FS, or RS. 1
Remove POT, FS, and RS

moval and Installation section to remove the switch 1
cap.
2. Remove the two Torx® screws (1) from the thumb-
wheels (2) and pull them from the axle (3). Make 3
sure that you keep the bushings (4). Refer to
Figure 99.
3. Remove the two Torx® screws (5) from the lower
cap (6) and remove the lower cap. Refer to 2
Figure 99.
Fig. 100 (25858-01)

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ELECTRICAL SYSTEM
Note: For steps 5–7, refer to Figure 101. SAS Removal and Installation
5. Disconnect the POT, FS, and RS connector
(CA411) from the primary printed circuit board (1). Remove SAS
6. Remove the two Torx® screws (2) from POT, FS, 1. Follow steps 7–9 in the Lower and Upper Shell Re-
and RS (3). moval and Installation section to remove the switch
cap.
7. Remove POT, FS, and RS (3) and the bushings (4)
from the axle (5). 2. Follow steps 2–4 in the POT, FS, and RS Removal
and Installation section to remove these compo-
nents:
• The thumb wheels
• The lower cap
• The switch cap cover.
Note: For steps 3–5, refer to Figure 102.
3. Remove the Torx® screw (1) and remove the but-
ton bridge (2).
4. Remove the button (3).
5. Remove the two Torx® screws (4) and remove
5 SAS (5).
2
4 2
3
4
1
3
5
2
1
Fig. 101 (25859-01)

Install POT, FS, and RS
Fig. 102 (25860-01)
8. To install POT, FS, and RS, do the opposite of the
removal procedures. Install POT, FS, and RS
6. To install SAS, do the opposite of the removal pro-
cedures.
01 Rev. 7/12
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ELECTRICAL SYSTEM
HNS1 and HNS2 Removal and Instal-

lation
Remove HNS1 and HNS2
1. Follow steps 7–12 in the Lower and Upper Shell
Removal and Installation section to remove these
components:
– The switch cap
– HNS1
– HNS2.
Install HNS1 and HNS2
2. To install HNS1 and HNS2, do the opposite of the
removal procedures.
Hand Grip Removal and Installation

Remove the hand grips
1. Follow steps 7–13 in the Lower and Upper Shell
Removal and Installation section to remove these
components:
• The switch cap
• HNS1
• HNS2
• The hand grips.
Install the hand grips
2. To install the hand grips, do the opposite of the re-
moval procedures.
truck.
6. Turn the truck ON and do a test of all the X10®
handle functions.

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ELECTRICAL SYSTEM
BATTERY INFORMATION
Battery Information
The condition of the battery has a considerable impact
on the performance of the truck. Optimum mainte-
nance is key to maintaining the performance and useful
life of the battery.
Charging the battery
CAUTION
The battery must be serviced and charged strictly
in accordance with the battery and charger manu-
facturers' instructions
Unsuitable chargers and incorrect maintenance will re-
sult in reduced truck performance in the short term. In
the medium term it will lead to premature battery fail-
ure.
Replacing the battery
WARNING
Incorrect battery sizes and weights can result in
fatal accidents
An incorrect battery weight and size will affect the
truck’s centre of gravity which can result in accidents.
 Only use batteries with the right dimensions, weight
and capacity requirements for this truck.
1. Replace the battery as outlined in the truck opera-

tor manual.
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ELECTRICAL SYSTEM
ON BOARD BATTERY CHARGER
On Board Battery Charger To set the battery tpye at the On

Board Battery Charger
CAUTION To prepare the truck for maintenance
Damage to the battery can occur. 1. Move the truck to a maintenance area with a level
Charging a battery with the wrong charger setting will floor.
damage the battery. 2. Fully lower the forks.
 When you replace the charger, set the battery type 3. Turn the truck OFF.
on the new charger. 4. Disconnect the battery.
 If you change the type of battery used for the truck, 5. Put the chocks against the wheels to prevent the
set this new battery type on the charger. movement of the truck. Refer to SAFETY > Control
1 7. Remove the power unit cover, knuckle cover, and
center cover.
3
To set the battery type
1. Make sure that the battery charger is not con-
nected to the wall outlet.
2. Remove the seal plug (3) to get access to the se-
lector switch.
3. If you use maintenance free batteries on this truck,
turn the selector switch either to position 0, 1 or 3.
4. If you use wet or dry cell batteries on this truck, turn
the selector switch to position 2.
To Prepare the truck for operation
5. Install the center cover, knuckle cover, and power
unit cover.
truck.
9. Turn the truck ON and make sure that the truck op-
erates correctly.
Fig. 103 (25971-01)

01 Rev. 7/12
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ELECTRICAL SYSTEM
BATTERY PACK REMOVAL AND INSTALLATION
Battery Pack Removal and In-

stallation
• A lift device.
CAUTION
Do not let an object made of metal touch the top of
the battery cells.
This could cause a short circuit when you remove or
move the battery.
 Use an insulator (such as plywood) as a cover on
the top of the battery before and during removal and
installation.

floor.
Remove or install a battery pack
7. Remove the knob (1) and cover assembly (2). Re-
fer to Figures 104 and 105.
8. Remove the battery cables (3) (remove the nega-
tive connections [4] first). Refer to Figures 104 and
105.
Remove or install a battery pack on trucks with
swing-out battery trays
1. Move the top battery tray (5) out to the direction of
the forks.
2. Install the top battery (6) or remove the top battery
from the top battery tray (5).
3. Lower the bottom battery (7) to install it or lift the
bottom battery to remove it from the bottom battery
tray (8). Refer to Figure 104.
01 Rev. 7/12
156
ELECTRICAL SYSTEM
4
_
3
3
4
_
4
_ 6
7
5
Fig. 104 (25974-01)
Remove or install a battery pack on trucks with

standard battery trays:
1. Use a lift device to lift the battery tray (5) into, or up
and out of, the battery compartment (6).
2. On wet or dry cell batteries (7), install or remove
the battery spacers (8) when you install or remove
the batteries.
Note: The battery spacers (8) are for wet or dry cell
batteries (7) because they are smaller than mainte-
nance free batteries. Refer to Figure 105.

01 Rev. 7/12
157
ELECTRICAL SYSTEM
4
_ 4
7
3
7
_
5
Fig. 105 (25975-01)

truck.
erates correctly.
01 Rev. 7/12
158
ELECTRICAL SYSTEM
BATTERY LOAD TEST
Battery Load Test

• A digital volt-ohm multimeter (DVOM).
Although the battery charges fully, and the battery acid
and specific gravity levels are good, you must repair or
replace a battery at some point. The best procedure to
see if you must repair or replace a battery is to do a
battery load test.
To do a battery load test
1. Connect a fully charged battery to the truck.
2. Connect a DVOM across the positive and negative
terminals of the battery.
3. Turn the truck ON.
4. Fully raise the forks. Momentarily raise the forks
again.
5. Read the voltage on the DVOM.
 The battery must not decrease more than 0.5 V a
cell.
Note: A 24 V battery has 12 cells. If the voltage drops
more than 6 V, you must repair or replace the battery.
Note: You can only do a test of the voltage of each cell
on an industrial battery.
6. If the battery is in the permitted voltage range, do a
test of the voltage of each cell.
 Make sure that each cell is equal.
 The voltage must not decrease more than 0.5 V a
cell.
Note: All cells must read almost the same voltage
when you do a cell load test. If the cell voltage is lower
than the others, there could be a problem with the cell.

01 Rev. 7/12
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ELECTRICAL SYSTEM
DISPLAY GAUGE
Display Gauge There are indicators on the display gauge to help the
operator:
The display gauge (TT) can receive and show CAN
messages (battery, hour meter, and event code data)
from ACCESS 3. The display gauge is not serviceable.
1
5
6
2
Fig. 107 (25950-01)

• Battery Discharge Indicator (1) - Shows the level of
battery charge.
• Battery Icon (2) - Monitors the level of battery
charge and flashes with the warning LED when the
level of battery charge is low.
• Hourglass Icon (3) - Monitors the hour meter total
and flashes when the hour meter total increases.
• Number Display (4) - Shows the hour meter totals
and the event codes.
• Warning LED (5) - Flashes with the battery icon
when the level of battery charge is low and with the
wrench icon during an event code.
• Wrench Icon (6) - Flashes with the warning LED
during an event code.
Fig. 106 (25949)
The back of the display gauge has a 4-pin connector.
Refer to the Display Gauge Chart and Figure 106 for
connector data.
Display Gauge Chart
Pin Number Function Description

1 B- BNEG
2 B+ +BV (max. 50 mA)
3 CAN HI CAN HI
4 CAN LO CAN LO
Operator Indicators
Refer to Figure 107.
01 Rev. 7/12
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ELECTRICAL SYSTEM
DISPLAY GAUGE
Display Messages
Display Messages Chart
Display Messages Description

Refer to ELECTRICAL SYSTEM > Event Codes > Event Code 322 or Event Code
OVER HEATa)
328.
LO VOLTS Refer to ELECTRICAL SYSTEM > Event Codes > Event Code 323.
OVER VOLTS Refer to ELECTRICAL SYSTEM > Event Codes > Event Code 324.
This display message shows a specified event code number. Refer to
CODE ___
ELECTRICAL SYSTEM > Event Codes.
This display message shows the traction hours available when the X10® handle is
H1
in the vertical position during truck travel.
This display message shows the hydraulic hours available when the X10® handle is
H2
in the vertical position when you raise the forks.
LO BDI This display message shows if there is a low battery charge level.
This display message shows if there is a static return to off. Refer to ELECTRICAL
SRO
SYSTEM > Event Codes.
a). To find out if the OVER HEAT display message is for Event Code 322 or Event Code 328:
• Use the handset to go into the FAULTS menu.
• From there, go to the FAULTS HISTORY menu to see Event Code 322 (ACCESS 3) or Event Code 328 (traction motor [M1]).
Troubleshooting
Troubleshooting Chart
Symptom Possible Cause

There is no display. The 4-pin connector is not connected.
The voltage quantity is incorrect.
The battery discharge indicator stays full. The display gauge voltage does not agree with the battery volt-
age.
B+ is connected to the incorrect pin.
The battery discharge indicator does not reset. The display gauge voltage does not agree with the battery volt-
age.
The battery charge level is not full.
The battery is defective.
The battery discharge indicator resets and the There is a bad CAN connection.
battery does not charge.

01 Rev. 7/12
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ELECTRICAL SYSTEM
HYDRAULIC PUMP MOTOR (M2)
Hydraulic Pump Motor (M2) 2. Remove the two screws (1) from the pump support
(2) and tilt the hydraulic unit to get access to the top
The hydraulic pump motor (M2) drives the hydraulic of M2.
pump. The pump supplies hydraulic oil flow to raise the
3. Remove the end head and insulating cap (3).
forks.
To replace the brushes
Brush Replacement 4. Replace all brushes (1, Fig. 109) at the same time.
To lockout/tagout the truck Note: When you replace the brushes, also replace the
springs (2). Refer to Figure 109.
floor. Note: The minimum brush length is 10 mm (0.40 in).
2. Fully lower the forks. 5. Blow the contamination from M2.
3. Turn the truck OFF. 6. Turn the armature (3) and examine for defects or
other damage. Refer to Figure 109.
Note: A carbon layer on the brush surface is OK.
6. Complete the lockout/tagout procedures for the 1 2
To prepare the truck for the brush replacement
center cover.
1 3
2 2
3
Fig. 109 (25962-01)
7. Look for damaged springs and replace them as
necessary.
To prepare the truck for operation
8. Install the end head and insulating cap (3). Refer to
Figure 108.
9. Install the lift pump and M2 assembly with the two
screws (1). Refer to Figure 108.
unit cover.
truck.
Fig. 108 (25961-01) 13. Connect the battery.
02 Rev. 7/12
162
ELECTRICAL SYSTEM
HYDRAULIC PUMP MOTOR (M2)
erates correctly.

02 Rev. 7/12
163
ELECTRICAL SYSTEM
EVENT CODE INTRODUCTION
Event Code Introduction Note: If a 300 or 800 series event code occurs, it will
also show on the display gauge.
CAUTION No Event Code

If the truck malfunctions and no event code shows, the
If you connect the control connectors when the
malfunction is usually not electrical. If you turn the truck
truck is ON, the truck could be damaged.
ON, but an event code does not show, the malfunction
The truck electrical system could be damaged.
is usually mechanical or hydraulic, but not electrical.
 Do not turn the truck ON with the control connectors The mechanical and hydraulic data is in the applicable
disconnected. section in this manual.
 Do not remove or connect the control connectors
while the truck is ON. Component Locations
The component and wire location maps are on the
CAUTION truck to help you quickly find the location of the compo-
nents. All components are clearly identified at the con-
When you replace a control module or do an up- nection points. Refer to the COMPONENTRY section
date to the module software, make sure that the for more data on each component.
software is correct.
The truck will not operate correctly. Power Cable Connections
 Use the handset to go into the CONTROLLER IN-
FORMATION and PROGRAMMER SETUP menus
to make sure that the software is correct. WARNING
Risk of burns by stored electrical energy.
Troubleshooting Steps The capacitors in the control modules store electrical
energy. You can be injured if you accidentally dis-
Most malfunctions occur in or at output devices (con-
charge the capacitors in a control module.
tactors, and motors). The next components to examine
are connectors, wires, and input devices (switches, po-  Discharge the capacitors before you do truck main-
tentiometers, and encoders). The last components to tenance around the bus bars and related power ca-
examine are the control modules. bles. Refer to the SAFETY > Control of Hazardous
Energy > Capacitance section for procedures to
Do a test of the output devices, input devices, and discharge the capacitors.
control modules
2. When you measure the voltage and resistance of
these components, use a digital volt-ohm multime-
ter (DVOM).
3. Make sure that you connect all components after
you complete the troubleshooting steps.
Malfunctions
When a malfunction occurs
2. Connect the handset connector to JC202.
4. Use the handset to go into the FAULTS menu to
show the current event codes.
Note: You can look at current event codes or the event
code history in the FAULTS menu.
M4.8-ITD-100 WP3015/3020 Models Crown 2012 PF25751-1
164
ELECTRICAL SYSTEM
EVENT CODES
Event Codes
Static Return to Off (SRO) Messages
During truck operation, messages may occur which are
intended to provide visual assistance to the operator of
the truck. Once the reason for the message is cor-
rected the message will be removed. Following is a list
of these messages as viewed on the display gauge
with a description of message intent.
Messages After Power Up and During Operation
Display Description
SrO Appears if ACCESS 8 (X10® Handle) is
pulled and then the truck is turned ON.
165
ELECTRICAL SYSTEM
EVENT CODE 300 SERIES
Event Code 300 Series • M1 is not operational.

• The line contactor is open.
Event Code 312 • BRK is not releasing.
• POT is not operational.
ACCESS 3 Over Current
• M2 is not operational.
Phase current U, V, W exceeds limits.
Follow the troubleshooting steps for Event Code 312.
Note: Possible effects of this event code are:
• BRK is not releasing.
Step 1: Disconnect the U, V and W cables from
ACCESS 3 and the traction motor (M1). Check M1 and
the cabling for phase to phase and phase to truck
frame shorts.
Fig. 111 (25905)
• If the U, V or W cables are shorted together or to the
truck frame. Event Code 314
– Then repair or replace as necessary.
Precharge Issue
• If the U, V or W cables are not shorted.
ACCESS 3 capacitors are not charging to the key
– Then check M1 for shorts. switch (KYS) voltage.
• If M1 is shorted. Note: Possible effects of this event code are:
– Then replace M1. • M1 is not operational.
• If M1 and the cabling are OK and the event code • The line contactor is open.
continues.
– Then replace ACCESS 3.
Event Code 313 • M2 is not operational.
Note: Pre-charge volts can be read using the handset.
Energize the line contactor (L) and scroll down to the
Monitor menu. From there, scroll to the Battery menu
and then to the Capacitor Voltage menu.
Step 1: Check if truck accessories are connected to
the +BV terminal and drawing excessive current.
• If the truck accessories are connected and drawing
excessive current.
– Then disconnect the truck accessories or correct
the issue.
Fig. 110 (25905)
Step 2: Check if the line contactor energizes.
ACCESS 3 Internal Current Sensor Issue • If the line contactor does not energize.
ACCESS 3 current sensor has an invalid offset read- – Then check for a short at the line contactor coil.
ing.
• If the line contactor energizes and the event code
Note: Possible effects of this event code are: continues.
166
ELECTRICAL SYSTEM
Event Code 315 – Then allow the truck to cool.

• If the ambient temperature is less than 95 °C and
ACCESS 3 Severe Under Temperature the event code continues.
ACCESS 3 heatsink temperature is less than -40 °C. – Then replace ACCESS 3.
• M1 is not operational. Event Code 317
• The line contactor is open. Severe Under Voltage
• BRK is not releasing. ACCESS 3 capacitors' voltage is less than 12.8 V.
• POT is not operational. Note: A possible effect of this event code is reduced
• M2 is not operational. drive torque.
Step 1: Using the handset, scroll down to the Monitor Step 1: Check battery voltage with the battery discon-
menu. From there, scroll to the Controller menu and nected.
then to the Temperature menu. Check the heatsink • If battery voltage is low.
temperature.
– Then charge or replace the battery.
Step 2: Determine the ambient temperature of the en-
• If battery voltage is OK.
vironment.
– Then proceed to Step 2.
• If the ambient temperature is less than -40 °C and
the truck has sat idle. Step 2: Check for wiring for +BV or BNEG is shorted to
the truck frame.
– Then warm ACCESS 3 heatsink to allow opera-
tion. • If +BV or BNEG is shorted.
• If the ambient temperature is more than -40 °C and – Then repair or replace as necessary.
the event code continues. • If +BV and BNEG are OK.
– Then replace ACCESS 3. – Then proceed to Step 3.
Step 3: Check for a bad battery under a load.
Event Code 316 • If the battery is bad.
ACCESS 3 Severe Over Temperature – Then replace the battery.
ACCESS 3 heatsink temperature is more than 95 °C. • If the battery is OK.
Note: Possible effects of this event code are: – Then replace ACCESS 3.
Event Code 318
• BRK is not releasing. Severe Over Voltage
• POT is not operational. Note: ACCESS 3 capacitors' voltage is more than
• M2 is not operational. 40 V.
Step 1: Using the handset, scroll down to the Monitor Note: Possible effects of this event code are:
menu. From there, scroll to the Controller menu and • M1 is not operational.
then to the Temperature menu. Check the heatsink • The line contactor is open.
temperature.
Step 2: Check the load weight.
• If the load weight exceeds the rated capacity of the
truck.
Step 1: Check battery voltage with the battery discon-
– Then reduce the load weight.
nected.
• If the load weight is OK.
• If battery voltage is high.
– Then charge or replace the battery.
Step 3: Determine the ambient temperature of the en-
• If battery voltage is OK.
vironment.
• If the ambient temperature is more than 95 °C.
167
ELECTRICAL SYSTEM
Step 2: Connect the battery, turn the truck ON and, us- Step 4: Check ACCESS 3 mounting to make sure it's
ing the handset, scroll down to the Monitor menu. From tight enough to allow heatsink heat transfer.
there, scroll to the Battery menu and then to the Capac- • If ACCESS 3 mounting is bad.
itor Voltage menu. Check the voltage on the handset
while performing a regen brake.
• If ACCESS 3 mounting is OK.
• If the voltage is more than 40 V.
– Then check the battery resistance; regen needs
a path to the battery. Check the power circuit, in- Step 5: Using the handset, scroll down to the Monitor
cluding the traction power fuse (FU1), which al- menu. From there, scroll to the Controller menu and
lows regen a path to the battery. then to the Current (RMS) menu. Check the current
while driving an empty truck.
• If an issue exists in the power circuit.
• If the current is more than 100 A.
– Then check the drive unit for bad bearings, bad
• If no issue in the power circuit exists.
gears, etc.
• If the bearings, gears, etc. are OK.
Event Code 322 – Then proceed to Step 5.
Step 6: Check the wiring from CA209-1 to CA209-2 for
Under Voltage Cutback 5 V.
ACCESS 3 heatsink temperature is more than 85 °C. • If 5 V exists.
Note: Possible effects of this event code are reduced – Then replace ECR.
brake and drive torque.
• If the current displayed in the Current (RMS) menu
Step 1: Determine the maximum operating tempera- is less than 100 A and ECR is OK.
ture of ACCESS 3 heatsink.
• If the maximum operating temperature is more than
85 °C.
– Then allow the truck to cool.
• If the maximum operating temperature is less than
85 °C.
truck.
Fig. 112 (25906)
Step 3: Using the handset, scroll down to the Monitor
menu. From there, scroll to the Motor menu and then to Event Code 323
the MotorSpeed A and MotorSpeed B menus. Check
the inputs while driving an empty truck. Under Voltage Cutback
• If no inputs exist. ACCESS 3 capacitors' voltage is less than 16.8 V.
– Then check the wiring from the traction speed en- Note: A possible effect of this event code is reduced
coder (ECR) (CA209-1, CA209-2, CA209-3 and drive torque.
CA209-4) to ACCESS 3 (CA201-7, CA201-26, Follow the troubleshooting steps for Event Code 317.
CA201-31 and CA201-32).
• If the wiring is bad. Event Code 324
– Then repair or replace as necessary. Over Voltage Cutback
• If the wiring is OK. ACCESS 3 capacitors' voltage is more than 30 V.
168
ELECTRICAL SYSTEM
Note: A possible effect of this event code is reduced Event Code 327
brake torque.
Follow the troubleshooting steps for Event Code 318. Digital Output Over Current
The travel alarm (ALM) output current exceeds 15 mA.
Event Code 325 Note: A possible effect of this event code is a disabled
ALM driver output.
5 V Supply Out of Range
Step 1: Check the wiring from ACCESS 3 (CA201-20)
Note: A possible effect of this event code is limited op-
to the line contactor for shorts.
eration.
• If the wiring is shorted.
menu. From there, scroll to the Outputs menu and then – Then repair or replace as necessary.
to the 5 Volts menu. Check for 5 V. • If the wiring is OK.
• If 5 V exists and the event code continues. – Then proceed to Step 2.
– Then replace ACCESS 3. Step 2: Check ALM for shorts.
• If less than 5 V exists. • If ALM is shorted.
– Then proceed to Step 2. – Then repair or replace as necessary.
Step 2: Disconnect CA209. Using the handset, scroll • If ALM is OK.
down to the Monitor menu. From there, scroll to the – Then replace ACCESS 3.
Outputs menu and then to the 5 Volts menu. Check for
5 V.
• If 5 V exists.
– Then replace ECR.
• If less than 5 V exists.
Step 3: Disconnect the wiring from ACCESS 3
(CA201-26). Using the handset, scroll down to the
Monitor menu. From there, scroll to the Outputs menu
and then to the 5 Volts menu. Check for 5 V.
• If 5 V exists.
Fig. 114 (25907)
– Then repair or replace the wiring from ACCESS 3
(CA201-26). Event Code 328
• If less than 5 V exists. Motor Temperature Hot Cutback
– Then replace ACCESS 3. M1 temperature is more than 145 °C.
Note: A possible effect of this event code is reduced
drive torque.
truck.
menu. From there, scroll to the Motor menu and then to
the Temperature menu. Check the temperature.
Fig. 113 (25906) • If the temperature is more than 145 °C.
– Then allow the truck to cool.
• If the temperature is less than 145 °C.
169
ELECTRICAL SYSTEM
– Then proceed to Step 3. – Then replace ACCESS 3.

Step 3: Check M1 for proper operation.
• If M1 is bad (i.e., conditions such as vibration or a
high pitch sound exist).
• If M1 is OK.
Step 4: Check ECR for proper operation (see Event
Code 336).
• If ECR is bad.
• If ECR is OK and the event code continues.
– Then replace ACCESS 3. Fig. 115 (25908)
Event Code 329 Event Code 331

Line Coil Driver Open or Short
Motor Temperature Sensor (TS) Out of Range
The line contactor driver is open or short.
TS in M1 is at voltage rail (0 V or 12 V) due to an open
or a short. Note: Possible effects of this event code are:
Note: Possible effects of this event code are limited op- • M1 is not operational.
eration and maximum speed. • The line contactor is open.
Step 1: Using the handset, scroll down to the Monitor • BRK is not releasing.
menu. From there, scroll to the Motor menu and then to • POT is not operational.
the Temperature menu. Check the temperature.
• If the temperature is 200 °C or 0 °C.
Step 1: Check if this event code occurs with Event
– Then check TS for opens or shorts. Repair or re- Codes 332, 333, 335 or 361.
place as necessary.
• If more than one event codes occur.
• If the temperature is not 200 °C or 0 °C.
– Then check the wiring from ACCESS 3
– Then proceed to Step 2. (CA201-13) to the line contactor for opens or
Step 2: Check the wiring from TS (CA208-1 and shorts. Repair or replace as necessary.
CA208-2) to ACCESS 3 (CA201-7 and CA201-8) and • If only this event code occurs.
M1.
• If the wiring is bad.
Step 2: Check the wiring from ACCESS 3 (CA201-6) to
– Then repair or replace as necessary. the line contactor and the line contactor for opens or
• If the wiring is OK. shorts.
– Then proceed to Step 3. • If the wiring or line contactor is open or shorted.
Step 3: Disconnect CA208 and place a resistor across – Then repair or replace as necessary.
CA208-1 (wire 101) and CA208-2 (wire 503) (approxi- • If the wiring and line contactor are OK and the event
mately 500 Ω). Then, using the handset, scroll down to code continues.
the Monitor menu. From there, scroll to the Motor menu
and then to the Temperature menu. Check the temper-
ature.
• If the temperature reading in the handset reads
200 °C when open and changes depending on re-
sistance.
– Then ACCESS 3 is reading correctly.
• If the temperature reading does not change and if
all wiring is OK.
170
ELECTRICAL SYSTEM
Event Code 333

Pump Coil Driver Open or Short
Fig. 116 (25907) Codes 331, 332, 335, 361 or 362.
Event Code 332 • If more than one event codes occur.
Brake Coil Driver Open or Short (CA201-13) to the line contactor and the wiring
The park brake (BRK) driver is open or short. from the line contactor to the pump contactor (P)
Note: Possible effects of this event code are: for opens or shorts. Repair or replace as neces-
sary.
• If only this event code occurs.
the pump contactor and the pump contactor for opens
• M2 is not operational. or shorts.
Step 1: Check if this event code occurs with Event • If the wiring or pump contactor is open or shorted.
Codes 331, 333, 335 or 361.
• If the wiring and pump contactor are OK and the
– Then check the wiring from ACCESS 3 event code continues.
(CA201-13) to the line contactor and the wiring
from the line contactor to BRK for opens or
shorts. Repair or replace as necessary.
BRK and BRK for opens or shorts.
• If the wiring or BRK is open or shorted.
• If the wiring and BRK are OK and the event code
Fig. 118 (25910)
continues.
Fig. 117 (25909)
171
ELECTRICAL SYSTEM
Event Code 335 • M1 is not operational.

Solenoid Valve (SV) Coil Open or Short
• BRK is not releasing. Codes 325, 369 or 373.
• POT is not operational. • If more than one event codes occur.
• M2 is not operational. – Then solve those event codes before proceed-
Step 1: Check if this event code occurs with Event ing.
Codes 332, 333, 361 or 362. Step 2: Using the handset, scroll down to the Monitor
• If more than one event codes occur. menu. From there, scroll to the Motor menu and then to
– Then check the wiring from ACCESS 3 the MotorSpeed A and MotorSpeed B menus. Check
(CA201-13) to the line contactor and the wiring the inputs.
from the line contactor to SV for opens or shorts. • If channel A input is missing.
Repair or replace as necessary. – Then check the wiring between ACCESS 3
• If only this event code occurs. (CA201-31) and ECR (CA209-4) for opens or
– Then proceed to Step 2. shorts. Repair or replace as necessary.
Step 2: Check the wiring from ACCESS 3 (CA201-2) to • If channel B input is missing.
SV and SV for opens or shorts. – Then check the wiring between ACCESS 3
• If the wiring or SV is open or shorted. (CA201-32) and ECR (CA209-3) for opens or
• If the wiring is OK.
• If the wiring and SV are OK and the event code con-
tinues. – Then replace ECR.
– Then replace ACCESS 3. • If the wiring and ECR are OK and the event code
continues.
Fig. 119 (25912)
Event Code 336

Motor Encoder Issue
Fig. 120 (25906)
ECR counts are inconsistent.
172
ELECTRICAL SYSTEM

Motor Open Main Contactor Welded
M1 U, V or W cables are open. The line contactor is not opening.
Note: Possible effects of this event code are: Note: Possible effects of this event code are:
• M1 is not operational. • M1 is not operational.
• The line contactor is open. • BRK is not releasing.
• BRK is not releasing. • POT is not operational.
• POT is not operational. • M2 is not operational.
• M2 is not operational. • The line contactor is shorted.
Step 1: Check for continuity on the U, V and W cables • The discharge path (M1 load) is open.
between ACCESS 3 and M1. Step 1: Check the line contactor tips for welds.
• If the U, V or W cables are open. • If the line contactor tips are welded.
– Then repair or replace as necessary. – Then replace the tips or line contactor.
• If the U, V and W cables are OK. • If the line contactor tips are OK.
– Then proceed to Step 2. – Then proceed to Step 2.
Step 2: Check for continuity between the U-V, V-W and Step 2: Check the U, V and W cables for opens or a
W-U terminals. bad connection.
• If the U-V, V-W or W-U terminals are open. • If the U, V or W cables are open or a bad connection
– Then replace M1. exists.
• If the U-V, V-W or W-U terminals are OK and the – Then repair or replace as necessary.
event code continues. • If the U, V and W cables and connection are OK.
– Then replace ACCESS 3. – Then proceed to Step 3.
Step 3: Check for an alternate voltage path providing
current to the +BV terminal.
• If an alternate voltage path exists.
– Then disconnect the alternate voltage path.
• If no alternate voltage path exists and the event
code continues.
Fig. 121 (25905)
Fig. 122 (25913)
173
ELECTRICAL SYSTEM

Main Contactor Did Not Close Raise Timeout
The line contactor is not closing; ACCESS 3 capacitors Raise is requested beyond the allowable time.
are not charging. Note: A possible effect of this event code is a non-op-
Note: Possible effects of this event code are: erational pump contactor.
• M1 is not operational. Step 1: Release the raise switch (RAS).
• BRK is not releasing. Step 2: Using the handset, scroll down to the Monitor
• POT is not operational. menu. From there, scroll to the Switch Inputs menu and
then to the RAS-Lift Switch menu. Check if RAS is
stuck ON.
Step 1: Check the condition of FU1.
• If RAS is stuck ON.
• If FU1 is bad.
• If RAS is not stuck ON.
• If FU1 is OK.
Step 2: Check the line contactor tips for obstacles or
corrosion.
• If the line contactor tips are obstructed or corroded.
– Then replace the tips or line contactor.
• If the line contactor tips are OK.
Step 3: Check for external loads on the +BV terminal
that would prevent it from charging (i.e., a short at
CA201-13).
• If an external load on the +BV terminal exists.
• If no external load on the +BV terminal exists and
the event code continues.
Fig. 123 (25913)
174
ELECTRICAL SYSTEM

Horn (HN) Driver Open or Short Pump Driver is Open or Short
Note: A possible effect of this event code is a disabled Note: Possible effects of this event code are:
HN. • M1 is not operational.
Note: After this event code is corrected, turn the truck • The line contactor is open.
OFF and back ON to reset the event code.
Codes 332, 333, 335 or 362.
– Then check the positive signal from ACCESS 3
Codes 332, 333, 335 or 361.
(CA201-3) to HN for opens or shorts. Repair or
replace as necessary. • If more than one event codes occur.
• If only this event code occurs. – Then check the wiring from ACCESS 3
(CA201-4) to the pump contactor for opens or
the line contactor for opens or shorts.
• If the wiring is open or shorted.
the line contactor for opens or shorts.
Step 3: Check HN for opens or shorts.
• If HN is open or shorted.
Step 3: Check the pump contactor for opens or shorts.
• If HN is OK and the event code continues.
• If the pump contactor is open or shorted.
• If the pump contactor is OK and the event code con-
tinues.
Fig. 124 (25914)
Fig. 125 (25915)
175
ELECTRICAL SYSTEM
Event Code 363 – Then the 12 V output is the issue. Check the wir-
ing from ACCESS 3 (CA201-25, CA201-28 and
Line Contactor Open or Short CA201-29) to JC202-1, JC202-3 and JC202-4, or
Note: Possible effects of this event code are: the wiring from ACCESS 3 (CA201-8) to
CA208-1 for opens or shorts. Repair or replace
as necessary.
• If the handset displays properly.
– Then the 5 V output is the issue. Proceed to Step
• POT is not operational. 2.
• M2 is not operational. Step 2: Disconnect CA209. Using the handset, scroll
Note: After this event code is corrected, return the down to the Monitor menu. From there, scroll to the
throttle to neutral to reset the event code. Outputs menu and then to the 5 Volts menu. Check for
Follow the troubleshooting steps for Event Code 331. 5 V.
• If 5 V exists.
Step 3: Disconnect the wiring from ACCESS 3
(CA201-26). Using the handset, scroll down to the
Monitor menu. From there, scroll to the Outputs menu
and then to the 5 Volts menu. Check for 5 V.
• If 5 V exists.
– Then repair or replace the wiring from ACCESS 3
Fig. 126 (25907) (CA201-26).
Event Code 368
VCL (Vehicle Control Language) Runtime Issue
Internal software issue in ACCESS 3.
Step 1: Replace ACCESS 3.
Event Code 369

External Supply Out of Range
The combined current (5 V and 12 V) is outside of the
expected range.
Note: Possible effects of this event code are limited op-
eration and maximum speed. Fig. 127 (25916)
menu. From there, scroll to the Outputs menu and then
to the 5 Volts menu. Check for 5 V. Then scroll to the
12 Volts menu and check for 12 V.
• If the handset does not display properly.
176
ELECTRICAL SYSTEM
Event Code 371

OS (Operating Software) Issue
Internal software issue in ACCESS 3.
• POT is not operational. Fig. 128 (25917)
Event Code 373
Stall Detected
Event Code 372 No ECR movement is detected.
PDO (Process Data Object) Timeout Note: Possible effects of this event code are limited op-
eration and maximum speed.
ACCESS 3 does not receive an expected CAN mes-
sage within the allotted time. Step 1: Check the load weight.
Note: Possible effects of this event code are: • If the load weight exceeds the rated capacity of the
truck.
menu. From there, scroll to the Controller menu and
Step 1: Check the wiring from ACCESS 3 (CA201-23) then to the Current (RMS) menu. Check the current
to CA205-4 for opens or shorts. while driving an empty truck.
• If the wiring is open or shorted. • If the current is more than 100 A.
– Then repair or replace as necessary. – Then check the drive unit for bad bearings, bad
• If the wiring is OK. gears, etc.
– Then proceed to Step 2. • If the bearings, gears, etc. are OK.
Step 2: Check the wiring from ACCESS 3 (CA201-35) – Then proceed to Step 3.
to CA205-1 for opens or shorts. Step 3: Using the handset, scroll down to the Monitor
• If the wiring is open or shorted. menu. From there, scroll to the Motor menu and then to
– Then repair or replace as necessary. the MotorSpeed A and MotorSpeed B menus. Check
the inputs while driving an empty truck.
• If the wiring is OK and the event code continues.
• If no inputs exist.
– Then replace the X10 handle.
– Then check the wiring from ECR (CA209-1,
• If the event code continues after replacing the X10
CA209-2, CA209-3 and CA209-4) to ACCESS 3
handle.
(CA201-7, CA201-26, CA201-31 and CA201-32).
177
ELECTRICAL SYSTEM
Step 4: Check the wiring from CA209-1 to CA209-2 for Event Code 392
5 V.
• If 5 V exists. Electric Brake Issue
– Then replace ECR. Movement occurs after the request to engage BRK.
• If the current displayed in the Current (RMS) menu Note: Possible effects of this event code are BRK not
is less than 100 A and ECR is OK. releasing and the traction accelerator potentiometer
(POT) not operating.
Step 1: Check if the truck is requesting BRK on a ramp
with a load weight that exceeds the rated capacity of
the truck.
• If the truck is requesting BRK.
– Then reduce the load weight and move away
from the ramp.
• If the event code continues.
– Then refer to the Brake section and repair or re-
place as necessary.
Event Code 853

Throttle Mismatch
Fig. 129 (25906) POT1 is more than 0 with FS and RS OFF or ON.
Event Code 389 Note: Possible effects of this event code are:
Motor Type Issue
M1 type and parameter issue.
Step 1: Check the condition of the control circuit fuse
• BRK is not releasing. (FU3) (this provides power to the X10 handle).
• POT is not operational. • If FU3 is bad.
• M2 is not operational. – Then repair or replace as necessary.
Step 1: Replace ACCESS 3. • If FU3 is OK.
Event Code 391 – Then proceed to Step 2.
Step 2: Check the wiring from the positive signal to
Software Mismatch CA205-3 and BNEG to CA205-2 for opens or shorts.
VCL and OS software do not match. • If the wiring is open or shorted.
Note: Possible effects of this event code are: – Then repair or replace as necessary.
• M1 is not operational. • If the wiring is OK.
• The line contactor is open. – Then proceed to Step 3.
• BRK is not releasing. Step 3: Using the handset, scroll down to the Monitor
• POT is not operational. menu. From there, scroll to the Tiller Throttle menu and
• M2 is not operational. then to the Raw Tiller Throttle menu. Check the value:
the POT value is 0 with the POT in neutral and changes
with throttle movement.
– Then replace POT.
• If the event code continues after replacing POT.
178
ELECTRICAL SYSTEM
– Then replace the main PC board in the X10 han-

dle.
Fig. 131 (25918)
Fig. 130 (25918)

Event Code 855
Event Code 854 Tiller Warning
X10 handle issue.
Throttle POT Out of Range
POT voltage is outside of the expected range.
Step 1: Replace the X10 handle switch cap.
Step 1: Check the condition of FU3 (this provides Event Code 856
power to the X10 handle).
Tiller Com Loss
• If FU3 is bad.
Communication to the X10 handle has been lost.
Note: This event code could appear in the Fault History
• If FU3 is OK. menu due to a timing issue during the initial truck
– Then proceed to Step 2. startup; this causes no unfavorable effects during oper-
Step 2: Check the wiring from the positive signal to ation.
CA205-3 and BNEG to CA205-2 for opens or shorts. Note: Possible effects of this event code are:
• If the wiring is open or shorted. • M1 is not operational.
– Then repair or replace as necessary. • The line contactor is open.
• If the wiring is OK. • BRK is not releasing.
– Then proceed to Step 3. • POT is not operational.
Step 3: Using the handset, scroll down to the Monitor • M2 is not operational.
menu. From there, scroll to the Tiller Throttle menu and Step 1: Check the condition of FU3 (this provides
then to the Raw Tiller Throttle menu. Check the value: power to the X10 handle).
the raw value should go from 0 - 255.
• If FU3 is bad.
– Then replace POT.
• If FU3 is OK.
• If the event code continues after replacing POT.
– Then replace the X10 handle switch cap.
Step 2: Check the CAN communication path. With the
truck OFF, check the CAN plug resistance from
CA203-1 to CA203-2. The value should be approxi-
mately 60 Ω.
• If the value is 60 Ω.
• If the value is not 60 Ω.
179
ELECTRICAL SYSTEM
– Then disconnect CA204 at the display gauge

(TT) and check the resistance from CA203-1 to
CA203-2. The value should be approximately
120 Ω.
– Then the issue is in the wiring from ACCESS 3;
check all CAN wiring.
– Then check the resistance from CA201-23 to
CA201-35 and check that the jumper at
CA201-21 and CA201-34 is in place.
• If the jumper is in place and the value is not 120 Ω.
– Then remove the connector at CA201 and recon-
nect the connector at CA204. Check the resist-
ance from CA204-3 to CA204-4.
Fig. 132 (25919)
– Then replace TT.
– Then check the wiring from CA203 to CA204.
CA205-3 and BNEG to CA205-2 for opens or shorts.
Step 4: Check the wiring from ACCESS 3 (CA201-35)
to CA205-1 for opens or shorts.
• If the wiring is OK and the code continues.
– Then replace the X10 handle switch cap.
180
ELECTRICAL SYSTEM
Event Code 857 Step 3: Using the handset, scroll down to the Monitor
menu. From there, scroll to the Switch Inputs menu and
SAS (Safety Reverse Switch) Mismatch then to the SAS-Emergency Reverse CAN menu.
There is a mismatch in the SAS CAN message and the Check if the input to ACCESS 3 is toggling when de-
hardwired SAS. pressed. Then scroll to the SAS-Emergency Reverse
Redundant menu and check if the input to ACCESS 3
is toggling when depressed.
• If the SAS-Emergency Reverse CAN menu is not
• The line contactor is open. toggling.
• BRK is not releasing. – Then check the wiring in the X10 handle and re-
• POT is not operational. pair or replace as necessary.
• M2 is not operational. • If the SAS-Emergency Reverse Redundant menu is
Step 1: Check the condition of FU3 (this provides not toggling.
power to the X10 handle). – Then check the wiring from ACCESS 3
• If FU3 is bad. (CA201-24) to CA205-6 and repair or replace as
necessary.
• If the menus are toggling and the event code con-
• If FU3 is OK.
tinues.
Fig. 133 (25920)
181
ELECTRICAL SYSTEM
Event Code 858 • If the menu inputs are stuck ON and the event code
continues.
SAS Anti Tie Down – Then replace ACCESS 3.
SAS is shown as being ON before it activates.
Step 1: Check the condition of FU3 (this provides
power to the X10 handle). Fig. 134 (25920)
• If FU3 is bad.
• If FU3 is OK.
menu. From there, scroll to the Switch Inputs menu and
then to the SAS-Emergency Reverse CAN menu.
Check if the input to ACCESS 3 is not stuck ON. Then
scroll to the SAS-Emergency Reverse Redundant
menu and check if the input to ACCESS 3 is not stuck
ON.
• If the SAS-Emergency Reverse CAN menu input is
not stuck ON.
– Then check the wiring in the X10 handle and re-
pair or replace as necessary.
• If the SAS-Emergency Reverse Redundant menu
input is not stuck ON.
(CA201-24) to CA205-6 and repair or replace as
necessary.
182
ELECTRICAL SYSTEM
NO EVENT CODE
No Event Code
Truck speed is limited.
menu. From there, scroll to the Controller menu and
then to the Current (RMS) menu. Check the current
while driving an empty truck.
• If the current is more than 100 A.
– Then check the drive unit for bad bearings, bad
gears, etc.
• If the bearings, gears, etc. are OK.
menu. From there, scroll to the Motor menu and then to
the MotorSpeed A and MotorSpeed B menus. Check
the inputs while driving an empty truck.
• If no inputs exist.
– Then check the wiring from ECR (CA209-1,
CA209-2, CA209-3 and CA209-4) to ACCESS 3
(CA201-7, CA201-26, CA201-31 and CA201-32).
Step 3: Check the wiring from CA209-1 to CA209-2 for
5 V.
• If 5 V exists.
• If the current displayed in the Current (RMS) menu
is less than 100 A and ECR is OK.
Fig. 135 (25906)
183
Notes:
184
BRAKE SYSTEM
185
Notes:
186
BRAKE SYSTEM
DESCRIPTION OF THE BRAKE SYSTEM
Description of the Brake Sys- Description of the Brake, Override,

tem and Travel Zones
This truck has 2 independent brakes: A service brake Refere to figure 136.
applied by the operator and a parking brake applied by
the truck automatically when the truck comes to a full Tiller is in position 1
stop. The override switch (ORS) and the brake switch (BRS)
are open, and the parking brake (BRK) is ON. With the
steer tiller in this zone, ACCESS 3 uses e-GEN® to
1 stop the truck and applies the parking brake.
2
Tiller in position 2
The override switch is closed and the brake switch is
3 open. If you operate the traction control, ACCESS 3 re-
leases the parking brake. The truck travels at a slow
speed only. With the steer tiller in this zone, ACCESS 3
uses e-GEN® to decrease the trucks speed.
4
1343 mm The override switch is open and the brake switch is
(53 in)
closed. If you operate the traction control, ACCESS 3
releases the parking brake and lets the truck travel at
5 the usual speed. This zone is the position for truck
552 mm travel.
(22 in)
The override switch and the brake switch are open.
ACCESS 3 uses e-GEN® to stop the truck and applies
Fig. 136 (27495) the parking brake.
The function of the service brake

The service brake is wear-free as the traction motor
(M1) in regenerative mode (EGen®) supplies all the
brake power. There are no brake pads and brake disks
for the service brake. The stopping distance is a func-
tion of the brake rate setting.
With the steer tiller in one of the brake positions (4 or
1), ACCESS 3 controls the brake effect of the traction
motor. When the speed of the traction motor is 0 min-1,
Access 3 applies the parking brake.
The function of the parking brake

The electromechanical parking brake (BRK) is applied,
when the speed of the traction motor is 0 min-1. The
parking brake holds the truck in position.
Crown 2011 PF25477-1 Rev. 9/12 WP3015/3020 Models
187
BRAKE SYSTEM
TO ADJUST THE STOPPING DISTANCE OF THE SERVICE BREAK
To Adjust the Stopping Dis-

tance of the Service Break
To measure the stopping distance
1. Operate the truck without a load to its top speed on
a dry, level concrete surface.
Fig. 137 (27483)

2. Move the X10® handle to the lower brake position
(1).
3. Measure the stopping distance from the point
where the brake was applied until the truck stops.
 If the stopping distance is < 0.5 m or > 0,7 m,
then continue with step 4.
 If the stopping distance is in the range of 0.5 -
0.7 m, the adjustment is correct.
To adjust the stopping distance
5. Connect the handset.
6. Turn the truck on.
7. Go to Program > Traction Performance > Slow
Speed (Turtle) [or High Speed (Rabbit)] > Brake
Rate.
8. Adjust the stopping distance.
9. Repeat steps 1 to 3.
WP3015/3020 Models
188
BRAKE SYSTEM
TO ADJUST THE AIR GAP OF THE PARKING BRAKE
To adjust the Air Gap of the

Parking Brake
The air gap is the distance between the magnet as-
sembly and the outer stator when the parking brake is
applied. As the brake pads and the rotor slowly wear,
the air gap increases and you must adjust it when it
4
measures more than 0.2 mm.
Note: If the air gap measures more than 0.2 mm, the
parking brake does not release.
You can adjust the air gap when: 2
• The brake pads are not worn, damaged or soaked 3
with lubricant.
• The rotor is not bent or damaged. 1
• The adjustable spacers are not at their limit.
5
To prepare the truck for maintenance
floor.
Fig. 138 (26018-01)
4. Disconnect the battery. To Adjust the air gap
5. Put the chocks against the wheels to prevent the 1. Use low pressure air to remove the dirt between
movement of the truck. Refer to SAFETY > Control the inner and outer stators (1) and the magnet as-
of Hazardous Energy > Lifting and Blocking. sembly (2).
6. Complete the lockout/tagout procedures for the 2. Loosen the 2 brake release screws.
3. With a feeler gauge (5), measure the air gap at
each of the adjustable spacers.
center cover. 4. Use the adjustable spacers (3) to adjust the air gap
(4) to 0.2 mm.
Note: Make equal and small adjustments. The air gap
must be 0.2 mm along the contour.
5. Torque the 2 brake release screws to 6 Nm.
189
BRAKE SYSTEM
TO RELEASE THE PARKING BRAKE MANUALLY
To Release the Parking Brake

manually
2
Fig. 139 (26016-01)
WARNING
Accident hazard!
If the 2 brake release screws are loose, the parking
brake does not operate. This can cause unintended
truck movement.
 Before you operate the truck, make sure that the 2
brake release screws are tight.
1. Loosen the 2 brake release screws (1) to release

the parking brake (2). Refer to Figure 139.
190
BRAKE SYSTEM
PARKING BRAKE MAINTENANCE
Parking Brake Maintenance 2. Remove the screws (2).
Parking Brake Disassembly

Parking Brake Removal
To disassemble the parking brake
1. Remove the magnet assembly (3) from the traction
motor (M1).
2
2 CAUTION
1 Prevent damage to the machined surfaces when you
remove the components in the next step.
2. Remove the rotor assembly (4) from the hub.

3 3. Remove the key between the traction motor shaft
and the hub. Dispose the key.
4. Remove the inner stator (5).
5. Remove the 2 nuts (6) from the magnet assembly
(3).
6. Remove the adjustable spacers (7) to remove the
outer stator (8).
To examine the components
1. Clean all components.
2. Examine the rotor assembly (4), inner stator (5),
6
and outer stator (8) for wear and damage.
3. If parts are worn or damaged, dispose them.
4. Measure the thickness of the rotor assembly (4).
8 5. If the thickness is less than 5.6 mm, then replace
the rotor assembly (4), inner stator (5), and outer
stator (8).
Parking Brake Assembly

p
To assemble the parking brake

7
1. Assemble the components in the reverse se-
quence of disassembly.
2. Adjust the air gap. Refer to BRAKE >parking brake
> Air Gap Adjustment.
To install the parking brake
3. Use a new key between the traction motor shaft
and the hub and install the parking brake on the
4 traction motor.
5 4. Torque the three screws (2) to 6 Nm. Refer to
Figure 140.
5. Make the electrical connection to the parking
Fig. 140 (26017-01)
brake.
To remove the parking brake.
1. Disconnect the 2 wires from the parking brake con-
nector (1).
191
BRAKE SYSTEM
PARKING BRAKE MAINTENANCE
To prepare the truck for operation

unit cover.
truck.
10. Turn the truck ON and make sure that the parking
brake operates correctly.
192
BRAKE SYSTEM
PARKING BRAKE, POSSIBLE TROUBLES
Parking Brake, Possible Trou-

bles
Park Brake Troubleshooting Chart
Issue Probable Cause Remedy
The park brake does not The air gap is more than 0.2 mm Adjust the air gap
release
An open circuit in the park brake wiring Measure the voltage in the park brake cir-
cuits and wiring
The park brake drags The air gap is less than 0.2 mm Adjust the air gap
The outer stator has dirt or contamination Clean the outer stator with low pressure air
The brake pads contain grease Replace as necessary
Abnormal noise when The park brake inner or outer stators or the Replace as necessary
you apply the park brake rotor assembly are distorted
The brake pads are loose or contain
grease, or contamination
The rotor assembly is thin, cracked, or the
splines have wear
WP3015/3020 Models M5.0-2730-103
193
Notes:
194
STEERING
195
Notes:
196
STEERING
REPAIRING CONTROL HANDLE RETURN SPRINGS
Repairing Control Handle Return spring pre-tension adjust-

Return Springs ment
If the return spring bias spring force reduces over time, Note: The axle (6) contains 2 holes for the dowel pin
the pre-tension can be adjusted in several stages. Re- which are offset by 90 degrees. This allows you to ad-
turn springs whose pre-tension cannot be increased just the pre-tension of the return springs by 90 degrees
any further must be replaced. respectively by turning the axle.
7
WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move
suddenly when you are working on it.
You should therefore carry out the following safety pro-
cedures before starting any operations on the truck:
6
 Lower the forks to the ground.
 Switch the truck off.
 Disconnect the battery. 4
 Prevent the truck from being switched on again.
 Jack up the truck until the drive wheel is clear of the
ground (see page 16).
Panel removal
5
1
Fig. 142 Pre-tension adjustment
4 Return spring
5 Spacer ring
2 6 Axle
7 Dowel pin
2. Set the control handle upright.

3. Fix the axle (6) using a fork wrench.
 This prevents the return springs (4) from discharg-
ing when the dowel pin (7) is deflected.
4. Remove the dowel pin (7).
5. Turn the axle (6) 90 degrees with the fork wrench.
 This will tension the springs.
6. Strike the dowel pin (7) in.
 This increases the pre-tension of the return
springs (4).
Fig. 141 Panel removal 7. Make sure the return springs have sufficient pre-
tension. The control handle should move automat-
1. Loosen two screws (1) and push the panel (2) up. ically to the horizontal position.
 The control handle springs are now accessible. 8. If necessary increase the pre-tension of the return
Note: Assembly is the reverse of disassembly. springs further.

01 Rev. 7/12
197
STEERING
9. After adjusting, grease the return springs (for lubri- Tools required:
cant see page 23). Shortened axle (8) on which the return springs can be
10. Assemble all the panels. pre-assembled. The axle must be shorter than 119 mm
11. Test the truck's brakes. so that it can be inserted with the control handle in the
control handle knuckle (9).
Replacing the return springs Pre-assembling the return springs
1. Push the return springs (4) with the spacer ring (5)
onto the shortened axle (8). The inner, angled end
WARNING of the return springs should enter the groove of the
shortened axle (8) in the process.
Risk of injury from pre-tensioned springs.
Note: Note that the shortened axle (8) moves with the
Pre-tensioned springs can snap off with extreme force.
axle (6). The return springs are pushed onto the axle
 Be particularly careful when handling springs and (6) at the same time. When inserting the axles make
wear protective goggles. sure the grooves are positioned accordingly (see
Fig. 143).
Return spring removal Return spring assembly
1. Remove the cover (see page 197). 2. Insert the pre-assembled return springs (4) with
2. Set the control handle upright. the control handle into the control handle knuckle
(9).
3. Remove the dowel pin (7).
3. Insert the axle (6) from the left hand side and make
 The axle (6) turns and the return springs (4) are
sure that the position of the groove corresponds to
discharged.
the groove of the shortened axle (8).
4. Set the control handle all the way down to fully dis-
4. Strike in the axle (6) carefully and drive out the
charge the return springs (4).
shortened axle (8).
Note: If the axle is jammed, turn it approx. 20 degrees
 The return springs are pushed onto the axle (6) in
clockwise with a fork wrench in order to discharge the
the process.
return springs.
5. Drive out the axle (6) from the right hand side. Return spring pre-tension adjustment
6. Remove the return springs (4). 5. Set the control handle upright.
6. Starting from the neutral position of the return
Return spring assembly springs, turn the axle (6) 90 degrees using a fork
wrench and increase the pre-tension of the return
springs.
7 4
7. Strike the dowel pin (7) in.
8. Make sure the return springs have sufficient pre-
tension.
 The control handle should move automatically to
6 8 the upright position.
9. If necessary increase the pre-tension of the return
springs further.
10. After adjusting, grease the return springs (4) (for
lubricant see page 23).
11. Assemble all the panels.
9 12. Test the truck's brakes.
Fig. 143 Return spring assembly
13.
8 Shortened axle
9 Control handle knuckle
01 Rev. 7/12
198
STEERING
Roller Bearings bearings (4 and 5) are between the steer bearing

flange and the truck frame (6). They are lubricated and
Refer to Figure 144. maintenance free. Figure 144 shows a cross section of
The X10® handle (1) connects to the drive unit by the the roller bearings with the drive unit disassembled.
knuckle (2) and a steer bearing flange (3). The roller
7 2
4 7
8 9
9 8
5
6 3
Fig. 144 (26033-01)
Roller Bearings Disassembly – The BRK connector.

– The traction speed encoder (ECR) connector
Disassemble the roller bearings (CA209).
Refer to Figure 144. 4. Use a rubber mallet to carefully push the steer
Special Tools and Equipment: bearing flange (3) and the drive unit down and out
• A rubber mallet. of the truck frame (6).
1. With the knuckle cover off, remove the center  The lower roller bearing (5), roller bearing cup (8),
cover. and seal (9) stay on the steer bearing flange.
Note: Make sure that you do not do damage to the 5. Remove the lower roller bearing (5), roller bearing
wires when you remove the components. cup (8), and seal (9) from the steer bearing flange
2. Remove the six cap screws (7) from the knuckle (2) (3).
to remove the X10® handle (1). 6. Remove the upper roller bearing (4), roller bearing
3. Disconnect these components: cup (8), and seal (9) from the steer bearing flange
(3).
– The three power cables from the traction motor
(M1). 7. Remove the outer rings of the roller bearings (4
and 5) from the truck frame (6).

01 Rev. 7/12
199
STEERING
Roller Bearings Assembly

Assemble the roller bearings
Note: Before you assemble the roller bearings (4 and
5), examine all components for wear, cracks, or other
damage. If it is necessary, replace the components at
this time.
Note: Apply grease to the roller bearings (4 and 5) be-
fore you assemble them.
1. Do the opposite of the disassembly procedures in
the Roller Bearings Disassembly section.
2. Torque the six cap screws (7) to 49 Nm.
3. Install the center cover and knuckle cover.
truck.
erates correctly.
01 Rev. 7/12
200
LIFTING MECHANISM
201
Notes:
202
CYLINDERS
LIFT LINKAGE
Lift Linkage
WARNING
Tension Bar Removal Injury or damage can occur.
Special Tools and Equipment: Injury to you or damage to your truck can occur if you
• A hydraulic jack with a capacity of 3620 kg do not keep the truck secure when you put it on its side.
• Hardwood blocks or jack stands with a capacity of  If you put the truck on its side to remove the tension
4500 kg. bars, make sure that it is secure.
Prepare the truck for maintenance  Remove the battery from the truck.
1. Move the truck to a maintenance area with a level  Put a plug in the fill plug opening on the drive unit
floor. and make sure that the reservoir lid is on the reser-
voir to prevent fluid leakage.
1. Lift the power unit with a hydraulic jack until you
4. Disconnect the battery. can get access to the tension bars. Put hardwood
5. Put the chocks against the wheels to prevent the blocks or jack stands below the power unit. Refer
movement of the truck. Refer to SAFETY > Control to SAFETY > Control of Hazardous Energy > Lift-
of Hazardous Energy > Lifting and Blocking. ing and Blocking.
6. Complete the lockout/tagout procedures for the To remove the tension bars
2. Remove the roll pins (2) from the opening in the top
To put the tuck on its side of the forks (3) to remove the riser pivot shafts (4).
3. Remove the roll pins (5) to remove the pivot shafts
(6).
WARNING 4. Remove the tension bars (1) from the truck.
Tipovers can result in fatal accidents.
You can be fatally injured by a truck tipover.
 Make sure the jack has sufficient capacity. Informa-
tion on the capacity required can be found on the
truck data plate under “Truck Weight Less Battery”
and “Battery Weight”.
 Do not do maintenance below or around a truck that
is not correctly blocked and safe.
 Read and follow all applicable safety procedures in
SAFETY > Control of Hazardous Energy.

01 Rev. 7/12
203
CYLINDERS
LIFT LINKAGE
Fig. 145 (26949)
01 Rev. 7/12
204
CYLINDERS
LIFT LINKAGE
Tension Bar Replacement

Replace the tension bars
1. Remove the tension bar ends (7) from the tension
bars (1).
Note: To make sure that the tension bars (1) install cor-
rectly into the tension bar ends (7), count the number
of turns to remove each end.
Note: There are left and right tension bar ends (7).
83 mm ± 1 mm
Make sure that you install the correct one in its correct
(3.27 in •} 0.04 in)
location.
2. Install the new tension bars (1) into the tension bar
ends (7).
Note: If the number of turns is different between the
two tension bar ends (7) during installation:
• Make sure that the threads engage equally.
• Keep an equal center distance between the tension 89 mm + 0 mm, -3 mm
bar ends (7). (3.50 in + 0 in, -0.1 in)
Tension Bar Installation

Install the tension bars 215 mm (tip)/221 mm (heel)1
Refer to Figure 145. 235 mm (tip)/241 mm (heel)2
1. Connect the tension bars (1) to the risers (8) with

the riser pivot shafts (4).
2. Install the roll pins (2) in the opening in the top of
the forks (3).
3. Connect the other end of the tension bar (1) to the
lower link assembly (9) with the pivot shafts (6) and
roll pins (5).
4. Lubricate all grease fittings. 132 mm (5.20 in) 1
152 mm (5.98 in) 2
Fork Height Adjustment
Adjust the fork height
1. Loosen the jam nuts (10) on the tension bars (1).
Refer to Figure 145. Fig. 146 (26951)
2. Turn the tension bars (1) with the welded nuts (11). 1 Trucks with 155 mm (6.10 in) trailer fork tip length
Refer to Figure 145. 2 Trucks with 184 mm (7.24 in) standard fork tip length
3. Remove the hardwood blocks or jack stands from
below the power unit and lower the power unit until
the drive tire is on the floor.
4. Make sure that the fork height at the riser pivot
point is 83 mm ± 1 mm and the fork heel height is
89 mm -3 mm. Refer to Figure 146.
Note: Make sure that the riser stops (1) touch the fork
ends (2) equally. Refer to Figure 147.

01 Rev. 7/12
205
CYLINDERS
LIFT LINKAGE
1 1
Fig. 147 (26950-01)
5. Lift the power unit with a hydraulic jack until you

can get access to the tension bars. Put hardwood
blocks or jack stands below the power unit. Refer
to SAFETY > Control of Hazardous Energy > Lift-
ing and Blocking.
6. After the adjustments are complete and the dimen-
sions are correct, torque the jam nuts (10) on the
tension bars (1) to 203 Nm. Refer to Figure 145.
7. Remove the hardwood blocks or jack stands from
below the power unit and lower the power unit until
the drive tire is on the floor.
truck.
12. Raise the forks and make sure that the fork lift
height is correct. The standard fork lift height is
152 mm and the trailer fork lift height is 132 mm.
M7.0-2730-004 WP3015/3020 Models

01 Rev. 7/12
206
CYLINDERS
207
Notes:
208
CYLINDERS
LIFT CYLINDERS
Lift Cylinders Lift Cylinder Removal

Lift Cylinder Operation
1. Move the truck to a secure non-traffic maintenance
The lift cylinders are single-acting. The piston rods are area with a level floor.
raised by the hydraulic fluid pressure and lowered by
the weight of the raised load. Figure 26135 shows a lift 2. Remove the top cover and the main cover.
cylinder cross section. 3. Extend the piston rods until the left-hand piston rod
attachment is next to the contactors so the roll pin
can be removed.
4. Block the fork carriage to prevent it from lowering
and to take the fork weight off of the lift cylinders.
5. Press and hold the lower switch for at least 10 sec-
onds to depressurize the hydraulic system.
WARNING
Avoid high pressure fluids.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
 Relieve pressure before disconnecting hydraulic
lines.
 Tighten all connections before applying pressure.
 Keep hands and body away from pinholes which
eject fluids under high-pressure.
 Use a piece of cardboard or paper to search for
leaks. Do not use your hand.
Consider any fluid injected into the skin under high-
pressure as a serious medical emergency despite an
initial normal appearance of the skin. There is a de-
layed onset of pain, and serious tissue damage may
occur. Seek medical attention immediately by a spe-
cialist who has experience with this type of injury.

7. Disconnect the battery. Lockout/Tagout the truck
as described in Lockout/Tagout in the Control of
Hazardous Energy section.
Fig. 148 (26135)
1 Piston Rod 8. Remove the roll pin (1) from the left-hand piston
2 Wiper rod attachment (2).
3 Guide Ring 9. Disconnect the electrical connections to the lift
4 Seal pump motor.
5 Hydraulic Fluid Inlet/Outlet 10. Remove the roll pin from the right-hand piston rod
6 Cylinder Tube attachment.
11. Lower the piston rods (3) into the cylinder tubes
(4).
12. Disconnect the hydraulic lines.

01 Rev. 10/11
209
CYLINDERS
LIFT CYLINDERS
13. Remove the cylinder clamp (5) at the base of the Lift Cylinder Disassembly
lift cylinder.
To disassemble the lift cylinder and carefully extract the
Note: Protect the piston rods (3) from scratches when
ram assembly from the cylinder bore, never allow the
removing them through the chassis hole (6) by using
ram assembly to contact any sharp edges.
cardboard or paper.
14. Remove the lift cylinder from the truck. Seals
The seals used in the lift cylinder are made from an
extremely durable, hard polyurethane material that can
be deformed temporarily to allow for installation without
permanent damage.
Seal Removal
Note:
When an excessive amount of hydraulic fluid is evident
around the area where the ram assembly exits from the
cylinder tube, the seal is damaged and must be re-
placed.
CAUTION
Never use a screwdriver to remove seals, as damage
and leakage may result.
CAUTION
The hooked tool must be constructed of aluminum or
brass to not scratch or nick any surfaces. The hooked
tool is not available through Crown.
The lift cylinder must be removed from the truck to per-

form seal replacement. The seal is seated inside the
cylinder tube so a hooked tool should be used to re-
move the seal. Refer to Figure 150.
Fig. 150 (16733)

1. Remove the wiper. The seal and the wiper should
Fig. 149 (26136)
always be replaced in pairs.
01 Rev. 10/11
210
CYLINDERS
LIFT CYLINDERS
2. Thoroughly clean the area where the seal seats. steel pin and two movable pins is required for this in-
Any burrs, dirt, or seal debris must be removed be- stallation. Refer to Figure 151.
fore installing new seals.
Lift Cylinder Inspection

1. Check the piston rods for signs of nicks, scratches,
or other damage to the surface.
2. Check the wiper for wear and fluid leakage.
3. Check the piston rod seal for damage or excess
wear that can cause hydraulic fluid leakage.
CAUTION
Close inspection of seal seating critical areas should
be made before the new 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 seating area, causing the seal to deform and lose Fig. 151 (16735-02)
its sealing ability. 1 Pin 1
2 Pin 2
3 Pin 3
4. When repairing the lift cylinder, check the condition
of the guide rings. Ideally, all seal components 4 Tool Body
should be replaced, not just worn or damaged To install the seal
seals.
1. Slip the seal over the fixed pin. Refer to Figure 151
5. Minor irregularities on the cylinder tube surface or and bend it over pin 2 as shown.
the piston rod can be removed with an aluminium
oxide cloth or a honing tool. 2. Continue bending the seal until pin 3 can be
pushed through the seal loop which locks the seal
6. After inspection, clean all lift cylinder components in position. Refer to Figure 151.
with a high grade solvent and dry with low pressure
compressed air. 3. Insert the installation tool with the mounted seal
into the lift cylinder bore until aligned with the seal
Seal Installation installation groove. Refer to Figure 152.
CAUTION
Tools used to install seals must be made of soft mate-
rial or suitable plastic, free of burrs and sharp edges.
Screwdrivers and other similar tools must not be used
as they may damage the sealing edges.
Note: The area in contact with the seal should be free

of burrs, sharp edges, and nicks. If a new seal must be
installed over sharp edges, slots, or corners, take the
appropriate protective measures.
Note: Lubricate all replacement parts with a thin coat
of hydraulic fluid before installing them. Fig. 152 (16736-01)
Note: An installation tool made of soft material or suit-
able plastic that is smooth and free of burrs with a fixed

01 Rev. 10/11
211
CYLINDERS
LIFT CYLINDERS
1 Pin 1
other areas of the hydraulic system. Refer to the Hy-
draulic System section for circuit bleeding and drift test
2 Pin 2
guidelines.
3 Pin 3
To assemble the lift cylinder
4. Remove pin 3 so the seal loop snaps into the seal
1. Apply a thin coat of hydraulic fluid to the ram as-
installation groove. Refer to Figure 153.
sembly and install it into the cylinder tube.
Fig. 153 (16737-01)

1 Pin 1
2 Pin 2
3 Pin 3
5. Remove pin 2 and the seal will completely snap

into the seal installation groove. Refer to
Figure 154.
Fig. 154 (16738-01)

1 Pin 1
2 Pin 2
3 Pin 3
6. Remove the installation tool.
Lift Cylinder Assembly

Note: Occasionally, a slight creep of the fork assembly
may occur. This may be due to internal leakage in the
seals but it also may indicate hydraulic fluid leakage in
01 Rev. 10/11
212
MISCELLANEOUS
213
Notes:
214
MISCELLANEOUS
GLOSSARY
Glossary connector on the truck. The Diagram column lists the

page number of the wiring diagram on which the con-
The Connector column below contains the connector nector appears. The callout in parenthesis following the
abbreviation that appears on wiring diagrams, In- page number matches the grid callouts on the diagram,
foPoint labels, event codes and truck connector labels. pinpointing the connector.
The Location column lists the general location of the
Connector Location Diagram
CA201 ACCESS 3 DIA-2730-002 (B-3)

DIA-2730-003 (B-3)
DIA-2730-004 (B-1)
DIA-2730-005 (B-1)
CA202 ACCESS 3 DIA-2730-002 (B-4)
DIA-2730-003 (B-4)
DIA-2730-004 (B-2)
DIA-2730-005 (B-2)
CA203 Drive/Tow Harness DIA-2730-002 (A-2)
DIA-2730-003 (A-2)
DIA-2730-004 (A-3)
DIA-2730-005 (A-3)
CA204 Display Gauge (TT) DIA-2730-006 (B-1)
CA205 X10® Handle Harness DIA-2730-006 (B-2)
CA206 Knuckle DIA-2730-006 (B-4)
CA208 Traction Motor (M1) DIA-2730-002 (C-3)
DIA-2730-003 (C-3)
DIA-2730-004 (C-2)
DIA-2730-005 (C-2)
CA209 Traction Speed Encoder (ECR) DIA-2730-002 (C-3)
DIA-2730-003 (C-3)
DIA-2730-004 (C-2)
DIA-2730-005 (C-2)
CA410 X10 Handle Main PC Board DIA-2730-002 (B-1)
DIA-2730-003 (B-1)
DIA-2730-006 (B-2)
DIA-2730-003 (B-2)
DIA-2730-006 (C-1)
DIA-2730-003 (B-1)
DIA-2730-006 (C-2)
DIA-2730-003 (B-1)
DIA-2730-006 (C-2)
CA414 X10 Handle R/T PC Board DIA-2730-006 (B-2)
CA415 X10 Handle Hydraulic PC Board DIA-2730-006 (B-3)
CA416 X10 Handle Hydraulic PC Board DIA-2730-006 (C-3)
Crown 2011 PF25481-1 WP3015/3020 Models M10-2730-001
215
MISCELLANEOUS
GLOSSARY
Connector Location Diagram
CA417 Horn Switch (HNS1) DIA-2730-006 (C-2)

CA419 Horn Switch (HNS2) DIA-2730-006 (C-2)
ALARM InfoLink® Harness DIA-2730-005 (A-4)
CURRENT InfoLink Harness DIA-2730-005 (A-3)
SENSOR
INFOLINK InfoLink Module DIA-2730-003 (B-1)
DIA-2730-005 (A-3)
PROX InfoLink Harness DIA-2730-005 (A-4)
RS232 InfoLink Harness DIA-2730-005 (A-3)
SHOCK InfoLink Harness DIA-2730-005 (A-3)
M10-2730-001 WP3015/3020 Models Crown 2011 PF25481-2
216
SCHEMATIC DIAGRAMS
217
Notes:
218
SCHEMATIC DIAGRAMS
INTRODUCTION TO DIAGRAM USE
Introduction to Diagram Use mits input or output signals. This helps to identify the
source of the signal or voltage.
Electrical Diagram Each page includes a section of the truck. When a fea-
ture is on the truck that is not standard, a new page
The power up electrical diagram shows the circuits that includes the standard and feature wires. Only one page
operate the truck (for example, CAN interface, of the truck section is necessary for the applicable truck
Access 1 2 3®, the contactor, and other components). setup.
The circuits that do not operate the truck are on the Wires that you identify by color and not by number are
pictorials (for example, freezer condition, the wire guid- usually wires from a different manufacturer.
ance system, lights, and other components).
The page titles, which are at the start of the electrical
When you use the electrical diagrams, the lower termi- diagrams, show the section of the truck wires on each
nal board or connector numbers are to the front of the page.
section. The numbers increase the further you go into
the diagrams. For example: a connector that starts with
a 2 could be on DIA-7332-032, while a connector that
starts with a 4 could be on DIA-7332-033.
Pictorials
The terminal board and connector numbers on the pic-
torials are in two different groups: power unit and plat-
form. The power unit terminal boards and connectors
are:
• 200s
• 400s
• 600s
• 800s.
The platform terminal boards and connectors are:
• 100s
• 300s
• 500s
• 700s
• 900s.
The wires start at a specified location (for example, the
distribution board) and the connection points start from
the lowest number. The next connection point from the
distribution panel is with the next group of 100s and
continue for each connection point away from the spec-
ified location.
The terminal board and connector numbers are in se-
quence on each page. A wire address with a connector
number or terminal board number shows which direc-
tion to look in the electrical diagrams for the other end
of the wire. When the wire goes to a component and
not a terminal board or connector, the pictorial shows a
terminal board to refer to. This terminal board is not a
solid line and has the terminal board number in paren-
theses. This terminal board is not on the truck.
The input and output arrows could be on terminal
boards and connectors. These show if the wire trans-
Crown 1991 PF8974-1 Rev. 6/12 WP3015/3020 Models DIA-ITD-001

03 Rev. 6/12
219
SCHEMATIC DIAGRAMS
INDEX
Index codes, power cable codes, and electrical diagram sym-

bols.
This electrical diagram index contains the electrical di-
agrams that are applicable to your truck. Refer to the
ELECTRICAL > Electrical System section for wire color
Title Page Number Revision
Electrical Schematic - Standard DIA-2730-010

Electrical Schematic with Options DIA-2730-011
Traction/Hydraulic - Standard (ACCESS 3) DIA-2730-012
Traction/Hydraulic with Options (ACCESS 3) DIA-2730-013
X10® Handle (ACCESS 8) DIA-2730-014
Power Cables DIA-2730-015 01 - 6/12
Wiring Harnesses DIA-2730-016
DIA-2730-009 WP3015/3020 Models Crown 2012 PF25691-1 Rev. 6/12
01 Rev. 6/12
220
SCHEMATIC DIAGRAMS
ELECTRICAL SCHEMATIC - STANDARD
Electrical Schematic - Standard
148568 D 1 of 2
Crown 2012 PF25691-2 WP3015/3020 Models DIA-2730-010
221
SCHEMATIC DIAGRAMS
ELECTRICAL SCHEMATIC WITH OPTIONS
Electrical Schematic with Options
148568 D 2 of 2
DIA-2730-011 WP3015/3020 Models Crown 2012 PF25691-3
222
SCHEMATIC DIAGRAMS
TRACTION/HYDRAULIC - STANDARD (ACCESS 3)
Traction/Hydraulic - Standard (ACCESS 3)
148569 D 1 of 2
223
SCHEMATIC DIAGRAMS
TRACTION/HYDRAULIC WITH OPTIONS (ACCESS 3)
Traction/Hydraulic with Options (ACCESS 3)
148569 D 2 of 2
DIA-2730-013 WP3015/3020 Models Crown 2012 PF25691-5
224
SCHEMATIC DIAGRAMS
X10® Handle (ACCESS 8)
148570 C
225
SCHEMATIC DIAGRAMS
POWER CABLES
Power Cables
A B C
1 1
1
125 A
FU1 1
2
NEG POS 175A
- +
+ TRACTION
CONTROL
ACCESS 3
+BV U
+BV
3
V
4
10
5
2 W 2
-B
6
PUMP LINE
L L
9
P
A B A B
7 8
M2
M2
W
PUMP
V M1
U
TRACTION
3 3
ITEM NA STD PART EU STD PART EU SCHALTBAU PART

1 148630-001 148630-011 148630-013
2 148630-002 148630-012 148630-014
3 148630-010 148630-010 148630-010
4 148630-008 148630-008 148630-008
5 148630-009 148630-009 148630-009
6 148630-005 148630-005 148630-005
7 148630-016 148630-016 148630-016
8 148630-015 148630-015 148630-015
9 148630-003 148630-003 148630-003
10 148630-004 148630-004 148630-004
4 4
A B C
148571 C
DIA-2730-015 WP3015/3020 Models Crown 2012 PF25691-7 Rev. 6/12
01 Rev. 6/12
226
SCHEMATIC DIAGRAMS
WIRE HARNESSES
Wire Harnesses
Harness Part Components Connected By:

Number
087245-095 Travel Alarm Harness

151602 Main Harness - PC201, JC202, JC203, PC203, PC204, JC205, PC206, JC208,
JC209, BRK, CAN LO, CAN HI, FU1, FU2, FU3, FU4, HN, KYS, L, LMS, SP1, SP2,
SP3, SP4, SV, ALM
148520 Tiller Handle Harness - PC205, PC410
148521 Drive/Tow Harness - JC203, DTS
149734 IEC Cable Charger
810562-002 LED PCB
826119 Horn Harness (Part of the Switch Cap) - PC413, PC417, PC419
826398 CAN Analog PCB Harness (Part of the Switch Cap) - PC414, PC415, PC418
227
SCHEMATIC DIAGRAMS
WIRE HARNESSES
DIA-2730-016 WP3015/3020 Models
228
HYDRAULIC SCHEMATIC
229
Notes:
230
HYDRAULIC SCHEMATIC
HYDRAULIC SCHEMATIC
Hydraulic Schematic
1 Lift Cylinders
2 Solenoid Valve (SV)
3 Filter
4 Check Valve (CV)
5 Lift Pump Motor (M2)
6 Lift Pump
7 Reservoir
8 Suction Filter
9 Return Filter
10 Vent Cap
11 Relief Valve (RV)
12 Flow Control
Fig. 155 (25656)
Crown 2000 PF11835-1 Rev. 7/11 WP3015/3020 Models HYD-2720-001

01 Rev. 7/11
231
Notes:
232

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WP3015/3020 MODELS

Order Number: 812601-006

Crown Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

The Function of the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Important Information Manual structure

Ordering spare parts Drive Unit

Crown 2011 PF25499-1 Rev. 7/12 WP3015/3020 Models ITD-2730-001

Truck Data Plate • Serial number

ITD-2730-002 WP3015/3020 Models Crown 2011 PF25499-2 Rev. 7/12

Truck Data Number 16 = 1450 mm

1.6 WP 3015 - 4 - 3 - 02 - S 26 = 1950 mm

Crown 2011 PF25499-3 Rev. 7/12 WP3015/3020 Models ITD-2730-002

WP3015/3020 Models Rev.2 08/2010

Rev.1 04/2009 WP3015/3020 Models

Repair work Cleaning work

WP3015/3020 Models Rev.1 04/2009

• Do not stand under a swinging load.

Rev.1 04/2009 WP3015/3020 Models

Crown 2011 PF25382-1 Rev. 9/12 WP3015/3020 Models MA-2730-100

• Consult the battery charger manual or refer to

Battery Removal and Installation

MA-2730-101 WP3015/3020 Models Crown 2011 PF25382-2 Rev. 9/12

• For industrial battery removal and installation pro-

Fig. 3 (25801-01) Fig. 4 (25802)

Crown 2011 PF25382-3 Rev. 9/12 WP3015/3020 Models MA-2730-102

Lockout/tagout the truck Release the Park Brake

MA-2730-103 WP3015/3020 Models Crown 2011 PF25382-4 Rev. 9/12

Lifting and Blocking 5

Crown 2011 PF25382-5 Rev. 9/12 WP3015/3020 Models MA-2730-104

Cleaning the Truck and Cleaning the entire truck

WP3015/3020 Models Rev.2 08/2010

Cleaning removed components

1. Components that have been removed should be

Rev.2 08/2010 WP3015/3020 Models

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

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

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

Type of Lubricant Part Number Package Quantity

Crown 2011 PF25240-1 Rev. 4/12 WP3015/3020 Models M1.0-04.0-050

Lubrication Identification Chart

363143-001 10.5 oz Can

M1.0-04.0-051 WP3015/3020 Models Crown 2011 PF25240-2 Rev. 4/12

Lubrication Identification Chart

Crown 2011 PF25240-3 Rev. 4/12 WP3015/3020 Models M1.0-04.0-051

Alternate Lubricants & Fluids Chart

D (2) Hydraulic Oil Crown Crown

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

M1.0-04.0-053 WP3015/3020 Models Crown 2011 PF25240-4 Rev. 4/12

Alternate Lubricants & Fluids Chart

Crown 2011 PF25240-5 Rev. 4/12 WP3015/3020 Models M1.0-04.0-054