C Model No.

Serial No.

SP 3000 Series
Service & Parts Manual

Crown 1995 PF10601-0GB Rev. 8/04 Printed in U.S.A.

 Crown Gabelstapler GmbH Crown Equipment Crown Lift Trucks Ltd.
Kronstadter Straße 11 Mervue Fishponds Road
81677 Munich Galway Wokingham,Berkshire, RG412J
Germany Ireland England
Tel: +49/89/93002-0 Tel: +353/91/706100 Tel: +44/118/979 2772
Fax: +49/89/93002-133 Fax: +353/91/751125 Fax: +44/118/977 0023

Service Policy and Warranty

Seller warrants that each Crown Machine manufactured by it shall be free from defects in material and workmanship. Seller's sole
obligation under this warranty shall be limited to making good, FOB seller's factory, any part of its product which, under normal and proper
use and maintenance, proves defective in material and workmanship within one hundred eighty (180) days after delivery to buyer,
provided that notice of any such defects and satisfactory proof thereof is promptly given by the buyer to the seller, and thereafter, such
part is returned to seller, with transportation charges prepaid, and seller's examination proves such part to have been defective.

This warranty does not apply in respect of damage to any product or accessory or attachment thereof, caused by overloading or other
misuse, neglect or accident nor does this warranty apply to any product, or accessory or attachment thereof, which have been repaired
or altered by other than the seller or its authorized representative in any way, which in the sole judgment of the seller affects the
performance, stability or purpose for which it was manufactured.

Improvements
Crown Equipment is constantly striving to improve its equipment. Change in design and improvement will be made whenever the
manufacturer believes the performance or operation of the equipment will be improved, with no obligation to incorporate any such
improvement in any equipment which has been shipped or is in service.

HOW TO ORDER SERVICE PARTS

To obtain fast, efficient service when ordering repair parts for your Crown Material Handling Equipment,
please follow this simple procedure:

1. Address all orders to your local Crown dealer.

2. Specify model and serial number of truck, which is shown on the metal serial number plate.
3. List the quantity needed.
4. List the part number and description, as shown in this Service Manual.
5. Show billing and shipping address.
6. Suggest fastest routing.

Your authorized Crown dealer stocks a large number of standard service parts. In addition, he has a
factory-trained Service Department to serve you.

Our Local Crown Dealer Is

NAME
ADDRESS

TELEPHONE

The information in this manual is the latest available at the time of printing for the unit with which it was
shipped. Should there be any variation due to vendor changes or special options on your unit, contact
your Crown Dealer or Crown at the above address.

Crown 1977 PF-3-451 Rev. 7/98 Printed in U.S.A.

 SP 3000 INDEX

This index is used for all SP 3000

SP 3000 Revision Title models from October 1, 2000 Page Number
TL TT No. - Date

X X Introduction ITD–7530–004

X X 02 - 12/01 General Maintenance MA–04.5–001

X X Lifting & Blocking Points MA–07.2–100

SECTION M1 LUBRICATION AND ADJUSTMENT

X X 13 - 9/02 Lubrication and Adjustment M1.0–04.0–001

X X Lubrication and Adjustment M1.0–7530–001
– General M1.0–7530–001
– Component Accessibility M1.0–7530–001
– Lubrication, Inspection & Adjustment Charts M1.0–7530–003
X X Lubrication and Adjustment M1.0–7530–200
X X Componentry M1.0–7532–050
X X Skid Inspection M1.5–7330–001
X X 03 - 11/02 Torque Values M1.9–14.0–001

SECTION M2 HYDRAULIC MAINTENANCE

X X 01 - 4/03 Hydraulics M2.0–7530–001

– Hydraulic Circuits M2.0–7530–002
– Reservoir M2.0–7530–007
– Hydraulic Lines and Fittings M2.0–7530–007
– Filter M2.0–7530–007
– Drift Test M2.0–7530–008
X X 03 - 1/02 Hydraulic Schematic Symbols M2.1–00.0–001
X X Pump Lift M2.1–10.0–001
– Oil Seal Removal & Replacement M2.1–10.0–001
– Disassembly & Assembly M2.1–10.0–002
– Parts Inspection M2.1–10.0–002
– Start-up Procedure M2.1–10.0–004
X X Manifold Lift/Lower M2.4–7530–001
– Relief Valve Operation & Adjustment M2.4–7530–001
X X Accumulator M2.6–7530–001
– Precharging M2.6–7530–001
X X Troubleshooting Chart M2.9–7530–001

SECTION M3 DRIVE UNIT MAINTENANCE

X X 01 - 1/01 Drive Unit M3.0–7330–001

– Drive Tire Replacement M3.0–7330–001
– Lubrication M3.0–7330–001
– Drive Unit Removal & Installation M3.0–7330–003
X X 01 - 5/95 Drive Unit Repair/Rebuild M3.0–1430–050
– Component Overview M3.0–1430–050
– Removing & Installing Axle Seal M3.0–1430–051
– Drive Unit Disassembly M3.0–1430–052
– Drive Unit Assembly M3.0–1430–057

5474

Crown 1995 PF10608-1 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–200 IDX–7530–200
 SP 3000 INDEX

SP 3000 Revision Title Page Number

TL TT No. - Date

SECTION M4 ELECTRICAL MAINTENANCE

X X 01 - 1/00 Fuses M4.0–7330–040

X X 01 - 1/97 Encoders M4.0–7330–080
– Steering Feedback Encoder M4.0–7330–080
X X Control Cables M4.0–7530–060
– Control Cable Tension Device M4.0–7530–060
– Cable Routing M4.0–7530–060
X X Relays M4.0–7530–110
X X Switches M4.0–7530–232
X X 01 - 5/95 Electrical Wiring M4.1–1430–001
– Wiring Color Codes M4.1–1430–001
– Power Cables M4.1–1430–001
– Symbols M4.1–1430–002
X X 06 - 6/02 Transistor Controller M4.2–7330–001
– Basics of Circuit Operation M4.2–7330–001
– Control Features M4.2–7330–003
– General Maintenance Instructions M4.2–7330–005
– Component Testing M4.2–7330–005
X X 03 - 7/00 Transistor Controller Troubleshooting M4.2–7330–400
X X 02 - 11/02 Truck Management Module TMM M4.2–7330–500
– Over Temperature Sensors M4.2–7330–501
– Brushwear Sensors M4.2–7330–501
X X Tune-Up M4.2–7530–205
– Service Terminal Operation M4.2–7530–205
– Function Adjustments For Truck Application M4.2–7530–207
X X Event Codes M4.2–7532–600
X X 01 - 4/95 Display Module and Steering Module M4.3–7330–100
– Power ON LED's M4.3–7330–101
– Service LED's M4.3–7330–101
– Torque Requirements M4.3–7330–101
X X Wire Guidance M4.3–7330–550
X X Traction Speed and Direction Sensor M4.3–7330–600
X X Line Driver Output M4.3–7330–702
X X 01 - 2/02 Truck Considerations M4.3–7330–802
X X Electronic System M4.3–7530–020
– Power Up M4.3–7530–022
– Brake Release M4.3–7530–024
– Traction M4.3–7530–025
– Raise M4.3–7530–027
– Lower M4.3–7530–028
– Manual Steering M4.3–7530–029
– Automatic Guidance Steering M4.3–7530–030
– Voltages, Speed Limits & Braking Force Chart M4.3–7530–031

Crown 1995 PF10608-2 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–201 IDX–7530–201
 SP 3000 INDEX

SP 3000 Revision Title Page Number

TL TT No. - Date

X X 02 - 11/02 Contactor 1A 110613-001, P1 & P2 110613-003 M4.4–04.2–001

– Inspection M4.4–04.2–001
– Component Replacement M4.4–04.2–002
X X 01 - 8/94 Contactor F & R 116794-001 M4.4–6535–001
– Inspection M4.4–6535–001
– Component Replacement M4.4–6535–002
X X 01 - 2/98 Contactor ED 118396 M4.4–7330–001
– Inspection M4.4–7330–001
– Component Replacement M4.4–7330–002
X X Steering Feedback Assembly M4.5–7330–100
X X Control Module M4.5–7530–001
– Access M4.5–7530–001
– Troubleshooting M4.5–7530–001
– Adjustments M4.5–7530–002
– Component Replacement M4.5–7530–003
X X 02 - 6/96 Battery M4.6–7530–001
– Safety Rules M4.6–7530–001
– Checking M4.6–7530–001
– Care M4.6–7530–002
– Charging M4.6–7530–003
– Removal M4.6–7530–004
– Installation M4.6–7530–005
– Cleaning M4.6–7530–006
– Troubleshooting M4.6–7530–006
X X Motor Information Chart M4.7–7330–001
– Traction M4.7–7330–001
– Lift M4.7–7330–002

SECTION M5 BRAKE MAINTENANCE

X X Brakes M5.0–7530–009
– Air Gap Adjustment M5.0–7530–010
– Stopping Distance Adjustment M5.0–7530–011
– Manual Release M5.0–7530–012
– Rotor and Brake Pad Replacement M5.0–7530–012
– Brake Assembly M5.0–7530–013
– Troubleshooting M5.0–7530–014

SECTION M6 STEERING MAINTENANCE

X X Steering M6.0–7530–001
– Steering Direction M6.0–7530–001
– Steering Wheel Direction Indicator M6.0–7530–001
– Steering Wheel Adjustment M6.0–7530–002
– Steering Gearbox M6.0–7530–002

Crown 1995 PF10608-3 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–202 IDX–7530–202
 SP 3000 INDEX

SP 3000 Revision Title Page Number

TL TT No. - Date

SECTION M7 MAST MAINTENANCE

X X Mast M7.0–7530–001
– General M7.0–7530–001
– Shim Basics M7.0–7530–001
X - – Mast Roller Removal TL Mast M7.0–7530–003
- X – Mast Roller Removal TT Mast M7.0–7530–004
– Shim Measurements (Tolerances) M7.0–7530–007
– Mast Testing (Assembled) M7.0–7530–008
– Flaking M7.0–7530–008
– Shim Removal M7.0–7530–008
– Mast Removal M7.0–7530–009
– Mast Reassembly M7.0–7530–010
X X 06 - 12/01 Lift Chain M7.5–18.0–001
– Inspection M7.5–18.0–001
– Lubrication M7.5–18.0–003
– Replacement M7.5–18.0–004
X X 01 - 1/00 Fork Inspection Lifting Fork M7.8–04.2–001
– Abrasion M7.8–04.2–001
– Overloading M7.8–04.2–002
– Fatigue M7.8–04.2–003
– Bent or Twisted Forks M7.8–04.2–003
– Hanger M7.8–04.2–003
X X Fork Inspection M7.8–07.2–001
– Abrasion M7.8–07.2–001
– Overloading M7.8–07.2–003
– Fatigue M7.8–07.2–003
– Bent or Twisted Forks M7.8–07.2–003
– Hanger M7.8–07.2–003

SECTION M8 CYLINDER MAINTENANCE

X X Cylinder Repair M8.0–7530–001

– General M8.0–7530–001
– Inspection M8.0–7530–002
– Disassembly M8.0–7530–002
– Accessing Rod Packing M8.0–7530–003
– Rod Packing Replacement M8.0–7530–003
– Mast Cylinder Removal M8.0–7530–005
X X – Lifting Fork Cylinder Removal M8.0–7530–005
- X – Free Lift Cylinder Removal M8.0–7530–006
– Free Lift, Mast & Lifting Fork Cylinder Assembly M8.0–7530–006
– Free Lift, Mast & Lifting Fork Cylinder Installation M8.0–7530–006

Crown 1995 PF10608-4 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–203 IDX–7530–203
 SP 3000 INDEX

SP 3000 Revision Title Page Number

TL TT No. - Date

SECTION M9 PLATFORM MAINTENANCE

X X 01 - 9/00 Platform M9.0–7530–001

– Floormat Replacement M9.0–7530–001
– Safety Shield Replacement M9.0–7530–001
– Forks M9.0–7530–002
– Pallet Grab M9.0–7530–003
– Operator Compartment Gates M9.0–7530–004
– Operator Egress System M9.0–7530–005
– Shim Basics M9.0–7530–006
X - – Platform Removal & Shimming TL Mast M9.0–7530–006
- X – Platform Removal & Shimming TT Mast M9.0–7530–009

SECTION M10 GLOSSARY

X X 01 - 5/03 Glossary M10–7530–015

WIRING DIAGRAMS

X X Wiring Diagram Introduction DIA–ITD–001

X X 01 - 4/03 Wiring Diagram Index DIA–7530–035

HYDRAULIC SCHEMATICS

X X 04 - 4/97 Hydraulic Schematic HYD–7330–001

SECTION 1 POWER UNIT PARTS

X X Power Unit 01.0–7532–001

X X Battery 01.2–7532–001

SECTION 2 HYDRAULIC PARTS

X X Hydraulic System Power Unit One Speed Lift 02.0–7332–001

X X Hydraulic System Power Unit Two Speed Lift 02.0–7332–050
X X Hydraulic System Mast 02.0–7530–104
X X Hydraulic System Power Unit One Speed Lift - Lifting Fork 02.0–7530–504
X X Hydraulic System Power Unit Two Speed Lift - Lifting Fork 02.0–7530–554
X X Hydraulic System Mast - Lifting Fork 02.0–7530–604
X X 01 - 3/03 Hydraulic System Platform Lifting Fork 02.0–7530–700
X X Pump Lift 02.1–07.3–002
X X 03 - 3/99 Motor Pump 02.2–07.3–001
X X 01 - 3/99 Motor (with sensors) Pump 02.2–7330–050
X X 03 - 6/99 Manifold One Speed Lift 02.4–7330–001
X X 03 - 6/99 Manifold Two Speed Lift 02.4–7330–052
X X 03 - 6/99 Manifold One Speed Lifting Fork 02.4–7530–500
X X 03 - 6/99 Manifold Two Speed Lifting Fork 02.4–7530–552

Crown 1995 PF10608-5 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–204 IDX–7530–204
 SP 3000 INDEX

SP 3000 Revision Title Page Number

TL TT No. - Date

SECTION 3 DRIVE UNIT PARTS

X X Drive Unit 03.0–7330–003

X X 01 - 9/02 Drive Unit Lubrication System 03.0–1452–200
X X 01 - 10/94 Motor Drive (6.7 in. [170 mm] dia.) 03.1–7330–001
X X 01 - 10/94 Motor Drive (7.5 in. [190 mm] dia. with sensors) 03.1–7330–050
X X Tire Drive 03.2–7530–001

SECTION 4 ELECTRICAL PARTS

X X Electrical Components Power Unit 04.0–7532–001

X X Traction Panel 04.1–7530–003
X X 01 - 9/02 Transistor Panel 04.2–7330–003
X X Wire Guide Module 04.3–7330–502
X X 01 - 4/02 Distribution Panel 04.3–7530–001
X X 01 - 10/00 Lift/Power Panel 04.3–7530–100
X X 02 - 6/03 Line Driver 04.3–19.0–550
X X 08 - 11/02 Contactor 1A 04.4–04.2–020
X X 06 - 9/02 Contactor F/R 04.4–06.5–250
X X 11 - 10/02 Contactor P1, P2 04.4–6535–050
X X Contactor F/R 04.4–7330–002
X X 04 - 10/02 Contactor ED 04.4–7330–050
X X Control Module Front 04.6–7330–003
X X Control Module Back 04.6–7530–020
X X 02 - 6/02 Control Lifting Fork 04.6–7530–500
X X 01 - 5/95 Switch Panel 04.8–7330–100
X X 01 - 1/02 Connectors 04.8–7330–172
X X 01 - 5/02 Steering Feedback 04.8–7330–200
X - Control Cable TL 04.8–7530–001
- X Control Cable TT 04.8–7530–027
X X Limit Switches 04.8–7530–058
X X Two Handed Control 04.8–7530–450
X X Flashing Light 04.9–7330–001
X X 01 - 5/03 Overhead Console 04.9–7330–052
X X Freezer/Corrosion Components Power Unit 04.9–7330–100
X X Freezer/Corrosion Components Control Module 04.9–7530–150
X X Freezer/Corrosion Components Mast & Platform 04.9–7530–202
X X 09 - 10/02 Strobe Light 04.9–10.0–550

SECTION 5 BRAKE PARTS

X X Brake Pedal 05.1–7330–001

X X Brake 05.3–7332–001

SECTION 6 STEERING PARTS

X X 02 - 4/03 Steering Command 06.0–7330–001

X X 03 - 9/02 Steering Gearbox 06.0–7330–102
X X Steer Motor 06.2–7330–003

Crown 1995 PF10608-6 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–205 IDX–7530–205
 SP 3000 INDEX

SP 3000 Revision Title Page Number

TL TT No. - Date

SECTION 7 MAST PARTS

X - Mast TL 07.1–7530–001
- X Mast TT 07.2–7530–003
X X Load Wheel 07.4–7530–001
- X Yoke TT 07.5–7530–003
X - Lift Chain TL 07.6–7530–005
- X Lift Chain TT 07.6–7530–054
X X Chain Limit Switches 07.7–7530–001

SECTION 8 CYLINDER PARTS

X X Cylinder Mast TT & TL 08.1–7530–003

- X Cylinder Free Lift TT 08.3–7530–003
X X Cylinder Lifting Fork 08.9–07.2–003

SECTION 9 PLATFORM PARTS

X X 01 - 2/03 Pallet Grab 09.0–7330–202

X X Fork 09.0–7330–250
X X Platform Operator Side 09.0–7530–003
X - Platform Mast Side & Under Side (TL) 09.0–7530–052
- X Platform Mast Side & Under Side (TT) 09.0–7530–104
X X 01 - 9/95 Gate 09.0–7530–150
X X 02 - 6/96 Rear Gate 09.1–7530–250
X X Platform Lifting Fork 09.1–7530–501

SECTION 10 ACCESSORIES

X X Aisle Guide Wheels 10.0–7530–003

X X Aisle Guide Wheels Low Profile 10.0–7530–052
X X Labels and Decals 10.9–7532–001

SECTION 11 SPECIFICATIONS

X X Service Specifications 1.25 11.0–7530–004

X X Service Specifications 1.0 11.0–7530–053

Crown 1995 PF10608-7 Rev. 6/03 Printed in U.S.A.

04 REV. 6/03
IDX–7530–206 IDX–7530–206
 GENERAL MAINTENANCE INSTRUCTIONS

WARNING
TO PREVENT SERIOUS RISK OF INJURY TO
WARNING
YOURSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS

Power industrial trucks may become hazardous if adequate 8. Brakes, steering mechanisms, control mechanisms,
maintenance is neglected. Therefore, adequate mainte- lift overload devices, guards, and safety devices shall
nance facilities, trained personnel and procedures should be be inspected regularly and maintained in a safe oper-
provided. ating condition.

Maintenance and inspection shall be performed in conform- 9. Capacity, operation and maintenance instruction plates
ance with the following practices: or decals shall be maintained in legible condition.

1. A scheduled planned maintenance, lubrication, and 10. All parts of lift mechanisms shall be inspected to
inspection system should be followed. maintain them in safe operating condition.

2. Only qualified and authorized personnel shall be per- 11. All hydraulic systems shall be regularly inspected and
mitted to maintain, repair, adjust and inspect truck. maintained in conformance with good practice. Cylin-
ders, valves, and other similar parts shall be checked
3. Before leaving the truck— to assure that “drift” has not developed to the extent
a. Stop truck. that it would create a hazard.
b. Fully lower the load engaging means.
c. Place directional controls in neutral. 12. Batteries, motors, controllers, limit switches, protective
d. Apply the parking brake. devices, electrical conductors, and connections shall
e. Turn off power (power disconnect). be maintained in conformance with good practice.
f. Remove key. Special attention shall be paid to the condition of
g. Block the wheels if truck is on an incline. electrical insulation.

13. Trucks shall be kept in a clean condition to minimize fire

4. Before working on truck—
hazards and facilitate detection of loose or defective
a. Raise drive wheel free of floor or disconnect power
parts.
sources.
b. Use chocks or other positive positioning devices.
14. Modifications and additions which affect capacity and
c. Block load engaging means, inter masts, or chassis
safe truck operation shall not be performed by the
before working under them.
customer or user without manufacturers prior written
d. Operation to check performance of truck or attach-
approval. Capacity, operation and maintenance plates
ments shall be conducted in an authorized safe
or decals shall be changed accordingly.
clearance area.
15. Care shall be taken to assure that all replacement parts
5. Before starting to operate truck— are interchangeable with the original parts and of equal
a. Be in operating position. quality to that provided in the original equipment.
b. Apply brake.
c. Place directional control in neutral. 16. Be sure that any equipment added to the truck (termi-
d. Before operating truck, check functions of lift systems, nal, fan, clipboard, etc.) is positioned so that it does not
directional control, speed control, steering, warning block your vision or interfere with safe and efficient
devices, brakes and any attachments if any used. operation of the truck.

6. Avoid fire hazards and have fire protection equipment For further information pertaining to operating and mainte-
present. Do not use an open flame to check level, or for nance procedures, refer to F.E.M. safety code - Power
leakage of electrolyte and fluids or oil. Do not use open Industrial Truck (section 4).
pans of fuel or flammable cleaning fluids for cleaning For copies send to:
parts. F.E. M .
10 Avenue Hoche
7. Keep shop well ventilated, clean and dry. 75382 Paris Cedex 08 France 1968

Crown 1980 PF6285-Int. Rev. 12/01 Printed in U.S.A.

02 REV. 12/01
MA–04.5–001 MA–04.5–001
 MAINTENANCE
5537
LIFTING & BLOCKING POINTS
SP36, SP42 & SP3000 SERIES TRUCKS

NOTES:

Move Truck to a Secure Non Traffic

Maintenance Area With a Level Floor

No Load on Forks
Side Disconnect Battery

Hydraulic Jack - Capacity 8000 LBS.

Crown P/N: 122599
Collapsed Height Minimum: 2.25 in. (57 mm)
Raised Height Maximum: 16 in. (405 mm)

Jack Stand - Capacity 10,000 LBS.

Commercially Available
! WARNING
Do Not Raise Platform
More Than 6.0 in. Steer Wheel
(152 mm) From Floor

Raise Platform
3 to 6 in.
(76 to 152 mm)
Load From Floor
Wheels
Hard
Wood
Block

! WARNING
Do Not Raise Load Wheels
More Than 0.5 in. (13mm)
from Floor to Position
Hard Wood Block Wheel Chock
Both Load Wheels

Set Jack Stand

Height as Required
Not to Exceed
!WARNING 16 in. (405 mm)
Before Raising Rear
of Truck Check That Locate Jack Stands
Jack Does Not Interfere With and Jack on Truck Skirt
Wire Guidance Sensors
961201 5099
Crown 1996 PF-11032 Printed in U.S.A.

MA–07.2–100 MA–07.2–100
 C INTRODUCTION

This manual is intended for the service mechanic who is seeking information about maintenance and service replacement
parts.

OPERATOR INSTRUCTIONS

This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each truck.
Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble-
free operation of your Crown Lift Truck. For SP 3000 Series operator instructions, refer to Crown publication, "SP3000
Operator Manual" (MOSPGB6/95).

DRIVER TRAINING

Crown has available a complete series of Driver Training programs, in two parts concerning basic safety rules and operating
characteristics of your truck. To obtain this information ask your Crown Dealer about "Its up to You" and "SP3000 Operator
Manual".

SERVICE TRAINING

Complete Service Training is available to the lift truck mechanic covering all Crown Lift Trucks, wire guidance, hydraulic and
electrical systems. To obtain more information concerning service training, contact your Crown Dealer.

REPLACEMENT PARTS

When ordering replacement parts from this manual, always specify, along with the part number, the model, serial number
and data number of the truck. This information will further enable us to give correct, fast and efficient service.

For SP 3000 Series capacities, technical information and dimensional specifications, please refer to the following sales
literature:
SP 3000 Series Literature VFB-SP-GB
SP 3000 Series Specifications VFS-SP3012/22-GB & VFS-SP3011/21-GB

Copies of publications can be obtained from your Crown dealer or by writing to:

Crown Gabelstapler GmbH Crown Lift Trucks Ltd. Crown Equipment Ltd.
Moojacher Str. 52 Fishponds Rd Galway,
80809 Munich Wokingham, Ireland
Germany Berkshire RG 11 2 JT Tel. +353 91 706100
Tel. +49 89 93 0020 England Fax. +353 91 751125
Fax +49 89 93002133

This manual is arranged according to major sections and covers maintenance and replacement parts. The descriptions are
as follows:

MAINTENANCE REPLACEMENT PARTS

SECTION DESCRIPTION SECTION DESCRIPTION

M1 Lubrication and Adjustments 1 Power Unit

M2 Hydraulics 2 Hydraulic System and Components
M3 Drive Unit 3 Drive Unit and Components
M4 Electrical 4 Electrical Components
M5 Brake 5 Brake Assemblies and Brake Systems
M6 Steering 6 Steering System and Components
M7 Mast and Main Frame 7 Main Frame and Mast Assemblies
M8 Cylinder 8 Cylinders
M9 Platform 9 Platform Assembly
030501
M10 Glossary 10 Accessories 5351/5539

Crown 2003 PF13562-1 Printed in U.S.A.

ITD–7530–004 ITD–7530–004
 C INTRODUCTION

The data plate for the SP 3000 Series

truck is located on the platform and
includes a model number and truck
data number. From these two num-
bers, you can identify truck model, se-
ries, series updates, determine perfor-
mance, capacity and specific truck data.
The next two pages explain the model
& truck data numbering system.

Lower Right Corner of

Mast Side of Platform

10856

MODEL NUMBER EXAMPLE

Series Update
Significant change(s) to the product
that would not merit a new series
number (generation).
*Capacity
Image Generator 1.25 = 1250 kg.
SP - Stockpicker 1.0 = 1000 kg.

SP 3011-1.25

Series Performance 1.25/1.0

Major technical and design changes 11/12 = Single speed raise &
making the product a new and im- lower, 2.6 kW drive motor
proved generation. 21/22 = Two speed raise & lower,
2.6 kW drive motor
(3.0 kW Optional)
21/22H= Two Speed raise & lower
High Lift Only
3.0 kw drive motor

Example of the model number shown above (SP 3011-1.25) is a SP 3000 Series truck. It's equipped with single speed raise
& lower, 2.6 kW drive motor and 1250 kg. capacity.

*Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the
overhead guard.
Crown 2003 PF13562-2 Printed in U.S.A.

ITD–7530–005 ITD–7530–005
 C INTRODUCTION

The truck data number provides you and your Crown dealer with a wealth of information to ensure selection of proper parts
for your Crown truck. You may simply provide this number to your Crown dealer, or use the following breakdown if selecting
your own part numbers or service information from this manual.
TRUCK DATA NUMBER EXAMPLE
Wire Guidance
(-) = Standard Drive Tire
W = Wire Guidance (--) = Standard
NM = Non-marking
DS = Diagonal (22%) Siped
Straddle Width
RS = Razor Siped
1070 mm
1220 mm
1370 mm
1420 mm Switch Options
1525 mm 1 = Standard
2 = Fork O.R.
3 = Fork O.R., Zone Select
Mast Type 4 = Work, Dome, Fan
TT = Telescopic Triple Stage 5 = Fork O.R., Work, Dome,
TL = Telescopic Limited Free Lift Fan
6 = Fork O.R., Zone Select,
Work, Dome, Fan
-TT495510701215-FNM10709 7 = Work, Dome, Fan, Spot
Standard/Special Truck 8 = Fork O.R., Work, Dome,
(-) = Standard Fan, Spot
S = Special 9 = Fork O.R., Zone Select,
Work, Dome, Fan, Spot
Lift Height
1.25 TL Mast 1.25 TT Mast

3455 mm 4955 mm Platform Width

3760 mm 5335 mm 1070 mm
4370 mm 6095 mm 1220 mm
4930 mm 7010 mm 1370 mm
5435 mm 7470 mm 1525 mm
7925 mm 1625 mm
8385 mm
8840 mm
9300 mm
Freezer Condition Option
Lift Height (-) = Standard
1.0 TL Mast 1.0 TT Mast F = With Freezer Condition
C = Corrosion Condition
4215 mm 5715 mm
4520 mm 6095 mm
5130 mm 6860 mm
5690 mm 7770 mm
Aisle Guide Wheel Width
6200 mm 8230 mm
(-----) = Standard
8685 mm
1156 thru 1810 mm in 6.5 mm Increments
9145 mm
9600 mm
An example of a truck data number shown above is a standard truck with telescopic triple stage mast, 4955 mm lift
height, straddle width of 1070 mm, aisle guide wheel width of 1215 mm, without wire guidance, with freezer condition,
non-marking drive tire, platform width of 1070 mm, with fork override switch, zone select switch, work light, dome light,
fan and spot light.
Crown 2003 PF13562-3 Printed in U.S.A.

ITD–7530–006 ITD–7530–006
 C LUBRICATION AND ADJUSTMENT

To obtain maximum life of any industrial equipment, a well Before performing maintenance to any unit, it should be
planned maintenance program (PM), performed by qualified taken to an area set aside for maintenance or a section
technical personnel should be followed. In conjunction with, where there is adequate space to perform required work.
and an integral part of, any planned maintenance program This is a must to insure the safety of others and to insure that
should be daily operator input. Operator involvement can proper maintenance is performed to the unit.
greatly reduce truck down time, assist in determining planned
maintenance (PM) schedules and ultimately save money. If desired, padded packs of this checklist (OF-3772) are
For these reasons, Crown recommends a checklist similar to available through your Crown dealer.
the Operators Daily Checklist shown below.

Operators
Daily Checklist
Model Serial No. Week beginning 20

This check must be made by the truck operator daily at the start of the shift. Certain items listed are Shift No.
not included on some models. Check all items applicable to unit noted above.
Truck No.
Check ( ) appropriate box OK OK Needs repair or adjustments (give details in comments section)

MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY

DAMAGE
bent, dented or broken parts OK OK OK OK OK OK OK
LEAKS
drive unit, brakes, hydraulics OK OK OK OK OK OK OK
TIRES & WHEELS
drive wheels, load wheels, casters OK OK OK OK OK OK OK
FORKS
in place, properly secured OK OK OK OK OK OK OK
VISUAL CHECKS

CHAINS, CABLES & HOSES

in place OK OK OK OK OK OK OK
HOUR METER
operating OK OK OK OK OK OK OK
BATTERY
water level, vent caps in place, cleanliness OK OK OK OK OK OK OK
BATTERY CONNECTOR
cracked, burnt, tight fitting OK OK OK OK OK OK OK
GUARDS
overhead, load backrest, battery retainer OK OK OK OK OK OK OK
SAFETY DEVICES flashing lights, indicator lights, safety shield
operator harness, warning labels, etc. in condition as equipped OK OK OK OK OK OK OK
HORN
sounds OK OK OK OK OK OK OK
STEERING
no binding, no excessive play OK OK OK OK OK OK OK
TRAVEL CONTROLS
all speed ranges, forward & reverse, no unusual noise OK OK OK OK OK OK OK
HYDRAULIC CONTROLS raise & lower, tilt forward & rearward
reach in & out, sideshift right & left, etc., no unusual noise OK OK OK OK OK OK OK
OPERATIONAL CHECKS

BRAKES stop truck within required distance, work smoothly,

brake override functions OK OK OK OK OK OK OK
PARKING BRAKE
seat, hand, foot OK OK OK OK OK OK OK
BATTERY CHARGE
discharge meter in full green or 75% charge after raising forks OK OK OK OK OK OK OK
POWER DISCONNECT
cuts off all electric power OK OK OK OK OK OK OK
ATTACHMENTS
function properly, no unusual noise OK OK OK OK OK OK OK
LIMIT SWITCHES
travel limit, lift limit, tilt limit, etc. OK OK OK OK OK OK OK
HOUR METER READING
OPERATOR’S INITIALS
SUPERVISOR’S OK

- If the truck is found to be in need of repair or in any way unsafe, or contributes to an unsafe condition, the matter shall be reported immediately to the designated
authority, and the truck shall not be operated until it has been restored to safe operating condition.
If during operation, the truck becomes unsafe in any way, the matter shall be reported immediately to the designated authority, and the truck shall not be operated until it has
been restored to safe operating condition.
Do not make repairs or adjustments unless specifically authorized to do so.

OF3772 Rev. 5/00 Printed in U.S.A.

12762
10549

Crown 1987 PF7886-1 Rev. 7/05 Printed in U.S.A.

15 REV. 7/05
M1.0–04.0–001 M1.0–04.0–001
 C LUBRICATION AND ADJUSTMENT

The following is a list of lubricants and maintenance products recommended when doing Planned Maintenance on Crown
Lift Trucks.

CHART 1 — LUBE IDENTIFICATION

TYPE OF LUBRICANT PART NO. PACKAGE QTY.
A. Gear Lube 80W-90 (Typical) 063002-003 1 Quart
Automatic Transmission Fluid
AA. 063001-010 1 Quart
Freezer Applications 32° F (0° C) and Below
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 Temp.)
063002-046 (40) 14.5 oz. Cartridges
C. Oil (SAE 40)
063001-001 1 Gallon
D. Hydraulic Oil
063001-015 (6) 1 Gallon
* DD. Hydraulic Oil (Low Temp.) 063001-006 1 Gallon
DDD. Hydraulic Oil (Standard for Blending) 063001-021 1 Gallon
063002-024 14.5 oz. Cartridge
E. Channel Grease
063002-022 35 lb. Pail
063002-024 14.5 oz. Cartridge
F. Gear Grease
063002-022 35 lb. Pail
363107-001 15 oz. Can
Chain and Cable Lube
363107-012 (12) 15 oz. Cans
G.
363115-001 12 oz. Can
Premium Chain and Cable Lube
363115-012 (12) 12 oz. Cans
H. Rubber & Vinyl Dressing
063002-039 1 lb.
I. Grease (Lift Pump Coupling)
063002-040 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
M. Silicon Grease (Clear) 063002-020 5.3 oz. Tube
363102-001 15 oz. Can
Brake & Parts Cleaner
363102-012 (12) 15 oz. Cans
363103-002 15 oz. Can
N. Low V.O.C. Brake & Parts Cleaner
363103-012 (12) 15 oz. Cans
363116-001 15 oz. Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 15 oz. Cans
* Trucks operated in below freezing temperatures must use Low Temp. Hydraulic Oil & Grease.

Crown 1987 PF7886-2 Rev. 7/05 Printed in U.S.A.

15 REV. 7/05
M1.0–04.0–002 M1.0–04.0–002
 C LUBRICATION AND ADJUSTMENT

CHART 1 — LUBE IDENTIFICATION (CONTINUED)

TYPE OF LUBRICANT PART NO. PACKAGE QTY.
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 20 oz. Can
R. Choke & Carburetor Cleaner
363109-012 (12) 20 oz. Cans
363106-001 10 oz. Can
S. Contact Cleaner
363106-012 (12) 10 oz. Cans
T. Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc

Crown 1987 PF7886-3 Rev. 7/05 Printed in U.S.A.

15 REV. 7/05
M1.0–04.0–003 M1.0–04.0–003
 MAINTENANCE

LUBRICATION AND ADJUSTMENT

GENERAL Component Accessibility

Before performing maintenance to the truck, move truck to For regular maintenance, access to various truck compo-
an area set aside for maintenance or where there is ad- nents is accomplished by removing covers, panels and/or
equate space to perform the required work. This is a must to doors. The following is a general explanation of what cover,
insure the safety of others and to insure that proper mainte- panel, etc. must be removed to allow for the most efficient
nance is performed. access when performing service and/or maintenance to
components. Refer to the illustrations in this section as an aid
in locating parts that require attention. More details are given
CAUTION in following sections on hydraulics, electrical, brakes, etc..
Be sure battery connectors are disconnected and
all wheels are chocked before proceeding. The top cover can be opened to allow access to battery
connector, battery cell caps, check battery condition, strobe
To obtain maximum life of any industrial equipment, a well light, additional mechanical and electrical components.
planned maintenance program should be followed. The
following information is intended to provide guidelines for The battery side covers can be removed to service and/or
proper lubrication intervals, and are according to hours of remove battery.
truck operation and/or a specific number of days or months.
These recommended figures should be used as an aid in The power unit doors can be opened to allow access to the
maintaining safe and efficient truck operation. Some operat- following: drive unit, traction panel, lift/power panel, drive
ing conditions will require more frequent checks and lubrica- motor, electric brake and related components, steer motor/
tion than listed. Applications with much dust or moisture will encoder and related components, lift pump(s) and motor(s),
require modification of the schedule to fit that particular hydraulic reservoir, filter, strainer and related components.
application.
Located under the platform are the horn, pallet grab, fork
Only high grade lubricants and fluids should be used. Sources pins, hydraulic components (on SP3000-1.0) and associ-
of these lubricants may be from almost any of the oil ated parts.
companies; those listed below are typical and any lubricant
with equal specifications may be used. (See Chart 1-1 on The console on the platform when removed will allow access
page M1.0-04-002). to side-gate switches, steering command encoder, display
panel, terminal boards and associated platform electrical
On trucks equipped to operate in below freezing tempera- wiring.
tures, low temperature hydraulic oil must be used.
Located on the front side of the platform are the chain slack
switches, pallet grab linkage and limit switch(s).

The control module must be removed to gain access to

directional and lift switches, various control switches and
linkages.

Refer to the illustrations and charts in this section as a guide

for inspection and adjustment that may be necessary. This
information used with a Planned Maintenance Inspection
Report for Stockpickers available from your Crown dealer
will be very helpful to a good maintenance program.

950612 4590 - 40705

Crown 1995 PF-10603-1 Printed in U.S.A.

M1.0–7530–001 M1.0–7530–001
 MAINTENANCE

L-2
I-3

L-3
PLATFORM
FLOORBOARD

L-1
L-4

I-2
I-1 L-5
L-1
L-6

I-5 L-7
I-4

POWER
UNIT

I-5
L-8 I-7
L-7

I-6

3701 ILLUSTRATION 1-1

Crown 1995 PF-10603-2 Printed in U.S.A.

M1.0–7530–002 M1.0–7530–002
 MAINTENANCE

LUBRICATION CHART

LUBE 60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT TYPE QTY. 250 hr. 500 hr. 1000 hr. 2000 hr.

L1 Brake Pedal Guides C AR †

L2 Platform Gates C AR †
L3 Battery Cover Hinge C AR L
L4 Power Unit Door Hinges C AR †
L5 Battery Rollers B AR †
L6 Battery Restraint Threads B AR †
L7 Aisle Guide Wheels B AR L
L8 Load Wheel Axles B AR L

L = Lubricate † = Check Chg. = Change AR = As Required

See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity.
See Illustration 1-1 for Lubrication locations.

INSPECTION AND ADJUSTMENT CHART

60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT 250 hr. 500 hr. 1000 hr. 2000 hr.

I-1 Brake Pedal Switch †

I-2 Brake Pedal Mechanism †
I-3 Platform Gates and Switches †
I-4 Load Wheels †
I-5 Aisle Guide Wheels and Switches †
I-6 Skids †
I-7 Aisle Guide Skids †

† = Inspect and/or Adjust. See Illustration 1-1 for component locations.

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

CHART 1-3

Crown 1995 PF-10603-3 Printed in U.S.A.

M1.0–7530–003 M1.0–7530–003
 MAINTENANCE

TT
I-11 SHOWN L-9
I-8 I-12

L-9
I-9
! WA
This
brakes RN
truck
switch or does ING

I-13
Steerinis travel
Warn in not
vehicle
happenthe g the contro have
caution.
that may Tow
pushing
and an
l when
not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

YEL
GRNFAU
TP1 POWLT
ER
TP2

I-10

L-9 I-15
I-12

I-17

PART
OF
POWER
DRIVE LIFT I-14 UNIT
MOTOR PUMP
MOTOR
I-16

STEER
MOTOR

I-18 I-14

I-19

3702
ILLUSTRATION 1-2
Crown 1995 PF-10603-4 Printed in U.S.A.

M1.0–7530–004 M1.0–7530–004
 MAINTENANCE

LUBRICATION CHART

LUBE 60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT TYPE QTY. 250 hr. 500 hr. 1000 hr. 2000 hr.

L-9 Mast Channels, Collumn Rollers E AR †

L = Lubricate † = Check Chg. = Change AR = As Required

See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity.
See Illustration 1-2 for Lubrication locations.

INSPECTION AND ADJUSTMENT CHART

60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT 250 hr. 500 hr. 1000 hr. 2000 hr.

I-8 Battery Connector †

I-9 Battery †
I-10 Strobe Light/Flashing Light †
I-11 Lift Cylinders and Restraints †
I-12 Column Rollers - Mast †
I-13 Column Rollers - Platform †
I-14 Power Unit to Mast Bolts †
I-15 Forks †
I-16 Motor Brushes - Lift †
I-17 Motor Brushes - Drive †
I-18 Motor Brushes - Power Steering †
I-19 Hydraulic Lines, Fittings, Hoses †

† = Inspect and/or Adjust. See Illustration 1-2 for component locations.

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

CHART 1-4

Crown 1995 PF-10603-5 Printed in U.S.A.

M1.0–7530–005 M1.0–7530–005
 MAINTENANCE

I-24

I-23
L-10
I-21 L-11
I-25
I-22

TT
MAST
SHOWN

L-10
I-21
I-22

L-10
I-21

I-22

L-10
I-21
L-11
I-25

I-22
I-23

I-26

3703
ILLUSTRATION 1-3
Crown 1995 PF-10603-6 Printed in U.S.A.

M1.0–7530–006 M1.0–7530–006
 MAINTENANCE

LUBRICATION CHART

LUBE 60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT TYPE QTY. 250 hr. 500 hr. 1000 hr. 2000 hr.

L-10 Lift Chain G AR †

L-11 Pallet Grab Linkage C AR †

L = Lubricate † = Check Chg. = Change AR = As Required

See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity.
See Illustration 1-3 for Lubrication locations.

INSPECTION AND ADJUSTMENT CHART

60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT 250 hr. 500 hr. 1000 hr. 2000 hr.

I-21 Lift Chains †

I-22 Chain Anchors †
I-23 Chain Break and Slack Linkage †
I-24 Brake Friction Plates and Operation †
I-25 Pallet Grab Linkage and Operation †
I-26 Horn †

† = Inspect and/or Adjust. See Illustration 1-3 for component locations.

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

CHART 1-5

Crown 1995 PF-10603-7 Printed in U.S.A.

M1.0–7530–007 M1.0–7530–007
 MAINTENANCE

L-13
I-28
L-12

I-29
I-27
DISTRIBUTION I-27
PANEL

PART
OF
PLATFORM
! WA
This
brakes RN
truck
switch or does IN
Steeri is travel not
Warn
ng in the contro
vehicle have
G
happenthe
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
Tow
extreme
could n.

Drive

YE
GRL FA
TP N UL
PO T
1

I-27
WE
TP R
2
TP
3
TP
4
TP
8
TP
5
BR
P AK
RE/ N 11
E
MO
V.– 75 DU
98 LE

PART
TP
6
TP
7

A1
OF
MAIN
B+
A2
B-

I-27
LIFT/POWER FRAME
PANEL

I-29 I-30

L-17

L-18

L-14

L-15
I-31
I-32

L-16

3704 ILLUSTRATION 1-4

Crown 1995 PF-10603-8 Printed in U.S.A.

M1.0–7530–008 M1.0–7530–008
 MAINTENANCE

LUBRICATION CHART

LUBE 60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT TYPE QTY. 250 hr. 500 hr. 1000 hr. 2000 hr.

L-12 Steering Gearbox Oil Level A 1.6 pts. *Chg. Chg.

L-13 Steering Gears F AR †
L-14 Hydraulic Filter † *Chg. Chg.
L-15 Hydraulic Reservoir - Single Pump D 11.6 qt. † Chg.
Hydraulic Reservoir - Dual Pump D 15.4 qt. † Chg.
L-16 Hydraulic Strainer Chg.
L-17 Drive Unit Thrust Bearing B AR L
L-18 Drive Unit Fluid Level A 1.2 pts. † Chg.

L = Lubricate † = Check Chg. = Change AR = As Required

See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity.
See Illustration 1-4 for Lubrication locations.
* Change first time only as noted, thereafter check at 250 hr./60 da. intervals and change at longer interval as
noted.

INSPECTION AND ADJUSTMENT CHART

60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT 250 hr. 500 hr. 1000 hr. 2000 hr.

I-27 Contactor Tips †

I-28 Steering Gears and Sprockets †
I-29 Chain Slack/Break Switches †
I-30 Stop Blocks †
I-31 Drive Tire †
I-32 All Electrical Termination Points †

† = Inspect and/or Adjust. See Illustration 1-4 for component locations.

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

CHART 1-6

Crown 1995 PF-10603-9 Printed in U.S.A.

M1.0–7530–009 M1.0–7530–009
 MAINTENANCE

I-37
I-36

I-38

USA
MAIN
FRAME PART
OF
PLATFORM MAINFRAME
TT
LIMIT
SWITCHES
SHOWN
I-35
I-34

I-33 I-39

DISTRIBUTION
PANEL
BACK
OF
PLATFORM

!W
AR
Th
brais
ketruck
sw s or
NIN
War
veh
itc
Ste h is trave
n
eri in
do
es
ng the cotntr
l no
ha
G
olve
cauiclethe
hap
pen thatpus ma To
hing y no w wh
tion
. and an
to accor Po en
tow t wo sit
useiden

PART OF
ing
extrt cou rk. ionTow
eme ld .

Driv
e

MAIN
FRAME

I-40 I-41

3705 ILLUSTRATION 1-5

Crown 1995 PF-10603-10 Printed in U.S.A.

M1.0–7530–010 M1.0–7530–010
 MAINTENANCE

INSPECTION AND ADJUSTMENT CHART

60 da. 90 da. 6 mo. 12 mo.

INDEX COMPONENT 250 hr. 500 hr. 1000 hr. 2000 hr.

I-33 Limit Switches - Mast and Platform †

I-34 Travel and Lift Controls †
I-35 Power Disconnect †
I-36 Panel Indicator Lights †
I-37 Panel Switches †
I-38 Cable Tension Devices †
I-39 Control Cables and Guides †
I-40 Mast Cushion Mechanisms †
I-41 Tow Switch †

† = Inspect and/or Adjust. See Illustration 1-5 for component locations.

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

CHART 1-7

Crown 1995 PF-10603-11 Printed in U.S.A.

M1.0–7530–011 M1.0–7530–011
 C COMPONENTRY

1A BRES1, BRES2
Bypass Contactor Battery Restraint Switch

Location: traction panel. Location: power unit skirt.

Purpose: provide full battery voltage to traction motor. Purpose: monitor presence of battery retainer/side
cover and disable travel if battery retainer is
Data: positive voltage provided directly from bat- not present.
tery, negative voltage controlled by MRC1.
Data: wired normally open, held closed when bat-
Adjustment: none required. tery retainer/side cover is in place.

ACCUMULATOR Adjustment: none required.

Location: front, lower right side of power unit BRK1

Brake
Purpose: shock absorber for lift/lower hydraulic sys-
tem. Location: traction motor.

Data: precharge 3445 kPa. See section M2.6 for Purpose: provide braking force to traction motor to stop
charging procedures truck and prevent movement of parked ve-
hicle.
Adjustment: none required.
Data: brake module release via operator request,
ALM1 spring applied.
Status Alarm
Adjustment: refer to section M5.0.
Location: steering command assembly.
BRS1, BRS2
Purpose: draws operator attention to changing truck Brake Switch
status.
Location: platform below floorboard.
Data: controlled by steering module.
Purpose: BRS1 allows operator to release or apply
Adjustment: none required. brake. BRS2 is actuated when brake pedal is
released there by allowing operation of raise/
BRAKE MODULE lower circuits.

Location: lift/power panel. Data: wired normally open, held closed when op-
erator is depressing brake pedal.
Purpose: controls brake force via HTS1200, HTS2500,
HTS4500, K3, DTS1 and operator input from Adjustment: none required.
BRS1.

Data: brake module release via operator request,

spring applied.

Adjustment: refer to section M5.0.

030501 5834

Crown 2003 PF13605-1 Printed in U.S.A.

M1.0–7532–050 M1.0–7532–050
 C COMPONENTRY
10955

Steering Command
Assembly

ALM1
Status Alarm

Brake Pedal

Lift/Power
Panel
BRS1/BRS2
Brake Switch

YE
GR L
N FAUL
PO
TP W T
1 ER
TP
2
TP
3
TP
4

Brake
TP
8
TP
5
BR
AK
E
MO
DU
LE

TP

Module
6

BRES2
TP
7

Battery Restraint
Switch

! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g may the
caution.
that
pushing Tow l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

BRK1
1A A1
B+
A2
B-
T

C
Brake
Bypass Contactor
C
AC

Traction
Panel
A1
B
A2
B-

BRES1
Accumulator Battery Restraint
Switch

Crown 2003 PF13605-2 Printed in U.S.A.

M1.0–7532–051 M1.0–7532–051
 C COMPONENTRY

CHB4, CHB5 Connector Module

Chain Break Switches
Location: steering feedback assembly.
Location: top of mainframe.
Purpose: provides connection for steering module and
Purpose: prohibits lowering when mast chains break. steering feedback encoder.

Data: wired normally open, held closed as chains Data: not applicable.
maintain proper tension.
Adjustment: none required.
Adjustment: none required.
Crown PAC (not shown)
CHB6, CHB7 (TT Mast Only) Crown Program Analysis Cartridge
Chain Break Switches
Location: service tool.
Location: base of platform, mast side.
Purpose: software download.
Purpose: prohibits lowering when mast chains break.
Data: not applicable.
Data: wired normally open, held closed as chains
maintain proper tension. Adjustment: none required.

Adjustment: none required. CV1

Check Valve
CHS1, CHS2
Chain Slack Switches Location: lift/lower manifold.

Location: top of mainframe. Purpose: prevent back flow into pump P1.

Purpose: prohibits lowering when mast chains become Data: not applicable.
slack.
Adjustment: none required.
Data: wired normally open, held closed as chains
maintain proper tension. CV2
Check Valve
Adjustment: none required.
Location: lift/lower manifold (high speed lift/lower only).
CHS3, CHS4 (TT Mast Only)
Chain Slack Switches Purpose: prevent back flow into pump P1.

Location: base of platform, mast side. Data: not applicable.

Purpose: prohibits lowering when mast chains become Adjustment: none required.
slack.
CV3, CV4
Data: wired normally open, held closed as chains Check Valve
maintain proper tension.
Location: lift/lower manifold (high speed lift/lower only).
Adjustment: none required.
Purpose: prevent back flow into pump P2.

Data: not applicable.

Adjustment: none required.

Crown 2003 PF13605-3 Printed in U.S.A.

M1.0–7532–052 M1.0–7532–052
 C COMPONENTRY
10956
TT
Mast
CHS1
CHB4 Chain Slack
Chain Break Switch
Switch CHB5
CHS2 Chain Break Part of
Chain Slack Switch Platform
Switch
CHB7
Right Chain Break
Side Switch CHS3
CHS4 Chain Slack
Chain Slack Switch
Switch CHB6
Left Chain Break
Side Switch
CHB4 TL
Chain Break Mast Ma
in
Switch Fr
am
e
CHS2 CHS1
Chain Slack Chain Slack
Switch
"One" Speed Lift Manifold
Switch
(With Lifting Fork)
CHB5
Chain Break
Switch CV2
Check Valve AC
C

Right CV1 "Two" Speed Lift Manifold

Side Check Valve (With Lifting Fork)

CV1 CV4
Check Valve AC
C
Check Valve
Left
Side CV3
Check Valve
Ma
in ! WA
RN

Fr
This
brakes
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in control
have
happenthe g the
caution.
that may Tow
pushing
and an when
not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

am
e CV2
Check Valve

T
A1
B+
A2
B- C

C
AC

Connector
Module

Crown 2003 PF13605-4 Printed in U.S.A.

M1.0–7532–053 M1.0–7532–053
 C COMPONENTRY

CYLINDER DPS
Free Lift (TT Mast Only) Display Switch

Location: 3rd stage mast. Location: switch panel.

Purpose: raise platform. Purpose: permits selection of different operation modes

of the message display.
Data: not applicable.
Data: three position, on-off-on, rocker switch.
Adjustment: none required.
Adjustment: none required.
CYLINDER
Mast DTS1
Drive /Tow Switch
Location: main frame.
Location: distribution panel.
Purpose: raise TL or TT mast and platform on TL mast
trucks. Purpose: to release brake allowing truck to be towed.

Data: not applicable. Data: two position, on-on, lever handle switch.

Adjustment: none required. Adjustment: none required.

DB1 ECR1
Diode Block Steering Command Encoder

Location: below steering gearbox. Location: steering command assembly.

Purpose: blocks feedback from travel alarm in direc- Purpose: provide steering command input to steering
tion circuit. module.

Data: double diode block. Data: 5 volts D.C., 258 counts per revolution reso-
lution.
Adjustment: none required.
Adjustment: see section M4.0.
DISPLAY MODULE

Location: operator compartment.

Purpose: display for operator information (including

direction, speed and position), service mode
messages and indicators.

Data: see section M4.3.

Adjustment: none required.

Crown 2003 PF13605-5 Printed in U.S.A.

M1.0–7532–054 M1.0–7532–054
 C COMPONENTRY
10957

Cylinder
(Mast)
DPS
Dislay Switch

Cylinder
(Free LIft)
Display
Module

USA
ECR1
Steering Feedback
Encoder

Control Module

Steering Command
Assembly

Distribution
Panel
! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g may the
caution.
that
pushing Tow l
and an when
not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

!W
AR
This
brak
truc
swit es ork doe
NIN
Steech is trav s
W
arn ring in
vehic
el not
the conhav
G
happe
cautiolethe
that may T trol e
pushi
n and
n. an ng not
ow whe
to accid
or Pos n
towin wor
use ent itionTow
extrem
could
g k. .
e

Drive

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

DTS1 A1
A1
B
B+
A2
A2
TT

Drive/Tow Switch
B-
B- CC
C
ACC
AC

Wire Guide
Module

DB1
Diode Block

Crown 2003 PF13605-6 Printed in U.S.A.

M1.0–7532–055 M1.0–7532–055
 C COMPONENTRY

ECR2 F
Steering Feedback Encoder Forward Contactor

Location: in front of traction motor. Location: traction panel.

Purpose: provide steer wheel movement feedback to Purpose: provide correct polarity voltage to traction
steering module. motor necessary for forward travel.

Data: 5 volts D.C., 258 counts per revolution reso- Data: positive voltage provided through GTS3 and
lution. GTS4 gate switches, negative voltage con-
trolled by MRC1.
Adjustment: see section M4.0.
Adjustment: none required.
ED
Emergency Disconnect Contactor Fan
Operator Fan
Location: lift/power panel.
Location: overhead console.
Purpose: provide ability to turn off power control cir-
cuitry. Purpose: operator comfort.

Data: positive voltage provided through K1 relay, Data: 24 volt.

negative voltage controlled by MRC1.
Adjustment: none required.
Adjustment: none required.
FC1
EDS Flow Control Valve
Emergency Disconnect Switch
Location: lift/lower manifold.
Location: control module.
Purpose: limit maximum rate of lowering oil flow.
Purpose: resets the emergency disconnect contactor,
removing battery power from steering, lift, Data: set at 19 l/m.
traction and control circuits.
Adjustment: none required.
Data: wired normally closed. Pressing switch but-
ton actuates switch. FC2
Flow Control Valve
Adjustment: none required.
Location: lift/lower manifold (high speed only).

Purpose: limit maximum rate of lowering oil flow.

Data: set at 19 l/m.

Adjustment: none required.

Crown 2003 PF13605-7 Printed in U.S.A.

M1.0–7532–056 M1.0–7532–056
 C COMPONENTRY
10958

EDS
Emergency Disconnect FAN
Switch Operator Fan

USA

Control Module

"Two" Speed Lift Manifold

(With Lifting Fork)

ED FC1
Emergency Disconnect Flow Control
Contactor Lift/Power Valve
C
AC

Panel

Traction FC2
Panel Flow Control
Valve
GR YE
N L
PO F
TP WAUL
1 ER T
TP
2
TP
3
TP
4
TP
8 ! WA
BR TP This
brakes RN
ING
AK 5
truck
switch or does
Steerinis travel
not

E
Warn
vehicle in contro
have
the g the

MO
happen
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.

/ DU
P
extreme Tow
could n.

REN 1 LE
V 1759
Drive

.– 8

TP
6
TP
7

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

T
A1
B+
A2
B- C

C
AC

A1

F
B
A2
B-

Forward
Contactor

ECR2
Steering Feedback
Encoder

Crown 2003 PF13605-8 Printed in U.S.A.

M1.0–7532–057 M1.0–7532–057
 C COMPONENTRY

FILTER FU2
Return Control Fuse

Location: near upper portion of reservoir. Location: distribution panel.

Purpose: remove contaminants from hydraulic fluid. Purpose: protect control circuitry from overcurrent.

Data: 10 micron. Data: 15A.

Adjustment: none required. Adjustment: none required.

FNS1 FU3
Fan Switch Spare Fuse

Location: switch panel. Location: distribution panel.

Purpose: allows operator to turn on/off fan. Purpose:

Data: three position, on-off-on, rocker switch. Data: 15A.

Adjustment: none required. Adjustment: none required.

FS FU4
Forward Switch Brake Module Fuse

Location: control module. Location: distribution panel.

Purpose: informs traction controller forward travel di- Purpose: protect brake module and associated wiring
rection is being requested by the operator. from overcurrent.

Data: 15A.
Data: wired normally open. Rotating twist grip away
from operator actuates switch. Adjustment: none required.

Adjustment: none required.

FU1
Lights and Fan Fuse

Location: distribution panel.

Purpose: protect overhead guard lights, strobe light,

fan and associated wiring from overcurrent.

Data: 15A.

Adjustment: none required.

Crown 2003 PF13605-9 Printed in U.S.A.

M1.0–7532–058 M1.0–7532–058
 C COMPONENTRY
10959

FNS1
Fan Switch

USA

Control
Module

FS
Forward Switch

FU2
FU3 Control Fuse
Spare
Fuse
FU1
FU4 Lights and FILTER
Brake Module Fan Fuse Return
Fuse
! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g may the
caution.
that
pushing Tow l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

!W
AR
This
brak
truck
switces or does
NIN
Stee h is trave
W
arn ring in
vehicle l not
the contr have
G
happenthe may T
ow ol when
caution
that
pushin
. and an g not
to accide
or Posi
use towingwork
nt
extrem
could
tion.
Tow
.
e

Drive

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

Distribution
Panel
FU5
T
A1
B+
A2
B- C

Traction
C
AC

Controller Fuse

Crown 2003 PF13605-10 Printed in U.S.A.

M1.0–7532–059 M1.0–7532–059
 C COMPONENTRY

FU5 FU9
Traction Controller Fuse Pump Motor 2 Fuse

Location: distribution panel. Location: lift/power panel.

Purpose: protect traction controller (MRC1) and asso- Purpose: protect lift pump motor 2 and associated
ciated wiring from overcurrent. wiring from overcurrent.

Data: 15A. Data: 175 ALS.

Adjustment: none required. Adjustment: none required.

FU6 FU10
Steer Relay Fuse Power Steering Motor Fuse

Location: distribution panel. Location: lift/power panel.

Purpose: protect steer relays no. 2, 4, 5 & 7 and Purpose: protect power steering motor 2 and associ-
associated wiring from overcurrent. ated wiring from overcurrent.

Data: 15A. Data: 175 ALS.

Adjustment: none required. Adjustment: none required.

FU7 FU11
Wire Guidance Module Fuse Freezer/Condition Platform Fuse

Location: lift/power panel. Location: freezer/condition panel.

Purpose: protect wire guidance module and associ- Purpose: protect freezer condition components
ated wiring from overcurrent. equipped on platform and associated wiring
from overcurrent.
Data: 15A.
Data: 15A.
Adjustment: none required.
Adjustment: none required.
FU8
Pump Motor 1 Fuse

Location: lift/power panel.

Purpose: protect lift pump motor 1 and associated

wiring from overcurrent.

Data: 175 ALS.

Adjustment: none required.

Crown 2003 PF13605-11 Printed in U.S.A.

M1.0–7532–060 M1.0–7532–060
 C COMPONENTRY
10960

Freezer/Corrosion Distribution Panel

(Mounted on Lift/Power Panel)

FU11
A
Freezer/Condition
Platform FU10
Fuse Power Steering
Motor
Fuse
FU8
A Pump Motor 1
Fuse

FU7
Wire Guidance FU9
Module Pump Motor 2
Fuse Fuse

FU5 Distribution
Traction Panel
Controller Fuse
Lift/Power
Panel
! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g may the
caution.
that
pushing Tow l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

!W
AR
NIN
This
brak
truc
swit es ork doe
Steech is trav s
W
arn ring in
vehic
el not
the conhav
G
happelethe
cautio
that may T trol e
pushi
n and
n. an ng not
ow whe
to accid
or Pos n
towin wor
use ent itionTow
extrem
e
could
g k. . This
brakes
! AR
W
truck
or
travel
does
NIN
Drive
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

T
A1
B+
A2
B- C

FU6
C
AC

Steer Relay
Fuse

Crown 2003 PF13605-12 Printed in U.S.A.

M1.0–7532–061 M1.0–7532–061
 C COMPONENTRY

FU12 GUS
Freezer/Condition Power Unit Fuse Guidance Switch

Location: freezer/condition panel. Location: control module.

Purpose: protect freezer condition components Purpose: allows operator to select manual or auto-
equipped on power unit and associated wir- matic steering.
ing from overcurrent. Data: wired normally open, held closed while in
manual steering mode.
Data: 15A.
Adjustment: none required.
Adjustment: none required.
HN1
FU13 Horn
Traction Motor Fuse
Location: on power unit side of platform, near the
Location: lift/power panel. bottom.

Purpose: protect traction motor and associated wiring Purpose: provide operator controlled audible warning.
from overcurrent.
Data: 24-48 volt, 0.4 amp.
Data: 140 ACK.
Adjustment: none required.
Adjustment: none required.
HN2
GTS1, GTS2, GTS3, GTS4 Travel Alarm
Side Gate Switches
Location: platform side of power unit near bottom.
Location: console.
Purpose: alert pedestrians of truck movement request.
Purpose: prevents lift/lower and traction when gates
are up. Data: reverse and/or forward switch.

Data: wired normally open, held closed when gates Adjustment: none required.
are down.

Adjustment: none required.

GTS5, GTS6, GTS7, GTS8 (SAA Only - not shown)

Rear Gate Switches

Location: rear post.

Purpose: prevents lift/lower and traction when gates

are up.

Data: wired normally open, held closed when gates

are down.

Adjustment: none required.

Crown 2003 PF13605-13 Printed in U.S.A.

M1.0–7532–062 M1.0–7532–062
 C COMPONENTRY
10971

GUS
Control Module Guidance Switch

USA
GTS1 & GTS3
Side Gate Switches
(Behind Console)

GTS1 & GTS3 GTS2 & GTS4

Rear Gate Switches Side Gate Switches
(1.25SP Only) (Behind Console)

Bottom Of
Platform

Freezer/Corrosion Distribution Panel

(Mounted on Lift/Power Panel)
HN1
FU12 Horn
Freezer/Condition
A Power Unit SB10
Fuse
HN2
! WA
This
brakes
truck
switch or does
Steerinis travel
Warn
vehicle
happen
in
the g
caution.
that
RN
not
contro
the
may Tow
pushing
and an
have

to accident
or
ING

use towingwork.
extreme
could
l when
not Positio
n.
Tow

Drive
Travel Alarm

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

T
A1
B+
A2
B- C

C
AC

FU13
Traction Motor
Fuse

Lift/Power
Panel

Crown 2003 PF13605-14 Printed in U.S.A.

M1.0–7532–063 M1.0–7532–063
 C COMPONENTRY

HNS1 HTS2500
Horn Switch 2500 mm Height Limit Switch

Location: control module. Location: TL mast trucks - lower portion of mainframe

between platform and mainframe.
Purpose: allows operator to sound horn. TT mast trucks - lower portion of platform
between platform and mainframe.
Data: wired normally open. Pushing horn button
actuates switch. Purpose: reduces travel speed to speed 1 when plat-
form is 2500 to 4500 mm from maximum lift
Adjustment: none required. height and if steer angle is within 10 degrees
of straight ahead travel. Travel speed is re-
HSLCS duced to speed 2 if steer angle is greater than
High Speed Lower Cutout Switch 10 degrees. Brake force reduced to 67 per-
cent.
Location: platform - between platform wall and mast.
Data: wired normally closed.
Purpose: cutouts out high speed lower when platform
is 305 mm from floor. Adjustment: see Switches, section M4.0.

Data: wired normally closed. HTS4500 (Wire Guidance Trucks Only)

4500 mm Height Limit Switch
Adjustment: see Switches, section M4.0.
Location: TL mast trucks - lower portion of mainframe
HSRCS between platform and mainframe.
High Speed Raise Cutout Switch TT mast trucks - lower portion of platform
between platform and mainframe.
Location: near top of mainframe.
Purpose: TT Mast - reduces travel speed to speed 1
Purpose: cutouts out high speed raise when platform is when platform is 2500 to 4500 mm with a
180 mm from maximum lift height. collapsed height up to 3330 mm (1.25SP), up
to 2720 mm collapsed height (1.0SP), 3635
Data: wired normally closed. mm and above collapsed height (1.25SP)
and 3025 mm and above collapsed height
Adjustment: see Switches, section M4.0. (1.0SP) from maximum lift height and if steer
angle is within 10 degrees of straight ahead
HTS1200 travel. Travel speed is reduced to speed 2 if
1200 mm Height Limit Switch steer angle is greater than 10 degrees. Brake
force reduced to 33 percent.
Location: platform - between platform wall and mast. TL Mast - reduces travel speed to speed 1
when platform is 2500 to 4500 mm with a
Purpose: cutouts out 1A travel speed when platform is collapsed height up to 2415 mm (1.0SP), and
1200 mm to 2500 mm from maximum lift 3025 mm and above collapsed heights
height and steer angle is greater than 10 (1.25SP) from maximum lift height and if
degrees. Brake force is at 100 percent. steer angle is within 10 degrees of straight
Data: wired normally closed. ahead travel. Travel speed is reduced to
speed 2 if steer angle is greater than 10
Adjustment: see Switches, section M4.0. degrees. Brake force reduced to 33 percent.

Data: wired normally closed.

Adjustment: see Switches, section M4.0.

Crown 2003 PF13605-15 Printed in U.S.A.

M1.0–7532–064 M1.0–7532–064
 C COMPONENTRY
10972

Control
Module

USA
HSRCS
High Speed Raise HNS1
Cutout Switch Horn Switch

HTS2500
HSLCS
2500 mm Pl
at High Speed Lower
Height Limit Switch fo
rm
Cutout Switch

TL Mast HTS1200
1200 mm
Height Limit Switch
All 1.0SP

HTS1200
1200 mm
Height Limit Switch HSLCS
Trucks W/Wire Guide High Speed Lower
Cutout Switch
HSRCS
HTS1200 High Speed Raise
1200 mm Cutout Switch
Height Limit Switch Pl
at
fo
rm

TTMast

HTS4500
4500 mm
Height Limit Switch
HTS2500
2500 mm
HTS2500 Height Limit Switch
2500 mm
Height Limit Switch For 3025 mm
Collapsed Ht. 1.25 SP
And All 1.0SP

Crown 2003 PF13605-16 Printed in U.S.A.

M1.0–7532–065 M1.0–7532–065
 C COMPONENTRY

K1 K5
Power Up Relay Steer Motor Relay

Location: distribution panel. Location: traction panel.

Purpose: provides control circuitry power. Purpose: provides current path for steer motor.

Data: 24 volt D.C. coil energized upon keyswitch Data: 24 volt D.C. coil energized by steer module.
test position closure.
Adjustment: none required.
Adjustment: none required.
K7
K2 Wire Guide Speed Reduction Relay
Stop/Enable Relay
Location: distribution panel.
Location: distribution panel.
Purpose: limit wire guide traction speed as determined
Purpose: removes power to the brake (brake applies) by height switches HTS1200 and HTS2500.
when a travel inhibiting fault is detected.
Data: 24 volt D.C. coil energized by steer module.
Data: 24 volt D.C. coil energized by steer module.
Adjustment: none required.

Adjustment: none required. K8

Travel Alarm Relay
K3
Stop Relay Location: below steering gearbox.

Location: distribution panel. Purpose: supply battery volts to travel alarm as deter-
mined by height switch HTS1200.
Purpose: provides current path to brake module and
enables traction control circuit. Data: 24 volt D.C. coil energized by closure of
HTS1200.
Data: 24 volt D.C. coil energized by brake module.
Adjustment: none required.

Adjustment: none required. K11

Freezer/Corrosion Relay
K4
Steer Angle Relay Location: freezer/corrosion distribution panel.

Location: distribution panel. Purpose: provide power to thermostat circuits.

Purpose: limit traction speed and change braking force Data: 24 volt D.C. coil energized when THS1 calls
as determined by height switches, HTS1200, for heat (closes) and THS2 is in temperature
HTS2500 and HTS4500. range.

Data: 24 volt D.C. coil energized by steer module. Adjustment: none required.

Adjustment: none required.

Crown 2003 PF13605-17 Printed in U.S.A.

M1.0–7532–066 M1.0–7532–066
 C COMPONENTRY
10973

Freezer/Corrosion Distribution Panel

(Mounted on Lift/Power Panel)

K12
Freezer/Corrosion
A
Relay K11
Freezer/Corrosion
Relay

K1
Power Up
A Relay Distribution
K3 Panel
Stop Relay

K4
Steer Angle
!W
AR
This
brak
truc
swit es ork doe
NIN
Steech is trav s
vehic ring in
Warn el not
the conhav
G
happe
cautiolethe
that may Tow trol e
pushi
n and
n. an ng not whe
to accid
or Pos n
towin wor
use ent itionTow
extrem
could
g k. .
e

Drive

Relay

K2
Traction Stop/Enable
Panel Relay
K7
Wire Guide Speed
Reducton Relay
K5
Steer Motor
Relay
A1
B
A2
B-

!W
AR
This
brakes
truck
switch or does
NIN
Steerinis travel
W
vehicle
arn in
not G
the contro have
happenthe g
caution. may T
that
pushing ow l when
and an not Positio
to accident
or
use towingwork.
extreme T
could n.ow

Drive

Wire Guide
T

Module C

C
A1
AC
B+
A2
B-

K8
Travel Alarm
Relay

Crown 2003 PF13605-18 Printed in U.S.A.

M1.0–7532–067 M1.0–7532–067
 C COMPONENTRY

K12 LGS2
Freezer/Corrosion Relay (See Previous Page) Work Light Switch

Location: freezer/corrosion distribution panel. Location: switch panel.

Purpose: provide power to heater circuits. Purpose: allows operator to turn on/off work light.

Data: 24 volt D.C. coil energized when THS1 calls Data: two position, on-off, rocker switch.
for heat (closes) and THS2 is in temperature
range. Adjustment: none required.

Adjustment: none required. LGS3

Spot Light Switch
KYS
Key Switch Location: switch panel.

Location: control module. Purpose: allows operator to turn on/off spot light.

Purpose: allows operator to power truck up and shut Data: two position, on-off, rocker switch.
truck down.
Adjustment: none required.
Data: key operated selector switch. Energizes K1
with start position and maintains K1 with on LGT1
position. Strobe or Flashing Light

Adjustment: none required. Location: power unit.

LCS1 Purpose: visual warning of lift truck presence.

Lower Cutout Switch
Data: 24 volt.
Location: right, lower portion, mast side of platform.
Adjustment: none required.
Purpose: prevents lowering at programed height.
LGT2, 5
Data: wired normally closed held open with mast Work Lights
channel.
Location: overhead console or mast.
Adjustment: see Switches, section M4.0.
Purpose: provide work area light outside operator com-
LGS1 partment.
Dome Light Switch
Data: 12 volt.
Location: switch panel.
Adjustment: minimal manual directional adjustment.
Purpose: allows operator to turn on/off dome light.

Data: two position, on-off, rocker switch

Adjustment: none required.

Crown 2003 PF13605-19 Printed in U.S.A.

M1.0–7532–068 M1.0–7532–068
 C COMPONENTRY
10974

LGS1
Dome Light
LGS3 Switch
Spot Light
Switch
LGT2
Work Light Control
Module
LGT5

USA
Work Light

LGS2
Work Light
Switch

KYS
Key Switch

Part of Platform Part of Platform

(TL Mast) (TT Mast)

! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g the
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

LCS1 TT

Lower Cutout
A1
A1
B+
B
A2
A2
B-
B- CC
C
ACC

Switch
AC

LGT1
Strobe Light

Crown 2003 PF13605-20 Printed in U.S.A.

M1.0–7532–069 M1.0–7532–069
 C COMPONENTRY

LGT3, 6 LOS2
Dome Lights High Speed Lower Switch

Location: overhead console. Location: control module.

Purpose: provide light inside operator compartment. Purpose: allows operator to lower platform.

Data: 12 volt. Data: wired normally open, held closed by fully

depressing the lower button.
Adjustment: none available.
Adjustment: none required.
LGT4, 7
Spot Lights LOS3 (Lifting Forks 1.0SP Only)
Low Speed Lower Switch
Location: overhead console.
Location: control module.
Purpose: provide work area light outside operator com-
partment. Purpose: allows operator to lower platform.

Data: 24 volt. Data: wired normally open, held closed by de-

pressing the lower button (partially on trucks
Adjustment: none available. with high speed lower).

LMS1 Adjustment: none required.

Lifting Fork Raise Cutout (1.0SP Only)
LOS4 (Lifting Forks 1.0SP Only)
Location: Platform High Speed Lower Switch

Purpose: raise cutout on lifting forks. Location: control module.

Data: wired normally open, held closed by de- Purpose: allows operator to lower platform.
pressing the lower button.
Data: wired normally open, held closed by fully
Adjustment: none available. depressing the lower button.

LOS1 Adjustment: none required.

Low Speed Lower Switch
M1
Location: control module. Traction Motor

Purpose: allows operator to lower platform. Location: drive unit.

Data: wired normally open, held closed by de- Purpose: provide driving force for traction.
pressing the lower button (partially on trucks
with high speed lower). Data: MRC1 provides traction control via operator
input (POT1).
Adjustment: none required.
Adjustment: none required.

Crown 2003 PF13605-21 Printed in U.S.A.

M1.0–7532–070 M1.0–7532–070
 C COMPONENTRY
10975

Control
Module

LGT4 LGT6
Spot Light Dome Light

USA
LGT7
LGT3
ECR1 Spot Light
Dome Feedback
Steering Light
Encoder

LOS1 & LOS2

Lower Switch

Lifting Fork Console

RAS4 1.0SP Trucks Only RAS3

LOS4 LOS3
LMS1
Lifting Fork 1.0SP
! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g the
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

Cutout Switch TL & TT Mast

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn
happenthe
mayin the when
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

M1
Traction Motor A1
A1
TT

B+
B
A2
A2
B-
B- CC
C
ACC
AC

Part Of
Lifting Forks

Crown 2003 PF13605-22 Printed in U.S.A.

M1.0–7532–071 M1.0–7532–071
 C COMPONENTRY

M2 MV1
Power Steering Motor Manual Release Valve

Location: steering gearbox. Location: lift/lower manifold.

Purpose: provide driving force for steering. Purpose: provide means to lower platform without pow-
ering up truck.
Data: steering module provides steering control via
steering command encoder ECR1 and power Data: not applicable.
unit steered wheel encoder ECR2.
Adjustment: none required.
Adjustment: none required.
ORS1
M3 Override Switch
Lift Pump Motor
Location: switch panel.
Location: reservoir.
Purpose: when raise lower cutout programmed for
Purpose: provide driving force for hydraulic pump sup- override is encountered, actuating switch
plying hydraulic oil flow for lift. permits continuation of function.

Data: energized via P1 contactor. Data: momentary contact switch.

Adjustment: none required. Adjustment: none required.

M4 P1
Lift Motor Low Speed Lift Pump Contactor

Location: reservoir. Location: lift/power panel.

Purpose: provide driving force for hydraulic pump sup- Purpose: provide battery volts to pump motor 1 upon
plying hydraulic oil flow for high speed lift. coil being energized.

Data: energized via P2 contactor. Data: positive voltage provided through RAS1
switch, negative voltage controlled by steer-
Adjustment: none required. ing module.

MRC1 Adjustment: none required.

Traction Control
P1 PUMP
Location: traction panel. Low Speed Lift Pump

Purpose: controls traction motor speed via operator Location: M3 lift pump motor.
input from POT1.
Purpose: provide hydraulic flow for lift.
Data: transistor control circuitry.
Data: not applicable.
Adjustment: refer to section M4.2.
Adjustment: none required.

Crown 2003 PF13605-23 Printed in U.S.A.

M1.0–7532–072 M1.0–7532–072
 C COMPONENTRY
10976
ORS1
Override Switch

USA
Control Module

"One" Speed Lift Manifold

(With Lifting Fork)

AC
C
"Two" Speed Lift Manifold
P1 (With Lifting Fork)
Low Speed Lift Lift/Power MV1
Pump Contactor Panel Manual Release
Valve

C
AC

P2
GR YE
N L
PO F
TP WAUL
1 ER T
TP
2
TP
3

High Speed Lift

TP
4
TP
8
BR TP
AK 5
E
MO
/ DU
P
REN 1 LE
V 1759
.– 8

Pump Contactor
TP
6
TP
7

! WA
This
brakes RN
truck
switch or does IN
Steeri is travel
Warn
vehicleng in
not
contro
thehave
G
happenthe
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

M2
Power Steering
T
A1
B+
A2

MRC1
B- C

C
AC

Traction
Control

P1 PUMP
Low Speed
A1
B
A2

Lift Pump
B-

Traction
Panel M4
M3 Lift Motor
Lift Pump
Motor

Crown 2003 PF13605-24 Printed in U.S.A.

M1.0–7532–073 M1.0–7532–073
 C COMPONENTRY

P2 PUMP (See Previous Page) PS2

High Speed Lift Pump Contactor Light Power Supply

Location: lift/power panel. Location: overhead console.

Purpose: provide battery volts to pump motor 2 upon Purpose: provide 12 volt for dome lights.
coil being energized.
Data: 24 volt D.C. input, 12 volt D.C. output.
Data: positive voltage provided through RAS2
switch, negative voltage controlled by steer- Adjustment: none required.
ing module.
RAS1
Adjustment: none required. Low Speed Raise Switch

P2 PUMP (See Previous Page) Location: control module.

High Speed Lift Pump
Purpose: allows operator to raise platform.
Location: M4 lift pump motor.
Data: wired normally open, held closed by de-
Purpose: provide hydraulic flow for high speed lift. pressing the raise button (partially on trucks
with high speed raise).
Data: not applicable.
Adjustment: none required.
Adjustment: none required.
RAS2
POT1 High Speed Raise Switch
Traction Request Potentiometer
Location: control module.
Location: control module.
Purpose: allows operator to raise platform.
Purpose: provide traction input to controller MRC1.
Data: wired normally open, held closed by fully
Data: 22 K ohms. depressing the raise button.

Adjustment: refer to section M4.5 - control module. Adjustment: none required.

PS1 RAS3 (Lifting Forks 1.0SP Only)

Light Power Supply Low Speed Raise Switch

Location: overhead console. Location: control module.

Purpose: provide 12 volt for work lights. Purpose: allows operator to raise platform.

Data: 24 volt D.C. input, 12 volt D.C. output. Data: wired normally open, held closed by de-
pressing the raise button (partially on trucks
Adjustment: none required. with high speed raise).

Adjustment: none required.

Crown 2003 PF13605-25 Printed in U.S.A.

M1.0–7532–074 M1.0–7532–074
 C COMPONENTRY
10977

PS1
RAS1 & RAS2
Light Power
Raise Switch
Supply

USA
PS2
Light Power
Supply

POT1
Traction Request
Control Potentiometer
Module
Lifting Fork Console
RAS4 1.0SP Trucks Only RAS3

LOS4 LOS3

RCS2
! WA
This
brakes RN
truck
switch or does IN
Steeri is travel
Warn
vehicleng in
not
contro
thehave
G
happenthe
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

Raise Cutout
Switch

RCS1
T
A1
B+
A2
B- C

Raise Cutout
C
AC

Switch

Mainframe
(TL or TT Mast)

P2 PUMP
High Speed
Lift Pump

Crown 2003 PF13605-26 Printed in U.S.A.

M1.0–7532–075 M1.0–7532–075
 C COMPONENTRY

RAS4 (Lifting Forks 1.0SP Only) (See Previous Page) RES4, RES5
High Speed Raise Switch Freezer/Corrosion Heater

Location: control module. Location: battery restraint switch brackets.

Purpose: allows operator to raise platform. Purpose: RES4 applies heat to battery restraint switch
BRES2 and RES5 applies heat to battery
Data: wired normally open, held closed by fully restraint switch BRES1.
depressing the raise button. Data: 50 watt, 15 ohm.

Adjustment: none required. Adjustment: none required.

RCS1, RCS2 (See Previous Page) RES6, RES7

Raise Cutout Switches Freezer/Corrosion Heater

Location: left side of mainframe. Location: main frame.

Purpose: prevents raise at programed height. Purpose: RES6 applies heat to chain slack switch
CHS3 and RES7 applies heat to chain slack
Data: wired normally open held closed with mast switch CHS4.
channel.
Data: 25 watt, 30 ohm.
Adjustment: see Switches, section M4.0.
Adjustment: none required.
RES1
Resistor RES8, RES9
Freezer/Corrosion Heater
Location: overhead console.
Location: platform gate.
Purpose: reduce fan speed.
Purpose: RES8 applies heat to gate switch GTSL, and
Data: 25 watt, 10 ohm. RES9 applies heat to gate switch GTSR.

Adjustment: none required. Data: 50 watt, 15 ohm.

RES2, RES3 Adjustment: none required.

Freezer/Corrosion Heater

Location: aisle guide wheel brackets.

Purpose: RES2 applies heat to aisle guide switch RGS2

and RES3 applies heat to aisle guide switch
RGS1.

Data: 50 watt, 15 ohm.

Adjustment: none required.

Crown 2003 PF13605-27 Printed in U.S.A.

M1.0–7532–076 M1.0–7532–076
 C COMPONENTRY
10978

RES2 (Shown),
RES1 RES3
Resistor F/C Heater

RGS2 (Shown)
RGS1
Part of
Power Unit

Part of
Mainframe

RES6
Part of
F/C Heater
Mainframe

BRES1

CHS3

RES5
F/C Heater
CHS4 RES7
F/C Heater

RES4
F/C Heater RES8,
RES9
F/C Heater

BRES2 GTSL,
Part of
GTSR
Power Unit

Crown 2003 PF13605-28 Printed in U.S.A.

M1.0–7532–077 M1.0–7532–077
 C COMPONENTRY
RAS2 10979

C
C
D
RAS1

RES12
F/C Heater

HNS1
LOS2

LOS1 RES11
F/C Heater

Rib Located on Back

of Control Module

EDS

RES13
F/C Heater

RES14
F/C Heater

RES10
F/C Heater

FS

RS

Crown 2003 PF13605-29 Printed in U.S.A.

M1.0–7532–078 M1.0–7532–078
 C COMPONENTRY

RES10 (Shown On Previous Page) RES14 (Shown On Previous Page)

Freezer/Corrosion Heater Freezer/Corrosion Heater

Location: control module. Location: control module.

Purpose: applies heat to emergency disconnect switch Purpose: applies heat to reverse switch RS.
EDS.
Data: 10 watt, 70 ohm.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Adjustment: none required.
RES15, RES19
RES11 (Shown On Previous Page) Freezer/Corrosion Heater
Freezer/Corrosion Heater
Location: platform (TT).
Location: control module.
Purpose: RES15 applies heat to chain slack switch
Purpose: applies heat to raise and lower switches CHS3 and RES19 applies heat to chain break
LOS1, LOS2, RAS1 & RAS2. switch CHB6.

Data: 25 watt, 30 ohm. Data: 25 watt, 30 ohm.

Adjustment: none required. Adjustment: none required.

RES12 (Shown On Previous Page) RES16

Freezer/Corrosion Heater Freezer/Corrosion Heater

Location: control module. Location: below floorboard.

Purpose: applies heat to horn switch HNS. Purpose: applies heat to brake switch BRS1/BRS2.

Data: 25 watt, 30 ohm. Data: 25 watt, 30 ohm.

Adjustment: none required. Adjustment: none required.

RES13 (Shown On Previous Page) RES18

Freezer/Corrosion Heater Freezer/Corrosion Heater

Location: control module. Location: main frame.

Purpose: applies heat to forward switch FS. Purpose: applies heat to limit switch HTS1200.

Data: 10 watt, 70 ohm. Data: 24 volt, 10 watt.

Adjustment: none required. Adjustment: none required.

Crown 2003 PF13605-30 Printed in U.S.A.

M1.0–7532–079 M1.0–7332–079
 C COMPONENTRY
10980

Brake
Pedal
BRS1
BRS2

Part of Platform
RES19
(TT Mast)
F/C Heater
RES16
F/C Heater

CHS3

HTS1200
RES18
F/C Heater
CHB6

RES15
F/C Heater

Crown 2003 PF13605-31 Printed in U.S.A.

M1.0–7532–080 M1.0–7532–080
 C COMPONENTRY

RES19, RES15 (shown on previous page) RES23

Freezer/Corrosion Heater Freezer/Corrosion Heater

Location: platform (TT). Location: platform gates

Purpose: RES15 applies heat to chain slack switch Purpose: RES23 applies heat to GTS4 gate switch.
CHS3 and RES19 applies heat to chain slack
switch CHB6. Data: 50 watt, 15 ohm.

Data: 25 watt, 30 ohm. Adjustment: none required.

Adjustment: none required. RES24

Freezer/Corrosion Heater
RES20
Freezer/Corrosion Heater Location: mast.

Location: 2 handed control box (console). Purpose: RES24 applies heat to CHS6 chain slack
switch.
Purpose: RES20 applies heat to DMS1 switch.
Data: 25 watt, 30 ohm.
Data: 50 watt, 15 ohm.
Adjustment: none required.
Adjustment: none required.
RES25
RES21 Freezer/Corrosion Heater
Freezer/Corrosion Heater
Location: mast.
Location: platform TT mast
Purpose: RES25 applies heat to CHS5 chain slack
Purpose: RES21 applies heat to CHS7 chain slack switch.
switch.
Data: 25 watt, 30 ohm.
Data: 50 watt, 15 ohm.
RES26 (Lifting Fork, 1.0SP Only)
Adjustment: none required. Freezer/Corrosion Heater

RES22 Location: lifting fork control assembly.

Freezer/Corrosion Heater
Purpose: RES26 applies heat to LOS3 switch.
Location: platform gates
Data: 25 watt, 30 ohm.
Purpose: RES22 applies heat to GTS3 gate switch.
Adjustment: none required.
Data: 50 watt, 15 ohm.
RES27 (Lifting Fork, 1.0SP Only)
Adjustment: none required. Freezer/Corrosion Heater

Location: lifting fork control assembly.

Purpose: RES27 applies heat to LOS4 switch.

Data: 25 watt, 30 ohm.

Adjustment: none required.

Crown 2003 PF13605-32 Printed in U.S.A.

M1.0–7532–081 M1.0–7532–081
 C COMPONENTRY
10982

DMS1

Two Handed
Control Box
RES20
F/C Heater Part of Platform
RES21 (TT Mast)
F/C Heater

CHS7
RES22,
RES23
F/C Heater

CHS6

RES24
F/C Heater

CHS5 GTS3, GTS4

Trucks With Lifting Forks
RES25
(1.0SP Only)
F/C Heater
RES29 RES28
F/C Heater F/C Heater
RAS4 RAS3

LOS4 LOS3
RES27 RES26
F/C Heater F/C Heater

Crown 2003 PF13605-33 Printed in U.S.A.

M1.0–7532–082 M1.0–7532–082
 C COMPONENTRY

RES28 (Lifting Fork, 1.0SP Only) (See Previous Page) RS

Freezer/Corrosion Heater Reverse Switch

Location: lifting fork control assembly. Location: control module.

Purpose: RES28 applies heat to RAS3 switch. Purpose: informs traction controller reverse travel di-
rection is being requested by the operator.
Data: 25 watt, 30 ohm.
Data: wired normally open. Rotating twist grip to-
Adjustment: none required. ward operator actuates switch.

RES29 (Lifting Fork, 1.0SP Only) (See Previous Page) Adjustment: none required.
Freezer/Corrosion Heater
RV1
Location: lifting fork control assembly. Relief Valve

Purpose: RES29 applies heat to RAS4 switch. Location: lift/lower manifold.

Data: 25 watt, 30 ohm. Purpose: limit operating pressure for lift circuit.

Adjustment: none required. Data: not applicable.

RESERVOIR Adjustment: refer to section M2.4.

Location: power unit. RV2 (Trucks With Lifting Forks) 1.0SP

Relief Valve
Purpose: hydraulic oil storage.
Location: lift/lower manifold.
Data: capacity - 13 liters for single speed lift and 17
liters for high speed lift. Purpose: limit operating pressure for lift circuit.

Adjustment: none required. Data: not applicable.

RGS1, RGS2 Adjustment: refer to section M2.4.

Rail Guide Switches
SB10
Location: aisle guide wheel bracket mounted under Suppressor Block
power unit.
Location: bottom of platform.
Purpose: provide ability to turn on automatic steering.
Purpose: suppress electrical noise from platform horn
Data: wired normally closed held open. (HN1).

Adjustment: none required. Data: not applicable.

Adjustment: none required.

Crown 2003 PF13605-34 Printed in U.S.A.

M1.0–7532–083 M1.0–7532–083
 C COMPONENTRY
10983

Control
Bottom Of
HN1 Module
Platform

USA
SB10
Suppressor Block

RS
Forward Switch

"One" Speed Lift Manifold

(With Lifting Fork)

"Two" Speed Lift Manifold

C
AC

(With Lifting Fork)

RV1
RV
1
RV
2

Relief Valve

RV2
Relief Valve AC
C

! WA
This
brakes RN
truck
switch or does IN
Steeri is travel
Warn
ng in
vehicle
not
contro
thehave
G
happenthe
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

RV
2 RV
1

RGS2
Rail Guide A1
B+
A2
T

Switch
B- C

C
AC

Reservoir

RGS1
Rail Guide
Switch

Crown 2003 PF13605-35 Printed in U.S.A.

M1.0–7532–084 M1.0–7532–084
 C COMPONENTRY

SB11 SB22
Suppressor Block Suppressor Block

Location: steering command assembly. Location: traction panel.

Purpose: suppress electrical noise from platform com- Purpose: suppress electrical noise from power unit
munications (steering). communications.

Data: not applicable. Data: not applicable.

Adjustment: none required. Adjustment: none required.

SB30
SB12 (1.0SP Trucks Only With Lifting Fork) Suppressor Block
Suppressor Block
Location: overhead console.
Location: bottom of platform on manifold block with
SV5. Purpose: suppress electrical noise from operation of
fan.
Purpose: suppress electrical noise from platform com-
munications (lifting forks). Data: not applicable.

Data: not applicable. Adjustment: none required.

Adjustment: none required. SENSOR BAR LOAD WHEEL

Wire Guidance

SB20 Location: base of mainframe.

Suppressor Block
Purpose: sense signal strength from guide wire em-
Location: lift/lower manifold. bedded in floor.

Purpose: suppress electrical noise from operation of Data: see section M4.3 - wire guide system.
low speed lower solenoid valve SV1.
Equipped on trucks with one speed lift/lower Adjustment: none required.
only.
SENSOR BAR STEER WHEEL
Data: not applicable. Wire Guidance

Adjustment: none required. Location: front and center of power unit below skirt.

SB21 Purpose: sense signal strength from guide wire em-

Suppressor Block bedded in floor.

Location: below strobe light. Data: see section M4.3 - wire guide system.

Purpose: suppress electrical noise from operation of Adjustment: none required.

strobe light.

Data: not applicable.

Adjustment: none required.

Crown 2003 PF13605-36 Printed in U.S.A.

M1.0–7532–085 M1.0–7532–085
 C COMPONENTRY
10984
SB11
Suppressor Block
SB30
Suppressor Block

Part of
Main Frame RK
FO ND
E

SENSOR BAR
LOAD WHEEL
Steering Command
Wire Guidance
Assembly

Located Below
Platform
SV5

Part Of
Lifting Fork Part of
Cylinder SB20 Reservoir
Suppressor Block
SB12
Distribution 1.0SP Trucks With
SB22 Panel Lifting Forks
Suppressor Block

! WA
This
brakes RN
truck
switch or does IN
Steeri is travel
Warn
vehicleng in
not
contro
thehave
G
happenthe
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

!W
AR
NIN
This
brak
truc
swit es ork doe
Steech is trav s
vehic ring in
Warn el not
the conhav
G
happe
cautiolethe
that may Tow trol e
pushi
n and
n. an ng not whe
to accid
or Pos n
towin wor
use ent itionTow
extrem
could
g k. .
e

Drive

T
A1
B+
A2
B- C

C
AC

SB21
Suppressor Block

SENSOR BAR
STEER WHEEL
Wire Guidance

Crown 2003 PF13605-37 Printed in U.S.A.

M1.0–7532–086 M1.0–7532–086
 C COMPONENTRY

SERVICE TERMINAL (Not Shown) SV1

Low Speed Lower Solenoid
Location: service tool.
Location: lift/lower manifold.
Purpose: provide means to calibrate software, trouble-
shoot and view truck and system information Purpose: provide path for hydraulic oil flow when low-
(such as hour meters, event codes, inputs, ering.
outputs, etc.).
Data: coil is controlled by low speed lower switch
Data: not applicable. LOS1. Coil resistance is 19 ohm. Coil voltage
is 20 volts.
Adjustment: none required.
Adjustment: none required.
SS1
Traction Speed and Direction Sensor SV2
High Speed Lower Solenoid
Location: top of brake.
Location: lift/lower manifold.
Purpose: sense traction speed and travel direction by
sensing speed and direction of traction motor Purpose: provide path for hydraulic oil flow for high
shaft. speed lowering.

Data: 32 pulses per revolution. Data: coil is controlled by high speed lower switch
LOS2. Coil resistance is 39 ohm. Coil voltage
Adjustment: none required. is 24 volts.

STEERING MODULE Adjustment: none required.

Location: traction panel. SV3

Low Speed Lower Solenoid
Purpose: control steering operation.
Location: lift/lower manifold.
Data: see section M4.3 and M6.0.
Purpose: provide path for hydraulic oil flow when low-
Adjustment: none required. ering.

STRAINER Data: coil is controlled by low speed lower switch

Suction LOS1. Coil resistance is 19 ohm. Coil voltage
is 20 volts.
Location: hydraulic reservoir.
Adjustment: none required.
Purpose: remove contaminants from hydraulic fluid.
SV4
Data: 100 mesh. High Speed Lower Solenoid

Adjustment: none required. Location: lift/lower manifold.

Purpose: provide path for hydraulic oil flow for high

speed lowering.

Data: coil is controlled by high speed lower switch

LOS2. Coil resistance is 39 ohm. Coil voltage
is 24 volts.

Adjustment: none required.

Crown 2003 PF13605-38 Printed in U.S.A.

M1.0–7532–087 M1.0–7532–087
 C COMPONENTRY
10985

"One" Speed Lift Manifold

(With Lifting Fork)
SV1
Low Speed Test Port
Lower Solenoid
"Two" Speed Lift Manifold
C (With Lifting Fork)
SV3 AC

Oil Flow To TDM

Lifting Fork Time Delay
Module

SV2
High Speed SV1
SS1 Lower Solenoid Low Speed
Traction Speed & Lower Solenoid
Direction Sensor

SV4
! WA
This
brakes RN
truck
switch or does IN
Steeri is travel
Warn
vehicleng in
not
contro
thehave
G
happenthe
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

Lifting Fork
SV3
Lifting Fork

T
A1
B+
A2
B-

Strainer
SV5
Lifting Fork Located Below
Platform

Traction
Panel
Part Of
Lifting Fork
Cylinder

SB12
A1
B
A2

Steering
B-

Module

Crown 2003 PF13605-39 Printed in U.S.A.

M1.0–7532–088 M1.0–7532–088
 C COMPONENTRY

SV5 (See Previous Page) THS2

High Speed Lower Solenoid Platform Thermostat

Location: lifting forks manifold bottom of platform. Location: mounted to plate assembled to brake switch,
BRS1/BRS2, located under platform floor.
Purpose: provide path for hydraulic oil flow for lifting
forks. Purpose: provide ability to turn on platform heaters.

Data: coil is controlled by high speed lower switch Data: wired normally closed. Contact closes at 40
LOS2. Coil resistance is 39 ohm. Coil voltage degrees and opens at 60 degrees.
is 24 volts.
Adjustment: none required.
Adjustment: none required.
TMM
TDM (See Previous Page) Truck Management Module
Time Delay Module
Location: traction panel.
Location: lift/lower manifold
Purpose: provide motor overtemp and brushwear indi-
Purpose: to provide a momentary delay between the cation.
opening of lowering valves, SV1 & SV2.
Equipped on trucks with high speed lift/lower Data: refer to M4.2-7330-500.
only.
Adjustment: none required.
Data: not applicable.
WIRE GUIDE MODULE
Adjustment: none required.
Location: below steering gearbox.
TEST PORT (See Previous Page)
Purpose: controls automatic guidance system (wire
Location: lift/lower manifold. guidance).

Purpose: quick pressure gauge connect/disconnect. Data: see section M4.3.

Data: not applicable. Adjustment: see section M4.3.

Adjustment: none required. ZSS

Zone Select Switch
THS1
Power Unit Thermostat Location: switch panel.

Location: power unit battery wall between power unit Purpose: allows selection of lift height cutout.
and mast.
Data: three position key switch.
Purpose: provide ability to turn on power unit heaters.
Adjustment: none required.
Data: wired normally closed. Contact closes at 120
degrees and opens at 140 degrees.

Adjustment: none required.

Crown 2003 PF13605-40 Printed in U.S.A.

M1.0–7532–089 M1.0–7532–089
 C COMPONENTRY
10998

ZSS
Zone Select
Switch

Control

USA
Module

Brake
Pedal

THS2
Platform
Thermostat

Traction
Panel

! WA
This
brakes RN
truck
switch or does
Steerinis travel
ING
not
Warn
vehicle in contro
have
happenthe g the
caution. may Tow
that
pushing l when
and an not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

This
brakes
! AR
W
truck
or
travel
does
NIN
switch
Steerin
vehicle g
is
not
control
have G
arn mayin the when

Located Next to
happenthe
that
pushingnot
andanW ow
accident work.
caution.
to
use or towing Positio
T
extreme
could
n.
Tow

Drive

HN2 (Travel Alarm)

TMM
Truck A1
B+
A2
T

Management
B- C

C
A1 AC

Module
A2
B-

THS1
Platform
Thermostat

WIRE GUIDE
MODULE

Crown 2003 PF13605-41 Printed in U.S.A.

M1.0–7532–090 M1.0–7532–090
 TORQUE VALUES

All Crown Trucks are manufactured with Grade 5 or better screws and bolts. The information contained in this section
will aid you when replacing any screws and bolts that are necessary when performing maintenance on your lift truck.

GRADE

GRADE MARKING SPECIFICATION MATERIAL BOLT AND SCREW

(ON HEAD) SIZE, IN.

SAE—Grade 2 Low Carbon Steel 1/4 through 1 1/2

SAE—Grade 5 Medium Carbon Steel, 1/4 through 1 1/2

Quenched and Tempered

SAE—Grade 8 Medium Carbon Alloy Steel 1/4 through 1 1/2

Quenched and Tempered

NOTE—Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted assemblies.
Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is replaced that is unmarked,
replace the fastener with a Grade 5.

TORQUE CHART

GRADE 5 GRADE 8
BOLT DIAMETER DRY TORQUE REQUIREMENT DRY TORQUE REQUIREMENT
ft. Ib. kgm Nm ft. lb. kgm Nm
1/4" 9±3 1.2 ± .4 12 ± 4 13 ± 4 1.8 ± .5 17.5 ± 5.5
5/16" 18 ± 5 2.5 ± .7 24.5 ± 7 25 ± 5 3.5 ± .7 34 ± 7
3/8" 32 ± 5 4.4 ± .7 43.5 ± 7 48 ± 10 6.6 ± 1.3 65 ± 13.5
7/16" 50 ± 10 6.9 ± 1.4 67.5 ± 13.5 75 ± 10 10.4 ± 1.4 102 ± 13.5
1/2" 75 ± 10 10.4 ± 1.4 101.5 ± 13.5 112 ± 15 15.5 ± 2.0 152 ± 20.5
9/16" 110 ± 15 15.2 ± 2.0 149 ± 20.5 163 ± 20 22.5 ± 3.0 221 ± 27
5/8" 150 ± 20 20.7 ± 2.8 203.5 ± 27 225 ± 30 31.1 ± 4.1 305 ± 41
3/4" 265 ± 35 36.6 ± 4.8 359 ± 47.5 400 ± 50 55.2 ± 6.9 542 ± 68
7/8" 420 ± 60 58.1 ± 8.3 569 ± 81 640 ± 80 88.3 ± 11.0 868 ± 108
1" 640 ± 80 88.5 ± 11.1 868 ± 109 960 ± 115 132.5 ± 15.9 1300 ± 156
1 1/8" 800 ± 100 110.6 ± 13.8 1085 ± 136
1 1/4" 1000 ± 120 138 ± 16.6 1356 ± 163
1 3/8" 1200 ± 150 166 ± 20.7 1630 ± 203
1 1/2" 1500 ± 200 207 ± 27.7 2034 ± 271
Mounting bolt torque requirements
involving hydraulic valves.
5/16" 13 ± 2 1.8 ± .3 17.5 ± 2.5
3/8" 24 ± 2 3.3 ± .3 32.5 ± 2.5
7/16" 39 ± 2 5.4 ± .3 53 ± 2.5

NOTE: Torque values called out in the maintenance section of this manual will take precedence over torque values found
on this page.

4217

Crown 1979 PF5067 Rev. 11/02 Printed in U.S.A.

03 REV. 11/02
M1.9–14.0–001 M1.9–14.0–001
 HYDRAULIC SYSTEM

The hydraulic system in your truck is powered by gear type RV2 is noted on the hydraulic schematics. Refer to the
pumps. These pumps, P1 & P2, supply oil flow for lift and service manual index for pump, valve and manifold informa-
accessory functions. tion.

Maximum pressure is limited by an adjustable relief valve, The illustration below shows hydraulic component location
RV1 & RV2, (refer to section M2.4). The setting for RV1 & in the power unit.

TWO SPEED LIFT ONE SPEED LIFT

Manual Release Quick Disconnect Quick Disconnect

Valve MV1 Test Point Test Point
Manual Release
Valve MV1

Lift/Lower
Manifold

Solenoid Valve
SV2
Solenoid Valve
SV1 Solenoid Valve
SV1
Relief Valve Relief Valve
RV2 Relief Valve RV1 RV1

Relief Valve
Solenoid Valve RV2
SV4 Solenoid Valve
Solenoid Valve SV2
SV3 Solenoid Valve
SV3
Part Of Power Unit Part Of Power Unit

Filter

Sight Gauge

Reservoir

Pump Motor M3

Pump Motor M4

Pump P1
Pump P2

Strainer

Accumulator

3706
ILLUSTRATION 1
950612 5576

Crown 1995 PF10646-1 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
M2.0–7530–001 M2.0–7530–001
 HYDRAULIC SYSTEM

Hydraulic Circuits Relief Valve Operation

These pages contain a brief description of the hydraulic During the lift function, relief valve RV1 monitors hydraulic
circuits for SP trucks which are typical of current standard pressure. If oil pressure exceeds the relief pressure setting,
units. Your unit may vary. Refer to section HYD in this the relief valve is forced open, allowing the pressurized oil to
manual for appropriate schematic. bypass the lift circuit. From the relief valve, oil exits from the
manifold block through port T. From port T, oil passes
Lift Circuit - One Speed Lift/Lower through the return line filter then back to the reservoir.

When lift is selected, oil is drawn from the hydraulic reservoir Accumulator Operation
to hydraulic pump P1. P1 supplies pressurized oil to the lift/
lower manifold block. The oil enters the manifold block The accumulator is used as a shock absorber for the lift/
through port P1 and goes directly to check valve CV1. Oil lower hydraulic system. If the platform is stopped suddenly,
passes through the manifold block until it exits port C. the change in oil flow exerts pressure on the hydraulic
Pressurized oil enters the lift cylinders and begins to extend system. The accumulator absorbs this oil pressure change
the mast. by using the gas pressurized bladder located within the
accumulator. The bladder acts as a pillow to the pressurized
Lifting Fork Lift Circuit oil, cushioning the applied pressure within the hydraulic
circuit. The typical symptom of a bad or de-pressurized
Depressing both lifting fork raise buttons starts the lift pump accumulator is abrupt starting and stopping of the platform
and energizes solenoid valves SV2 and SV3, within the during lift or lower.
combination valve. Energizing SV3 opens a path for oil flow
to the lifting fork cylinder and SV2 blocks the path for oil flow
to the reservoir. The lift pump draws oil from the reservoir
through a filter. Pressurized oil then flows through the
energized solenoid valve SV3, out the combination valve to
the static positioned solenoid valve SV5. Pressurized oil
passes through flow control valve FC, unrestricted, into the
lift cylinder.

1.25SP One Speed Lift/Lower

Accumulator
*RV1 Setting: 3.45 MPa Suction
TL 16.13 to 16.31 MPa Pressure
Precharge Return
TT 19.20 to 19.37 MPa Relief
TP
Lift/Lower Manifold ACC

TTMast
Pump & Motor *RV1 FC MV1
19 l/m Mast Mast
M1 Cylinder Free Lift Cylinder
Cylinder
CV1 SV C
P1 P1
TP T

Reservoir Filter

Strainer
Velocity Fuse

Velocity Fuse Velocity Fuse

10897 ILLUSTRATION 2
Crown 1995 PF10646-2 Rev. 4/03 Printed in U.S.A.
01 REV. 4/03
M2.0–7530–002 M2.0–7530–002
 HYDRAULIC SYSTEM

Lower Circuit - One Speed Lift/Lower Lifting Fork Lower Circuit

When lower is selected, oil begins to exit the lift cylinder. Oil Depressing both lifting fork lower buttons energizes solenoid
leaving the cylinder is monitored by the internal velocity fuse valve SV5, opening a path for return oil flow. Return oil
in each cylinder. passes through flow control valve FC, restricted, controlling
lowering speed. From FC, return oil flows through solenoid
Velocity fuses are designed to prevent the sudden release of valve SV5 into the combination valve. Return oil then passes
hydraulic oil from the cylinder under such conditions as a through the check valve CV2 and solenoid valve SV2, out the
rupture. If a cylinder line ruptured, the oil exiting the cylinder combination valve, through a filter into the reservoir.
would create pressure on the velocity fuse forcing the fuse to
close. This blocks the oil from exiting the cylinder. For accumulator operation, see previous page.

During normal operation, oil exiting the lift cylinders enters

the lift/lower manifold block through the open envelope
(envelope without a check valve) of solenoid valve SV which
is in the energized position. Oil is directed from SV to the flow
control valve FC. FC limits the maximum oil rate to 5 gpm.
The oil exits the flow control valve and out of the manifold
through port T. From port T, the oil enters the return line filter
then back to the reservoir.

1.0SP One Speed Lift/Lower

Suction
Accumulator Pressure
3.45 MPa Return
Precharge Relief
*RV1 Setting:
TL 16.13 to 16.31 MPa
TT 19.20 to 19.37 MPa
*RV2 Setting: SV5 Lifting Fork
TL & TT 12.0 to 12.4 MPa Cylinder
Lift/Lower Manifold
FC TT MAST
F
SV3
M1 Mast
Cylinder
*RV2 Mast Free Lift
P1 C Cylinder Cylinder

SV2 MV1
SV1

*RV1 FC
19 l/m

Filter

Strainer

Reservoir

10898 ILLUSTRATION 3

Crown 1995 PF10646-3 Rev.4/03 Printed in U.S.A.

01 REV. 4/03
M2.0–7530–003 M2.0–7530–003
 HYDRAULIC SYSTEM

Lift Circuit - Two Speed Lift/Lower Relief Valve Operation

Low Speed Lift During the lift function, relief valve RV1 monitors hydraulic
pressure. Oil pressure exceeding the relief pressure setting
When the lift button is depressed to the first detent, oil is will force RV1 open, allowing the pressurized oil to bypass
drawn from the hydraulic reservoir to hydraulic pump P1. the lift circuit. Oil exits the manifold block through port T.
The hydraulic pump supplies pressurized oil to the lift/lower From port T, oil passes through the return line filter then back
manifold block. The oil enters the manifold block through the to the reservoir.
port P1 and goes directly to check valve CV2. The oil passes
through the manifold block until it exits port C. Pressurized oil Accumulator Operation
enters the lift cylinders and begins to extend the mast.
The accumulator is used as a shock absorber for the lift/
High Speed Lift lower hydraulic system. If the platform is stopped suddenly,
the change in oil flow exerts pressure on the hydraulic
When the lift button is completely depressed, pump P2 turns system. The accumulator absorbs this oil pressure change
on simultaneously with pump P1. The hydraulic pump P2 by using the gas pressurized bladder located within the
supplies pressurized oil to the lift/lower manifold block. The accumulator. The bladder acts as a pillow to the pressurized
oil enters the manifold block through port P2 and goes oil, cushioning the applied pressure within the hydraulic
directly to check valve CV4. This oil passes through the circuit. The typical symptom of a bad or de-pressurized
manifold block where it joins the oil supplied from the pump accumulator is abrupt starting and stopping of the platform
P1 out to the lift cylinders. during lift or lower.

1.25SP Two Speed Lift/Lower

Suction
Pressure
Return
Relief
Accumulator
Pump & Motor *RV1 Setting: 3.45 MPa
TL 16.13 to 16.31 MPa Precharge TT Mast
TT 19.20 to 19.37 MPa
M1 Mast Mast
TP
Lift/Lower Manifold Cylinder Cylinder
ACC
P1
P1 SV2 C Free Lift
CV2
Cylinder
CV1 FC2
*RV1 19 l/m
Pump & Motor

FC1
CV3 19 l/m MV1
M2 Velocity Fuse
SV1
P2 CV4
P2
Velocity Fuse Velocity Fuse
Filter T
Reservoir

Strainer

10899
ILLUSTRATION 4

Crown 1995 PF10646-4 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
M2.0–7530–004 M2.0–7530–004
 HYDRAULIC SYSTEM

Lower Circuit - Two Speed Lift/Lower High Speed Lower

When lower is selected, oil begins to exit the lift cylinder. Oil When the lower switch is completely depressed, solenoid
leaving the cylinder is monitored by the internal velocity fuse valve SV2 energizes simultaneously with solenoid SV1. The
in each cylinder. hydraulic flow rate is now doubled. Oil is directed through the
open envelope of solenoid valves, SV1 and SV2 to the flow
Velocity fuses are designed to prevent sudden release of control valves, FC1 and FC2. These valves limit the maxi-
hydraulic oil from the cylinder under a condition such as a line mum oil rate to 19 l/m. For high speed lower, SV1 and SV2
rupture. If a cylinder line ruptures, the oil exiting the cylinder energize simultaneously permitting a flow rate of 38 l/m to
would create pressure on the velocity fuse, forcing the fuse return back to tank. Once the oil exits the flow control valves,
to close. This will block the oil from exiting the cylinder. it is directed out of the manifold through port T. From port T,
oil enters the return line filter then back to the reservoir.
Low Speed Lower
For accumulator operation, see previous page.
When the lower button is depressed to the first detent, oil
exits the lift cylinders and enters the lift/lower manifold block
through port C. The oil passes through the open envelope
(envelope without a check valve) of the solenoid valve SV1
which is in the energized position. Oil is directed from SV1 to
the flow control valve FC1. FC1 limits the maximum oil rate
to 19 l/m. Once the oil exits FC1, it is directed out of the
manifold through port T. From port T, the oil enters the return
line filter then back to the reservoir.

1.0SP Two Speed Lift/Lower

Suction
Pressure
Accumulator Return
3.45 MPa Relief
*RV1 Settings Precharge
TL 16.13 to 16.31 MPa
TT 19.20 to 19.37 MPa
*RV2 Setting SV5
TL & TT 12.0 to 12.4 MPa Lifting Fork
Lift/Lower Manifold ACC FC Cylinder
SV4 F
M1
CV4
P1
P1 *RV2 C
TT Mast
CV CV1
SV3 SV2
Mast Mast
Cylinder Cylinder
FC2 Free Lift
19 l/m Cylinder
T

*RV1 FC1
CV2
19 l/m
M2
CV3 MV
SV1
P2
P2 Velocity Fuse
Reservoir Filter
Velocity Fuse Velocity Fuse

Strainer

10900
ILLUSTRATION 5

Crown 1995 PF10646-5 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
M2.0–7530–005 M2.0–7530–005
 HYDRAULIC SYSTEM

MANUAL LOWER CIRCUITS

The manual lowering feature is used to lower the mast during is directed to the manual lowering valve's open envelope
truck down situations. The manual lowering valve MV1 is (envelope without check valve). Oil exits the manifold through
located on the raise/lower manifold block. When MV1 is port T. From port T, the oil enters the return line filter then
actuated, oil trapped in the cylinder is released. Oil enters the back to the reservoir.
raise/lower manifold through port C. From port C the oil flow

Manual Lower - One Speed Lift/Lower

Accumulator Suction
*RV1 Settings: Pressure
TL 16.31 to 16.31 MPa 3.45 MPa
Precharge Return
TT 19.20 to 19.37 MPa Relief
Lift/Lower Manifold ACC

TT Mast
Pump & Motor *RV1 FC
19 l/m MV1
Mast Mast
M1 Cylinder Cylinder
Free Lift
SV1 C Cylinder
P1
P
TP T

Filter
Reservoir

Strainer
Velocity Fuse

Velocity Fuse Velocity Fuse

10901

Lower-Two Speed Lift/Lower

Accumulator
Pump & Motor *RV1 Settings: 3.45 MPa
TL 16.31 to 16.31 MPa Precharge
TT Mast
TT 19.20 to 19.37 MPa
M1 Mast Mast
Cylinder Cylinder
Lift/Lower Manifold
ACC Free Lift
Cylinder
P1
P1 C
CV2 SV2
CV1
FC2
*RV1 19 l/m
Pump & Motor
TP FC1
19 l/m MV1
M2 CV3 Velocity Fuse
SV1
P2 CV4
P2 Velocity Fuse
Velocity Fuse
Filter T
Reservoir

Strainer

10902 ILLUSTRATION 6
Crown 1995 PF10646-6 Rev. 4/03 Printed in U.S.A.
01 REV. 4/03
M2.0–7530–006 M2.0–7530–006
 HYDRAULIC SYSTEM

Reservoir
WARNING
With all cylinders in the retracted position and after all air has AVOID HIGH PRESSURE FLUIDS—Escaping
been bled from the hydraulic system, fill reservoir so that the fluid under pressure can penetrate the skin caus-
oil level is at the high mark on the reservoir sight gauge. The ing serious injury. Relieve pressure before dis-
total capacity of the hydraulic system at this level should be connecting hydraulic lines. Tighten all connec-
approximately 13 litres for trucks with one speed lift, and 17 tions before applying pressure. Keep hands and
litres for trucks with two speed lift. body away from pin holes which eject fluids under
high pressure. Use a piece of cardboard or paper
to search for leaks. Do not use your hand.

Any fluid injected into the skin under high pres-

sure should be considered as a serious medical
Sight
Gauge emergency despite an initial normal appearance
of the skin. There is a delayed onset of pain, and
serious tissue damage may occur. Medical atten-
tion should be sought immediately by a specialist
who has had experience with this type of injury.

3243 ILLUSTRATION 7 Filter

Hydraulic Lines and Fittings The spin on filter cartridge has been tightened by Crown.
When replacing filter, apply a film of oil 063001-001 to the
1. Blow air through all hose and lines to remove loose seal and hand tighten until seal snugly contacts filter head.
particles before installing. Any rubber hose with wire
braid inner construction and any steel tube lines which NOTE
have been collapsed or kinked are permanently dam-
aged and must be replaced even if the damage is not Do not tighten filter with the use of a wrench. A
externally visible. wrench should only be used for removal of the
filter.
2. Flexible hose must be replaced if it collapses in normal
operating position. Use only a good grade of hydraulic oil such as Mobil DTE 24
(Crown No. 063001-001) or equal. On trucks equipped to
3. All hoses and lines are to be clear of any surface or operate in below freezing temperatures, Mobil Aero HFA or
edge which will cause damaging wear and cuts, or on equal is recommended (Crown No. 063001-006) in a 50/50
which they can become caught. blend with standard hydraulic oil.

4. All connections are to be leak free. NOTE

5. The beaded elbows in suction ports of all pumps must Do not use hydraulic brake fluid.
be positioned such that the suction hose retains its full
volume flow and does not collapse.

Crown 1995 PF10646-7 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
M2.0–7530–007 M2.0–7530–007
 HYDRAULIC SYSTEM

DRIFT TEST FREEZER PREPARATION

All drift tests should be conducted with a capacity load (refer Crown trucks may require a mixture of low temperature
to serial plate for the rated capacity of your truck). The hydraulic oil, Crown P/N 063001-006 (3.79 liters), blended
material used for the test load must be evenly stacked within with standard hydraulic oil, Crown P/N 063001-021 (3.79
the limits of a four foot square pallet and must be secured to liters) when used in a freezer or cooler. 100% low tempera-
the fork carriage with the forks spread to their maximum ture oil is too thin for most cold storage operations and
width. therefore could shorten the life of cylinder packings and
pumps if used in higher ambient temperatures.
CAUTION
Never stand or work under a suspended load. NOTE

Lift Drift Test Trucks equipped with velocity fuses may experi-
ence staging issues if an insufficient mix of low
Elevate the test load above staging height. After five min- temperature oil has been used.
utes, measure the distance the forks have drifted. Drifting in
excess of 15 mm over a five minute period is considered For truck applications operating continually in temperatures
unacceptable. at or above 4° C, use 100% standard hydraulic oil (063001-
001).
NOTE
For truck applications primarily operating in a cooler environ-
The lift measurement is to be taken from the tip of ment with intermittent freezer entry, use a 50/50 blend, 50%
the fork to the floor. low temperature (063001-006) and 50% standard hydraulic
oil (063001-021).
Occasionally, a slight creep of the fork assembly may occur
due to internal leakage in the piston pack, but it can also be
caused by leakage in check or manifold valves. To seat
these valves properly when this occurs, lift and lower the
forks to flush out any foreign material from the valve seat.

A thorough check for leaks in the system should be con-

ducted if abnormal oil losses occur. The hydraulic system is
designed to eliminate mechanical damage even if fittings
become loose.

50 120
40 100 Standard Hydraulic Oil
30 80 (063001-001 [100%])
20 60
50/50 Mix of Low-Temp 10
40
(063001-006 [50%] & 0
Standard Hydraulic Oil 10 20
(063001-021 [50%]) 0 80/20 Mix of Low-Temp
20 (063001-006 [80%] &
30 20 Standard Hydraulic Oil
40 40 (063001-021 [20%])
C F

SP Models
6351

Crown 1995 PF10646-8 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
M2.0–7530–008 M2.0–7530–008
 HYDRAULIC SCHEMATIC SYMBOLS
3559-02

VENTED RESERVOIR
with lines above fluid level
M ELECTRIC MOTOR
unidirectional single speed

VENTED RESERVOIR
with lines below fluid level

M ELECTRIC MOTOR
unidirectional variable speed

FILTER or STRAINER

HYDRAULIC LINE HYDRAULIC PUMP

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

PILOT or DRAIN LINE

limited flow HYDRAULIC MOTOR
bi-directional

LINES CROSSING

GAUGE
LINES CONNECTED pressure

QUICK DISCONNECT
(disconnected)
GAUGE
temperature

PLUGGED PORT
(test port)

ACCUMULATOR
gas charged diaphragm type
FLOW METER

2128

Crown 1979 PF5066-1 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1–00.0–001 M2.1–00.0–001
 HYDRAULIC SCHEMATIC SYMBOLS
3560-02

PRESSURE SWITCH
ACTUATOR MANUAL

CYLINDER
SPRING
double acting unequal area
(bias to normal de-energized position)

CYLINDER
double acting equal area
(steer) (double end) SOLENOID
single coil or winding

CYLINDER
single acting spring returned
(rod end vented)
HYDRAULIC PILOT OPERATED

CYLINDER
single acting ram type
SOLENOID
pilot operated

CYLINDER
single acting with cushion
SOLENOID DUAL

COMPONENT ENCLOSURE
manifold block
SOLENOID PROPORTIONAL

VALVE PILOT CHECK

ACTUATOR MANUAL LEVER
(pilot to open)

Crown 1979 PF5066-2 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1–00.0–002 M2.1–00.0–002
 HYDRAULIC SCHEMATIC SYMBOLS
3561-02

ORIFICE THROTTLE
fixed VALVE SHUTTLE

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
regulated flow
pressure compensated

VALVE RELIEF VALVE MANUAL SHUTOFF

fixed setting

P TORQUE GENERATOR
VALVE RELIEF T
adjustable

T L STEER UNIT
VALVE CHECK hydrostatic
P R

Crown 1979 PF5066-3 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1–00.0–003 M2.1–00.0–003
 HYDRAULIC SCHEMATIC SYMBOLS
3562-02

VALVE
2 way 2 position VALVE
3 way 2 position
spring bias, solenoid control

VALVE
3 way 2 position

VALVE
4 way 3 position
dual spring centered,
manual lever control
VALVE
4 way 2 position

VALVE
4 way 3 position

NOTE: The type of valve

depends on the number of
spools found in the
VALVE component enclosure
(Triple spool valve
2 way infinite positions shown)

VALVE
4 way infinite positions

Crown 1979 PF5066-4 Rev. 1/02 Printed in U.S.A.

03 REV. 1/02
M2.1–00.0–004 M2.1–00.0–004
 MAINTENANCE

3
4
6
7

1 5
3
2
10
3 5

6
9
4
3
11
9221 ILLUSTRATION 1

PUMP - GEAR

Overhaul the pump only in a clean, dust-free location, using then be removed with the use of a seal removing tool. Be
clean tools and equipment. Dirt or grit will damage the highly careful not to damage the mounting flange seal bore or the
polished machined surfaces and will result in leakage or drive shafts sealing surface.
premature failure of the pump.
OIL SEAL REPLACEMENT
Before beginning the disassembly, scribe match marks on
the body assembly, the end cover and mounting flange to 1. Make sure the seal housing in the pump mounting
insure that the pump will be reassembled properly. This flange is clean and free from burrs.
pump can be assembled for either clockwise or counter-
clockwise rotation as viewed from the end of the splined drive 2. Pack the space between the lips of the seal with a high
gear assembly. Arrows are molded in to the body assembly melting point, mineral based grease.
and the word "ROTATION" appears on the mounting flange
to aid in determining the pumps rotation. Note which direc- 3. Seat the oil seal.
tion the arrow is pointing next to the word "ROTATION" prior a. If the mounting flange has been removed:
to disassembly. Start the oil seal squarely into the housing, with the
garter spring facing inward and press home to the
OIL SEAL REMOVAL full depth of the recess.
b. If the pump is assembled:
The oil seal (index 11) is best removed by applying pressure Slide an "Assembly Sleeve" (available from Crown
simultaneously to the pump inlet and outlet ports. This has [#93170]) over the shaft splines until it comes in
the effect of pressurizing the seal cavity and forcing out the contact with the shaft shoulder. Lightly grease the
oil seal while ensuring that the pressure on each side of the sleeve. Slide the oil seal, with the garter spring
lobe seals (item 3 & 4) is equalized so that these seals are facing inwards, over the sleeve and start it squarely
not displaced. If the oil seal is distorted and leaking badly, it into the housing.
may not be possible to build up sufficient pressure to remove
it in this way. In this case, disassemble the pump as far as 4. Press the seal into the full depth of the recess.
step 5 of the "DISASSEMBLY PROCEDURE" and clamp the
mounting flange securely in a soft-jawed vice. The seal can 5. Remove the Assembly Sleeve.

Crown 1982 PF5372-1 Printed in U.S.A.

M2.1–10.0–001 M2.1–10.0–001
 MAINTENANCE

PUMP DISASSEMBLY the body should be rejected. It is not advisable to fit worn
bushings into a new body. Check to make sure the two
1. Remove the bolts which hold the pump to the lift motor. hollow dowels are not loose.

2. Lightly mark or scribe the end cover (index 2), the body Composite Bushings
(index 7) and the mounting flange (index 10) to ensure
re-assembly in the correct relationship. Also note the Examine the bearing inserts for signs of wear and check the
direction of rotation of the pump. bushing faces adjacent to the gears for scoring or pitting.
Make sure the holes and slots in the bushings are not
3. Loosen the bolts and lockwashers (index 1) and pull plugged. Light scored on the bushings faces can be polished
out the bolts. out on a lapping plate.

4. Remove the end cover (index 2) and carefully lift out the NOTE
two backing washers (index 3), the lobe seals (index 4) If new bushings are to be used in an old body, check
and the body "O" ring seals (index 6). The body seal is for any burrs at the edge of the wear track. If present,
a moulded rubber seal on early pumps but changed to this burr must be polished out or it may hold the
an "O" ring on newer units (Specify when ordering). bushing faces away from the gears and increase the
internal leakage.
5. Fit an "Assembly Sleeve" tool (available from Crown
[#93170]) over the splines on the drive shaft before Gears
withdrawing the mounting flange. Lightly tap the mount-
ing flange clear of the two hollow dowels in the pump Examine the gears for discoloration, caused by overheating.
body and slide it squarely off of the shaft. Check the shafts for scoring. Make sure the contact marks on
the teeth are evenly distributed across each tooth surface
6. Carefully lift out the body "O" ring seal (index 6), the two and that none of the teeth are chipped.
backing washers (index 3) and the lobe seal (index 4).
NOTE
7. Hold the pump body vertically with the mounting flange
end downward and with one hand underneath to pre- Bushings and/or gears are matched for widths within
vent the bushings (index 5) from falling out. Tap the .0002" (0.005 mm) and can only be sold and re-
side of the body with a rawhide mallet to dislodge the placed as a matched pair.
lower bushings, and slide them carefully out of the
body. Keep the bushings as a pair and place them on End Cover
or near the mounting flange. Examine the cover to insure flatness and inspect for scoring
and pitting.
8. Invert the body and lift out the drive (index 9) and the
idler (index 8) gears. Mounting Flange

9. Remove the remaining pair of bushings as described in Check for damage and check the condition of the oil seal. If
step 7 and place on or near the end cover. the seal needs replacement refer to the "Oil Seal Replace-
ment" section.
PARTS INSPECTION

Wash all metal parts thoroughly with a good cleaning fluid.

Inspect, in the order disassembled, for wear and damage.
LOBE SEAL
Body

To obtain high efficiency the design allows for the tips of the
gear teeth to wipe the walls of the body bores when the pump
BACKING WASHERS
is running. Pressure will force the gears against the inlet side
of the bores a wear pattern will be visible in this area. If
excessive wear of the bushing inserts or gear journals
occurs this wear pattern will deepen to form a step in the
bore. Examine the body bores and if a pronounced step is felt 9222 ILLUSTRATION 2
Crown 1982 PF5372-2 Printed in U.S.A.

M2.1–10.0–002 M2.1–10.0–002
 MAINTENANCE
CLOCKWISE ROTATION
COVER END MOUNTING FLANGE END

BUSHING LOBES
BUSHING LOBES FLAT

ASSEMBLE DRIVE GEAR ASSEMBLE DRIVE GEAR

IN THIS BORE IN THIS BORE

COVER END MOUNTING FLANGE END

BUSHING
FLAT LOBES FLAT

ASSEMBLE DRIVE GEAR ASSEMBLE DRIVE GEAR

IN THIS BORE IN THIS BORE
COUNTER-CLOCKWISE ROTATION
9223 ILLUSTRATION 3
PUMP REASSEMBLY

Make sure that all pump components are perfectly clean and 5. Pick up the mounting flange bushing complete with
lubricated with the hydraulic oil to be used in the pump, prior lobe seal and backing washers, and slide them into the
to assembly. body bores with the lobes facing outwards and away
from the flat at the intersection of the body bores. The
1. Prepare the bushings (index 5) for mounting flange end bushings must be inserted squarely into the bores and
of the body for assembly as follows: must be kept square to each other. Do not use force
(Refer to illustration 2) when installing the bushings. If the bushings should
Place the bushings on the workbench with their lobes cock in the bores, remove them and examine for
up and the flats in contact. Lubricate the lobe seal scored body walls. Light scoring can be stoned out with
(index 4) with a mineral based grease and fit it around a fine grit hand stone.
the bushing lobes. Fit a backing washer (index 3) inside
each lobe seal. When fitted correctly, the backing 6. Lubricate the body seals "O" ring (index 6) with a
washer must be level and flush with the top surface of mineral based grease and seat it in the body.
the bushing lobes.
7. Refer to illustration 3 to find the position of the drive
2. Prepare the bushings for the cover end of the body for gear bore for the direction of rotation you require. Lay
installation into the pump in the same manner. the pump body on its side and slide the drive gear
(index 9) through the drive gear bore (as called out in
3. Pack the space between the lips of the oil seal (index illustration 3) so that the shaft protrudes out of the
11) with a high melting point, mineral based grease. hollow dowel end of the body.

4. Pick up the body and hold it with the hollow dowels up

and with the fingers of one hand inside the bores of the
body, ready to support the bushings.
Crown 1982 PF5372-3 Printed in U.S.A.

M2.1–10.0–003 M2.1–10.0–003
 MAINTENANCE

8. Slide the "Assembly Sleeve" (#93170) over the end of START UP PROCEDURE
the splined shaft. Hold the drive gear journal with one
hand and slide the mounting flange (index 10) squarely A pump that has been re-assembled with new gears, bush-
over the shaft and onto the two hollow dowels, flush ings or body must be carefully broke-in before it is subjected
against the body. The "Assembly Sleeve" provides a to full load working conditions.
lead-in for the oil seal. Remove the "Sleeve" and clamp
the mounting flange in a soft jawed vice with the pump When test rig facilities are not available the following proce-
body above the flange. If the sleeve is stuck on the dure must be carried out:
splines it can be removed by tightening a 1/4"-28 bolt
into the end of the "Assembly Sleeve". 1. Install the pump on the application.

9. Check that the bushings are flush against the mounting 2. Where the pump speed is variable set the speed to
flange face and that the lobe seals (index 4) and 1500 rev/min; otherwise run the pump at its normal
backing washers (index 3) have not become dis- operating speed.
lodged. Check to see that the arrow on the body,
adjacent to the word "ROTATION" is pointing in the 3. Run the pump at this speed for a period of 10 minutes
correct pump rotation. at minimum pressure, that is, with the hydraulic system
unloaded.
10. Mesh the idler gear (index 8) with the drive gear. If the
original gears are being replaced on a new shaft, make 4. If the pump operating pressure can be directly con-
sure that the marked side of the teeth are in contact so trolled, ensure that the pressure is progressively in-
the bedded-in position of the teeth is maintained. creased up to full working requirements over the first
hour of operation. In circumstances where the pres-
11. Pick up the bushings for the end cover side of the sure cannot be directly controlled the same effect can
pump, complete with lobe seals and backing washers be obtained by progressively increasing the work load
and slide them over the gear journals with the lobes on the machine, over the same period of time.
facing outward and away from the flats in the bores.
Again, the bushings must be installed squarely and 5. During this period make frequent checks of the pump
without force. casing temperature, or the oil temperature, if a tem-
perature gauge is included in the system. The tempera-
12. Lubricate the body seal "O" ring (index 6) and seat it in ture should not exceed that experienced under normal
the body. working conditions. If the temperature does rise exces-
sively then it is possible that the pump has been
13. Place the end cover in position, aligning the scribe assembled incorrectly and it must be dismantled to
marks made earlier. check this. If no fault is found then further period of
running-in at low pressure, as in step 3, must be carried
14. Insert the bolts and lockwashers into the body and out.
hand tighten into the tapped holes in the mounting
flange. Apply a torque load of 4.7 to 5 kgm (34 to 36 ft
lbs.) to each bolt head.

15. Pour a small amount of hydraulic oil into the ports and
check the pump for freeness and direction of rotation.

Crown 1982 PF5372-4 Printed in U.S.A.

M2.1–10.0–004 M2.1–10.0–004
 C DRIVE UNIT

DRIVE TIRE REPLACEMENT If Present, Remove Paint on Tapered

Lug Seats and on Inner Hub Face that
When replacing the drive tire, make sure the composition Contacts Truck Axle
and size are such that maneuverability and braking require-
ments are maintained. The drive tire is a “press-on” type; Hub
press the old tire off the hub and press new tire on.

1. Disconnect battery and chock wheels.

Inner Tapered Lug Seats
2. Raise and block the power unit so drive tire is off of the Hub
floor. Loosen and remove the 8 lug bolts and remove Face
wheel and hub from drive unit.

3. Remove old drive tire and replace with new drive tire.
The outside of the hub must be pressed flush with the
outside edge of the tire.

4. Inspect hub and remove any paint that may be present

on tapered lug seats or on inner hub face that contacts 1
truck axle. See Illustration 1.
4 5
5. Finger tighten lug bolts, then tighten to 135/150 Nm
7 8
(100/110 ft. lbs.) making sure that they are tightened in
the sequence shown in Illustration 1.
3 2
6

Tighten Lug Nuts in Sequence Shown

11150
ILLUSTRATION 1

6. Remove blocks, lower power unit, connect battery and

remove wheel chocks.

941222 7363 - EO12027

Crown 1994 PF10343-1 Rev. 2/04 Printed in U.S.A.

02 REV. 2/04
M3.0–7330–001 M3.0–7330–001
 C DRIVE UNIT

DRIVE UNIT LUBRICATION

The drive unit has a capacity of approximately 1000 ml (1.5 Oil Pump Disassembly (Refer to Illustrations 3 & 4)
pints) of 90W gear lube Crown no. 063002-003. The drive
unit has a capacity of approximately 1000 ml (1.5 pints) of 1. Disconnect battery and chock wheels.
90W gear lube, Crown no. 063003-003 (or 063001-023, ATF
for trucks operating in freezer applications below 32°F AXLE
[0°C]). Remove drain plug to completely drain unit. To fill,
remove fill plug. Add gear oil until present at oil level check BEARING
CAM CONE
plug. Refer to Illustration 2.
O- RING (3) BEARING
CUP
DRIVE PISTON(9)
UNIT SPRING(8)
HOUSING
BALL(7)
O- RING (2)
PLUG
Fill & Oil OIL PUMP SPECIAL(6)
Level Check HOUSING
Plug SPRING(5)
BALL4)

1895S ILLUSTRATION 3

Drain
Plug

3512 ILLUSTRATION 2

Crown 1994 PF10343-2 Rev. 2/04 Printed in U.S.A.

02 REV. 2/04
M3.0–7330–002 M3.0–7330–002
 C DRIVE UNIT

2. Remove drain plug (23); drain oil from drive unit. Oil Pump Assembly (Refer to Illustrations 3 & 4)
19
18
20 21
Inspect all component parts and drive unit casting for dirt and
burrs before assembly.
17

1. Place ball (4) and spring (5) into oil pump housing (1).

TUBING IS INSTALLED THROUGH

CORED HOLE IN CASTING
2. Place ball (7), spring (8) and special pipe plug into
piston (9). Lubricate piston with oil to aid in smooth
action and install piston into oil pump housing installed
22 16
in drive unit housing.
13
15 12 3. Install O-rings (2) and (3) onto pump body.
14
11
4. Oil pump body and port thoroughly and screw pump
assembly into casting until seated.

18 5. Apply hydraulic sealer (06004-005) to drain plug and

10 replace drain plug. Fill drive unit wit 1000 ml (1.5 pints) of
90W gear lube, Crown no. 063002-003 (or 063001-023,
ATF for trucks operating in freezer applications below
3
32F [0°C]).
3

2 23
5 9

1 4 8
7
6

1837S ILLUSTRATION 4

3. Remove oil pump housing (1) from drive unit and move
to a clean work area for further disassembly.

4. Check O-rings (2) and (3) for damage and replace if

necessary.

5. Remove piston (9), spring (8) and ball (7) from oil pump
housing.

6. Remove special pipe plug (6), spring (5) and ball (4)
from oil pump housing.

7. Thoroughly clean housing and all parts.

Crown 1994 PF10343-3 Rev. 2/04 Printed in U.S.A.

02 REV. 2/04
M3.0–7330–003 M3.0–7330–003
 C DRIVE UNIT

DRIVE UNIT REMOVAL & INSTALLATION

(Refer to Illustration 5)

1. Disconnect battery and chock wheels. 4. Remove the drain plug in the bottom of the drive unit
with a 1/4" hex key wrench and allow gear oil to drain.
2. Open power unit doors.
5. Raise and block power unit. Remove the drive tire.
3. Disconnect all electrical wiring to the drive motor and Refer to drive tire replacement when assembling drive
electric brake. Remove the 4, 7/16" bolts that secure tire.
the drive motor and electric brake to the drive unit and
remove. 6. Remove the 4, 3/4" bolts and the 2 dowel pins that
fasten the drive unit to the power unit. When reattach-
NOTE ing the drive unit with these bolts, apply a small amount
of thread locking adhesive (061004-009) and tighten
Make note of all electrical connections removed to 340 - 370 Nm (250 - 275 ft. lbs.).
in step 3.
7. Stabilize the drive unit and raise and block the power
ELECTRIC BRAKE unit until the drive unit will clear the power unit.
STEERING MOTOR &
GEARBOX ASSEMBLY DRIVE MOTOR 8. Move the drive unit to a clean work area for further
disassembly.

9. Reverse steps 1 thru 7 to install drive unit. Align the

marks on the drive unit and the drive unit mounting
bracket. This ensures that the steered wheel is in the
straight ahead position.

10. Apply hydraulic sealer (06004-005) to drain plug and

replace drain plug. Fill drive unit wit 1000 ml (1.5 pints) of
90W gear lube, Crown no. 063002-003 (or 063001-023,
ATF for trucks operating in freezer applications below
32F [0°C]).

STEERING
ENCODER (ECR2)

DRIVE UNIT MOUNTING

ALIGNMENT MARKS BOLTS & DOWEL PINS
ON DRIVE UNIT AND
DRIVE UNIT MOUNTING BRACKET
3272 ILLUSTRATION 5

Crown 1994 PF10343-4 Rev. 2/04 Printed in U.S.A.

02 REV. 2/04
M3.0–7330–004 M3.0–7330–004
 MAINTENANCE

DRIVE UNIT REPAIR/REBUILD

The drive unit used on your Crown Lift Truck, is a double reduction gearbox incorporated spiral bevel gears for strength,
quietness and smooth operation. The unit is totally enclosed and oil is pumped throughout to give maximum lubrication to
both bearings and gears.

DRIVE UNIT COMPONENT OVER VIEW

Shown in the illustrations below is a parts breakdown and two cross sectional views of the drive unit components. The views
shown may vary slightly between the RR, RS, RD, SP 3000, TS and TSP trucks.

2910S

RR, RS, & RD

SHOWN

RR, RS, & RD

SHOWN

1199S-02

2911S
4295MI

Crown 1994 PF10344-1 Printed in U.S.A.

01 REV. 6/95
M3.0–1430–050 M3.0–1430–050
 MAINTENANCE

FIELD INSPECTIONS AND REPAIRS

This drive unit location facilitates the inspection of the drive unit as well as the replacement of the drive axle seal. To inspect
the drive unit, the bottom side cover can be removed. This will allow access to the drive unit lower half which consists of
the axle nut and spiral bevel gear.

REMOVING AXLE SEAL

To remove the drive axle seal, drill two holes 180 degrees
apart into the seals steel lip. Attach a small sheet metal screw
to the end of a slide hammer. Insert the screw into each of the
holes and gently remove seal.

2876P

INSTALLING NEW AXLE SEAL

When installing the new seal apply a thin coat of sealant (part
# 065005-001) to the outer diameter of the seal. Next push
seal into place. To seat the seal, place a wood block over the
seal and use a rubber mallet to drive in as shown. This will
prevent damage to the seal.

2875P

NOTE

RR truck shown. Access to axle on SP 3000, TS and TSP trucks may vary. Refer to appropriate truck service
manual, section M3.0.

Crown 1994 PF10344-2 Printed in U.S.A.

M3.0–1430–051 M3.0–1430–051
 MAINTENANCE

DRIVE UNIT DISASSEMBLY

Once the drive unit is removed it is ready to be taken to the bench for disassembly.

1. REMOVING RETAINING RING FROM MO-

TOR PINION GEAR

To begin drive unit disassembly, remove

the retaining ring from the motor pinion gear
area.

3048P

2. SLIDE PULLER ON MOTOR PINION GEAR

The pinion gear is drilled and tapped to

facilitate use of a slide hammer for removal
as shown. If the pinon gear and associated
components are to be reused, record the
position and number of shims removed.

3049P

3. REMOVING PINION AREA O-RING FROM

CASTING

Remove the O-Ring from the pinion area of

the housing.

3050P

Crown 1994 PF10344-3 Printed in U.S.A.

M3.0–1430–052 M3.0–1430–052
 MAINTENANCE

4. REMOVING UPPER PINION GEAR

Remove the locknut securing the upper reduction gear to

the pinion gear. Remove the pinion mounted reduction
gear as shown.

3051P

5. REMOVING IDLER GEAR SHAFT

Insert a 5/16" course thread screw into the idler gear shaft
and remove it with a pry bar.

3052P

6. REMOVING 6 BOLTS FROM PINION BEARING RE-

TAINER

Remove the 6 bolts from the pinion bearing retainer.

3053P

Crown 1994 PF10344-4 Printed in U.S.A.

M3.0–1430–053 M3.0–1430–053
 MAINTENANCE

7. PULLING PINION GEAR

The pinion gear can now be pulled as an assembly with

bearings and spacer. If the pinion gear and bearings are
reused record and retain the shim pack. Once the pinion
assembly is removed the idler gear and spacers can now
be removed. Inspect the bearings and gear for excessive
wear. The gear and bearings can be replaced separately.

3054P

8. REMOVING MOTOR PINION GEAR, BEARING AND

RETAINER

Remove the motor pinion gear bearing and bearing re-

tainer from the drive housing. The bearing cup can be
driven out from the bottom. Now remove the O-ring from
the housing bore that seals the bearing and retainer just
removed.

3055P

9. STUD BEARING REMOVAL

When the motor pinion gear and lower bearing are re-
moved the stud bearing can be driven out from the top. If
the drive unit is not to be rebuilt, but the stud bearing
requires replacement it can be removed separately. To
remove the stud bearing, split the bearing shell with a
chisel. Use pliers to bend the retainer over and remove the
stud bearing.

3056P

Crown 1994 PF10344-5 Printed in U.S.A.

M3.0–1430–054 M3.0–1430–054
 MAINTENANCE

10. OIL PUMP REMOVAL

Remove the oil pump from the housing. This will facilitate
removal of the drive axle. Inspect the oil pump for contami-
nates or damage. Rebuilding or replacement of the oil
pump is recommended before drive unit reassembly.

3057P

11. REMOVING LOCKNUT FROM AXLE

Remove axle locknut. Due to the thread locking adhesive

the locknut may need to be heated during removal.

Cut the wirelocks and remove the 8 bolts that secure the
ring gear to the hub.

3058P

12. REMOVING GEAR AND SHIMS

The spiral bevel gear can be removed with a slide hammer

using a 3/8" course threaded bit.

3059P

Crown 1994 PF10344-6 Printed in U.S.A.

M3.0–1430–055 M3.0–1430–055
 MAINTENANCE

13. SPIRAL BEVEL GEAR REMOVED

Behind the spiral bevel gear is the shim pack used to

control backlash between the spiral bevel gear and the
pinion. These shims can be reused provided the axle, hub
or related components are not removed or replaced.

3060P

14. REMOVING HUB WITH PULLER

The hub is heat press fitted to the axle. Depending on

wear pulling may require the use of a puller and heat. If
the hub can be removed without a puller, the hub and axle
assembly should be replaced.

The axle can be removed. Do not use the seal flange for
support if pressing is required to remove the axle, use the
housing. Replace the seal.

3061P

15. PRESSING OR DRIVING OUT BEARING RACE

If the bearings are to be replaced, remove the two cups

from the housing as shown.

3062P

Crown 1994 PF10344-7 Printed in U.S.A.

M3.0–1430–056 M3.0–1430–056
 MAINTENANCE

ASSEMBLING DRIVE UNIT

1. DRIVE UNIT COMPONENTS

Shown are all the components that make up the drive unit.
Before reassembly be sure to inspect all components for
wear or damage. Install the housing components which
include the bearing cups and oil pump tubing.

3063P

2. PINION COMPONENTS

The pinion assembly can be completely disassembled

when bearing removal is required. Inspect and replace
any components showing signs of wear.

3044P

3. INSTALLING PINION

Install the pinion assembly with a starting shim pack of

.050 or five .010 in. (1.3 or five .25 mm) shims. With the
pinion gear in place install two bolts 180 degrees apart
and tighten.

3064P

Crown 1994 PF10344-8 Printed in U.S.A.

01 REV. 6/95
M3.0–1430–057 M3.0–1430–057
 MAINTENANCE

4. PINION HEIGHT ADJUSTMENT TOOL PART NUMBER

116207

The tool shown is required to accurately determine the

correct pinion gear height or pinion gear to spiral gear
relation. After the bearing cups are installed insert the tool
with the nut side toward the axle seal retainer. Tighten the
nut until it is snug.

3065P

5. TOOL INSTALLED

The face of the tool shown has a radius of exactly 1 in.

(25mm) from the center of the axle bore.

3066P

6. SLIDING PARALLEL

Place the sliding parallel supplied in the kit between the

tool and the pinion gear. Squeeze the sliding parallel
firmly together and tighten down the screws.

3067P

Crown 1994 PF10344-9 Printed in U.S.A.

M3.0–1430–058 M3.0–1430–058
 MAINTENANCE

7. MEASURING THE SLIDING PARALLEL

Remove the sliding parallel. With a micrometer measure

the dimension of the sliding parallel and record. In this
example the measured dimension is 1.378 in. (35mm).

3068P

8. ETCHED PINION GEAR DIMENSION

Located on the bottom of the pinion gear is a etched

dimension that represents the distance from the bottom of
the pinion gear to the center of the axle bore. In this
example the etched dimension is 2.378 in. (60mm).

3069P

9. AXLE CENTER TOTAL

The dimension stamped on the bottom of the pinion gear,

in the previous step, is used to identify the proper depth of
the pinion gear to the axle center line. The pinion height
tool measures exactly 1 in. (25mm) from the center to any
side (radius). In this example the sliding parallel mea-
sured exactly 1.378 in. (35mm). These two numbers
added together equal 2.378 in. (60mm) which exactly
matches the dimension on the bottom of the pinion
assembly. The measured dimension and the pinions
etched measurement should not be more than + .003 in.
(.08mm) difference. If the measured dimension did not
check within the maximum tolerance the shims under the
pinion gear will require adjustment. The shims are avail-
able in .008, .010 and .013 in. (.2, .25 and .3mm) thick-
3045P ness.

Crown 1994 PF10344-10 Printed in U.S.A.

M3.0–1430–059 M3.0–1430–059
 MAINTENANCE

10. AXLE INSPECTION

Inspect the axle before installation to insure there are no

nicks or scratches.

Before installing bearings on the axle heat each bearing

and the pump cam to 250°F (120°C) for approximately 25
minutes. To insure proper heating only use a temperature
controlled oven or oil bath. Heating the bearings by any
other method or exceeding the 250°F (120°C) will cause
bearing damage.

The hub should be heated to 450°F (232°C) for approxi-

mately 35 minutes. Heating the hub will ease installation
and insure proper seating.
3070P

11. AXLE ASSEMBLED

After the axle is assembled install it.

3071P

12. PRESSING THE HUB

Press the hub onto the axle.

3072P

Crown 1994 PF10344-11 Printed in U.S.A.

M3.0–1430–060 M3.0–1430–060
 MAINTENANCE

13. UPPER HOUSING ASSEMBLY

The axle and hub are assembled into the drive unit, begin
assembly of the upper half. Install the drive motor pinions
lower bearing and cup. Pre-lubricate the bearing by filling
it 1/4 of the way with drive unit oil.

3073P

14. IDLER GEAR

Temporarily remove the main pinion assembly. Install the

idler gear and spacer. To ease installation grease each
spacer and place it on the bearing of the idler gear.

3074P

15. TIMING MARK ON PINION AND SPIRAL BEVEL GEAR

The pinion gear and spiral bevel gear are matched sets
and should never be replaced individually. Each of the
gears are marked with X’s. To time the gears correctly, the
pinion gears X should be placed between the two X’s on
the spiral bevel gear. Before installation of either gear,
mark the tooth of the pinion gear and outside surface of
3075P the spiral bevel gear with a black marker.

Crown 1994 PF10344-12 Printed in U.S.A.

M3.0–1430–061 M3.0–1430–061
 MAINTENANCE

16. PINION GEAR INSTALLATION

Install the pinion gear and proper shim pack. Install the
bolts for the pinion gear and tighten. Install the woodruff
key on the pinion gear shaft and install the gear.

3076P

17. TIGHTENING NUT

Tighten the nut with Crown tool part number 100253-001.

Once the nut is tight bend the tab over on the locking
washer.

3077P

18. IDLER GEAR SHAFT INSTALLATION

Position the idler gear and align the spacers. Install a

5/16" course thread screw into the idler shaft. Carefully
tap the shaft until it is fully seated.

3078P

Crown 1994 PF10344-13 Printed in U.S.A.

M3.0–1430–062 M3.0–1430–062
 MAINTENANCE

19. DRIVE MOTOR PINION INSTALLATION

Install the drive motor pinion and bearing.

3079P

20. SEATING DRIVE MOTOR PINION

Using a piece of 2 3/8 pipe, carefully drive the pinion and

bearing until fully seated.

3080P

21. O-RING INSTALLATION

Lubricate and install the O-ring.

3081P

Crown 1994 PF10344-14 Printed in U.S.A.

M3.0–1430–063 M3.0–1430–063
 MAINTENANCE

22. SHIMS AND SPACER

The size of the shim pack must be determined. Shim sizes

include .008, .010 and .013 in. (.2, .25 and .3mm).

3082P

23. BEARING DEPTH

To determine the proper shim pack size, measure the

dimension from the top of the pinion bearing to the top of
the drive unit housing and record. In this example it is
1.125 in. (30mm). Install the snap ring, measure its depth
and record. Example .275 in. (7mm).

3083P

24. SPACER DIMENSION

Measure the spacer thickness and record. Example .720

in. (18mm).

3084P

Crown 1994 PF10344-15 Printed in U.S.A.

M3.0–1430–064 M3.0–1430–064
 MAINTENANCE

25. SNAP RING THICKNESS

Measure the snap ring thickness. Example .095 in.

(2.4mm).

3085P 26. MEASUREMENT ILLUSTRATION

With the previously recorded dimensions calculate the

shim pack required. Take the total depth dimension 1.125
in. (30mm), subtract the dimensions of the snap ring,
spacer, and snap ring depth.

.275 in. (7 mm) Snap ring depth

.095 in. (2.4mm) Snap ring thickness
+ .720 in. (18.3mm) Spacer thickness
1.090 in. (27.6mm) Total measured dimensions

1.125 in. (30mm) Top of bearing to top of drive unit housing

- 1.090 in. (27.6mm) Total measured dimension
.035 in. (.9mm)
+ .030 in. (.8mm) Added Dimension
.065 in. (1.7mm) Total
3046P
The snap ring groove inherently adds an additional .030
in. (.8mm) that was not measured during the previous
procedure. For this reason add .030 in. (.8mm) to your
total measurement. In this example the total shim pack
measures .065 in. (1.7mm). The dimension tolerance is
+.003 in. (.08mm), therefore a shim pack of four .010 in.
(.25mm) shims and two .013 in. (.3mm) shims will provide
a total of .066 in. (1.7mm) meeting our dimension.

27. SPACER AND SHIM INSTALLATION

Install the shims and spacer with the 2 3/8 pipe as shown.
After the spacer is seated install the snap ring.

3086P

Crown 1994 PF10344-16 Printed in U.S.A.

01 REV. 6/95
M3.0–1430–065 M3.0–1430–065
 MAINTENANCE

28. COVER INSTALLATION

Install the cover and fasten the screws.

3087P

29. SPIRAL BEVEL GEAR INSTALLATION

The shims between the spiral bevel gear and hub are
used to set the backlash between the spiral bevel and
pinion gears. The shim sizes available are .005, .007 and
.020 in. (.13, .18 and .5mm). Begin with three .020 in.
(.5mm) shims and install the gear. Install at least two of
the spiral bevel gear bolts and tighten.

3088P

30. NUT INSTALLATION

Install the axle nut and torque to a 100 ft. lbs. (135Nm).

3089P

Crown 1994 PF10344-17 Printed in U.S.A.

M3.0–1430–066 M3.0–1430–066
 MAINTENANCE

31. CHECK BACKLASH

With the use of a dial micrometer, measure the backlash

of the gear at the axle nut. This dimensions should be
between .003 to .006 in. (.08 to .15mm) total. Be sure to
place the micrometer feeler arm tip, or ball, on the very
edge of the nut cutout as shown. The addition of shims will
increase backlash while the removal of shims will de-
crease the backlash. A change of .006 in. (.15mm) shim
will change this dimension by .002 in. (.05mm), or a 3-1
ratio.

3090P

32. SPIRAL BEVEL INSTALLATION

Install the remaining gear bolts and tighten. Next install

the lock retainer wire around each of the bolts.

3091P

TORQUE REQUIRED
14 FT./LBS. (1.9 MKG)

TORQUE REQUIRED TORQUE REQUIRED

100 FT./LBS. (13.8 MKG) 90-110 FT./LBS. (12.4-15.2 MKG)
3116S

Crown 1994 PF10344-18 Printed in U.S.A.

M3.0–1430–067 M3.0–1430–067
 MAINTENANCE

33. AXLE NUT INSTALLATION

Remove the axle nut and apply red thread lock adhesive
to the axle threads.

3092P

34. NUT INSTALLED

Install and torque the axle nut to a 100 ft. lbs. (135Nm).

3093P

35. OIL PUMP INSTALLATION

Install the oil pump. Install the lower cover and gasket.

3094P

Crown 1994 PF10344-19 Printed in U.S.A.

M3.0–1430–068 M3.0–1430–068
 MAINTENANCE

36. CHECKING PUMP OPERATION

Fill the drive unit with oil. Use an old motor coupling
connected to a 1/2 drill to operate the drive unit. Remove
the pipe plug at the top of the drive unit and look for oil flow
as the drive unit turns. Oil should start to flow out of the
pipe plug hole. If oil does not appear the oil pump or pump
lines are malfunctioning and disassembly will be required.

3095P

Crown 1994 PF10344-20 Printed in U.S.A.

M3.0–1430–069 M3.0–1430–069
 SWITCHES

All switches should be checked regularly to assure safe and BRS1

efficient operation. When adjustments are made to any BRS2 (Optional)
switches, make certain the locking devices are tightened to Brake Switches
maintain correct adjustment. Verify electrical and mechani-
cal operation of switches before replacing covers. The brake switch is located with the brake pedal assembly,
below the platform floor. When the brake pedal is released,
WARNING this switch is actuated, opening the normally closed contact.
Remove rings, watches and other jewelry before This interrupts power to the electric brake which in turn
working on an energized circuit. Serious burns applies the brake.
can result from contact with truck battery voltage.
When the brake pedal is released, BRS2 is actuated closing
BRES1 (Left) the normally open contacts thereby allowing operation of
BRES2 (Right) raise/lower circuits.
Battery Restraint Switches
These switches require no adjustment.
Battery restraint switches are located next to the battery BRAKE SWITCH
retainer on either side of the power unit. When the battery PLATFORM FLOOR BRS
retainers are installed properly, the battery restraint switch
lever is depressed and BRES1 and BRES2 are actuated.
This closes the normally open contact, allowing operation of
traction, lift/lower and steering. The mounting bracket must
be positioned to actuate these switches when battery retain-
ers are installed.

BRES2
BRAKE PEDAL
DEPRESSED
BRAKE PEDAL
RELEASED
0121S-01 ILLUSTRATION 2

Part Of
Power BRES1
Unit

3156
ILLUSTRATION 1

030501 5345

Crown 2003 PF13561-1 Printed in U.S.A.

M4.0–7530–232 M4.0–7530–232
 SWITCHES

CHS1 (Left) CHB6 (Left)

CHS2 (Right) CHB7 (Right)
Chain Slack Switches Chain Break Switches - TT Platform Only

Chain slack switches 1 and 2 are located toward the top of These chain break switches are located under the operator
the mainframe. When the chain is tight, the plate weldment compartment floor. These switches are activated by a spring
leaves the switch in a normally closed position. The normally loaded lever mechanism which acts upon the lift chain. In a
closed contact is in the lowering circuit. Should the chain broken chain situation, the lever mechanism is pushed
become slack, e.g. forks resting on racks, pallet etc., the outward by its corresponding spring. A switch plunger which
spring will push the plate, causing the switch actuating end is internally spring loaded in the switch box assembly, opens
of the plate to move toward the switch. This action opens the the normally closed contacts. This causes both lift and lower
normally closed contact, preventing any additional lowering. functions to be disabled. Positioning the switch assembly
This switch does not require adjustment. However, correct against the lever is the only adjustment needed.
chain adjustment is important.
CHS3 (Left)
CHB4 (Left) CHS4 (Right)
CHB5 (Right) Chain Slack Switches - TT Platform Only
Chain Break Switches
These chain slack switches are located under the operator
Chain break switches are located toward the top of the compartment floor. When the chain is tight, the lever
mainframe. They are normally closed switches and are mechanism leaves the switch in a normally closed position.
placed in series, in the lift and lower circuits. When the chain Should the chain become slack; for instance, with the forks
is intact, the switches remain closed. If the chain breaks, the resting on racks or pallets, the lever mechanism is pushed
compression force on the spring is released and the actuat- outward by its corresponding spring. A switch plunger,
ing plate moves towards the switch, opening the normally internally spring loaded in the switch box assembly, opens
closed contact and cutting out both the lift and lower func- the normally closed contacts, thus preventing any addi-
tions. These switches do not require adjustment. tional lowering. These switches do not require adjustment,
however, correct chain adjustment is important. Position-
ing the switch assembly against the lever is the only
adjustment required.

Compartment
Wall
CHS2
CHB4
Lever

Platform Chain
CHS1
Switch Switch Assembly
CHB5 CHS3, CHB6
Plunger
CHS4, CHB7
5135
ILLUSTRATION 4
5136 ILLUSTRATION 3

Crown 2003 PF13561-2 Printed in U.S.A.

M4.0–7530–233 M4.0–7530–233
 SWITCHES

DMS1 DTS1
2 Handed Control Switch Drive/Tow Switch

This switch is located on the two handed control box on the The drive/tow switch is located on the distribution panel in the
console. Depressing the handle actuates DMS-1 closing the power unit. When this switch is in Drive position, the normally
normally open contacts allowing operation of main raise/ closed contact opens and the normally open contact closes
lower circuits and traction circuits. When truck is in guided which allows the brake to release. Traction is allowed. If the
mode, the message "2 HAND", appears on the console LED. truck requires towing, the switch may be placed in Tow
This switch requires no adjustment. position to release the brake. Traction is disabled at this time.
For normal operation, the switch must be returned to the
Drive position. This switch does not require adjustment.

DMS1

DTS1
!W
AR
Th
bra is
NI
NG
ketru

ILLUSTRATION 5
sw s ock d

10854
itc r oe
Ste h is trave sn
e
vear rin in
W l coot
ha n
hic
ca pp lethe
g the nhtraove
pu ma
en that
ution
sh y Tow l wh
. and aning n
or ot P en
to accid
us en to w osi
e ex wit ng ork tio Tow
trecould . n.
e m

Dr
ive

DPS
Display Switch

The display switch is located on the switch panel of the

control module on the platform. This switch does not require
adjustment.

3280 ILLUSTRATION 7
US
A

DPS

3279
ILLUSTRATION 6

Crown 2003 PF13561-3 Printed in U.S.A.

M4.0–7530–234 M4.0–7530–234
 SWITCHES

EDS FNS1
Emergency Disconnect Switch Fan Switch

The emergency disconnect switch is located in the control The fan switch is a rocker switch located in the switch panel
module assembly, above and to the left of the raise and lower above the control module. The OFF position removes power,
buttons. This switch is actuated by a button in the control turning the fan off. Placing the switch in the DOWN position
module. Depressing the button removes power from the operates the fan at less than full speed by routing the
emergency disconnect contactor coil, which opens its con- operating voltage through a dropping resistor. With the
tact and the latching contacts around the switch contact. This switch in the "up" position, full operating voltage is applied to
removes power from the electric steering, lift, traction and the fan. This switch does not require adjustment.
control circuit. To power the truck back up, EDS must be
released and the keyswitch cycled OFF, START and back to FNS1
ON. This switch requires no adjustment.

US
A
US
A

3282 ILLUSTRATION 9

FS
Forward Switch

EDS The forward switch is located inside the control module

assembly, left of the raise and lower buttons. When the twist
grip is rotated away from the operator, the actuator arm of FS
contacts a cam lobe, closing the normally open contacts
which completes the circuit to energize the forward contactor.
For adjustment of this switch, refer to Control Module As-
3281 ILLUSTRATION 8
sembly section M4.5.
FS

3283 ILLUSTRATION 10
Crown 2003 PF13561-4 Printed in U.S.A.

M4.0–7530–235 M4.0–7530–235
 SWITCHES

Gate Switches - GTS-1, GTS-2, GTS-3, GTS-4 GUS

Guidance Switch
Side gate switches (GTS-1, GTS-2 [used on 1.25SP and
1.0SP], GTS-3 and GTS-4 [used on 1.0SP only]) located The guidance switch is a push button switch located in the
behind the operator compartment tray weldment, operate off control module. This switch is present only on trucks with a
cams of the lower pivot point of the side gates. wire guidance system. Placing this switch in the MANUAL
mode will cause the steering of the truck to be controlled by
Rear gate switches (GTS-3 and GTS-4 [used on 1.25SP the operator. Placing the switch in the AUTOMATIC mode
only]) located on the corner posts in the rear of the platform, will, provided wire guidance is acquired, steer the truck
operate off switch actuators mounted on the lower shaft of automatically. Refer to the Wire Guidance section for more
the rear gates. detailed description. Adjustment of this switch is not re-
quired.
Before raise, lower or traction can be accomplished, the
gates must be down, operating the switches. Operating the
switches closes the normally open contacts and allows
operation of raise, lower and traction circuits.

Side Gate Raised

USA
Side Gate Lowered

GUS

Side Gate Switch

GTS-1, GTS-2 (.62, 1.0 &
1.25SP), GTS-3 and
GTS-4 (1.0SP only) 3285
ILLUSTRATION 13
1115S-01 ILLUSTRATION 11

Rear Gate Raised

Rear Gate Lowered

Rear Gate Switch

GTS-3 and GTS-4
(.62 & 1.25SP only)

1116S-01
ILLUSTRATION 12

Crown 2003 PF13561-5 Printed in U.S.A.

M4.0–7530–236 M4.0–7530–236
 SWITCHES

HSLCS HSRCS
High Speed Lower Cutout Switch High Speed Raise Cutout Switch

This switch is located on the platform, between the platform This switch is located on the platform, between the platform
wall and mast. With the platform 300 mm from the floor, wall and mast. With the platform 180 mm from maximum lift
HSLCS is actuated and opens its normally closed contact, height, HSRCS is actuated and opens its normally closed
disabling high speed lowering. contact, disabling high speed lifting.

For switch adjustment, loosen switch mounting bolts and For switch adjustment, loosen switch mounting bolts and
adjust so the switch actuates when roller contacts actuating adjust so the switch actuates when roller contacts actuating
channel and resets when roller loses contact. bar and resets when roller loses contact.
MOUNTING BOLTS MOUNTING BOLTS

HSLCS HSRCS

3286 ILLUSTRATION 14 3287

ILLUSTRATION 15

Crown 2003 PF13561-6 Printed in U.S.A.

M4.0–7530–237 M4.0–7530–237
 SWITCHES

HTS1200 HTS4500
1200 mm Height Limit Switch 4500 mm Height Limit Switch

This switch is located on the lower main frame on 1.25 SP TL This switch is located on the main frame and is actuated by
mast trucks and lower platform on 1.0 SP trucks. On TT mast a mast channel contacting the switch roller. Above 4500 mm,
trucks, this switch is located on the back of the lower the normally open held closed contact of HTS4500 opens.
platform. From 1200 - 2500 mm, braking force is reduced to Braking force is at 33%.
67%.
To adjust this switch, loosen mounting bolts and adjust so
For switch adjustment, loosen switch mounting bolts and switch actuates when roller contacts actuating channel and
adjust so the switch actuates when roller contacts actuating resets when roller loses contact.
bar and resets when roller loses contact.

HTS2500
2500 mm Height Limit Switch
HTS1200
HTS2500 is located on the main frame on all TL trucks HTS2500
and 1.25 TT trucks with a collapsed height of 2720 mm HTS4500
and lift height of 6095 mm or less. Collapsed/lift heights
above 2724/6095 mm this switch is located on the back of
the platform. At 2500 mm, the normally open held closed
contact of HTS2500 opens. From 2500 - 4500 mm,
braking force remains at 33%.

To adjust this switch, loosen mounting bolts and adjust so

switch actuates when roller contacts actuating channel and
resets when roller loses contact.

10853 ILLUSTRATION 16

Crown 2003 PF13561-7 Printed in U.S.A.

M4.0–7530–238 M4.0–7530–238
 SWITCHES

KYS LCS1
Keyswitch Lower Cutout Switch

The keyswitch, located in the control module, is a key The Lower Cutout Switch is located on the platform and is
operated, three position, spring return-to-center switch. In actuated by roller contacting the mast channel. While in
the OFF position, all electrical controls are disabled. Turning contact with the mast channel, LCS1A is held open removing
this switch to the START position energizes a latching circuit battery common to the lower solenoid valve(s) and LCS1B is
and allows the keyswitch to be returned to the ON position. held closed supplying battery common to the display module
When the latching circuit is energized and the keyswitch is in (CA304-12) for use with the display’s lower cutout LED.
the ON position, power is available for electrical controls.
KYS has a mechanical restriction which requires the key to NOTE
be returned to OFF from the ON position before it can be
turned to the START position. This switch requires no This switch is service terminal selectable and
adjustment. must be selected to enable the lower cutout LED
(only).

To adjust this switch, loosen mounting bolts and adjust so

switch actuates when roller contacts mast and resets when
roller loses contact.
US
A

MOUNTING BOLTS

LCS1
KYS

3288 ILLUSTRATION 17

5936 ILLUSTRATION 18

Crown 2003 PF13561-8 Printed in U.S.A.

M4.0–7530–239 M4.0–7530–239
 SWITCHES

LGS1 LGS3
Dome Light Switch Spotlight Switch

LGS1 is located in the switch panel above the platform Trucks equipped with spotlights will have a rocker switch
control module. When this rocker switch is placed in the "up" located on the switch panel of the control module in the
position, the dome lights will illuminate. This switch does not operator compartment. When this switch is placed in the "up"
require adjustment. position, the spotlights will illuminate. This switch does not
require adjustment.
LGS1

LGS3
US
A

US
A
3289 ILLUSTRATION 19
3291 ILLUSTRATION 21
LGS2
Work Light Switch HNS
Horn Switch
LGS2 is located in the switch panel above the platform
control module. When this rocker switch is placed in the "up" The horn switch is located inside the control module, below
position, the work lights will illuminate. This switch does not the raise and lower buttons. When the horn button is de-
require adjustment. pressed, the normally open contact of HNS closes and the
horn will sound. This switch requires no adjustment.

LGS2
US
A

US
A

3290 ILLUSTRATION 20

HNS

3292 ILLUSTRATION 22

Crown 2003 PF13561-9 Printed in U.S.A.

M4.0–7530–240 M4.0–7530–240
 SWITCHES

LOS1 ORS
LOS2 Override Switch
Lower Switches
ORS is a momentary contact switch located in the switch
These switches are located inside the control module. LOS2 panel above the control module. When a raise or lower
works only in trucks with two speed lower. Depressing the cutout programmed for override is encountered, holding this
lower button (partially on trucks with two speed lower) switch actuated will permit the continuation of the function.
actuates LOS1, closing the normally open contact, which This switch requires no adjustment.
energizes the lower solenoid valve. On trucks with two speed
lower, completely depressing the lower button actuates
LOS2 and maintains LOS1 actuated, which energizes the
second speed lower solenoid valve. These switches require
no adjustment.
ORS

US
LOS2

A
LOS1

3293 ILLUSTRATION 25
0142 ILLUSTRATION 23

LOS3
LOS4
Lower Switches (1.0SP Only)

LOS3 and LOS4 are located inside the lifting fork control
assembly. Depressing both lower buttons actuates LOS3
and LOS4, closing the normally open contacts which ener-
gizes the lower valve solenoid. Both buttons must be de-
pressed to energize the lower valve solenoid. These switches
require no adjustment. Refer to Illustration 25.

RAS4 RAS3

LOS4 LOS3
10855S
ILLUSTRATION 24

Crown 2003 PF13561-10 Printed in U.S.A.

M4.0–7530–241 M4.0–7530–241
 SWITCHES

RAS1 RCS1 (Lower)

RAS2 RCS2 (Upper)
Raise Switches Raise Cutout Switches

These switches are located inside the control module. RAS2 The raise cutout switches are located on the main frame.
works only on trucks with two speed raise. Depressing the These switches are actuated by the switch roller contacting
raise button (partially on trucks with two speed raise) actu- a mast channel. A normally closed contact of RCS1 and
ates RAS1. The normally open contact closes, energizes the RCS2 is connected between the raise cutout switch inputs
P1 contactor which starts pump 1. Completely depressing for the different cutout levels and battery common. When the
the button on trucks with two speed raise, actuates switch switch roller loses contact with the mast channel, the contact
RAS2 while maintaining RAS1 actuated. Actuating RAS2 closes which removes the negative connection to the steer-
closes the normally open contact, energizing the P2 contactor ing module which in turn removes the negative connection to
which starts pump 2. These switches require no adjustment. P1 and P2 contactor coils changing truck speed levels.

RAS1 RAS2 To adjust, loosen mounting bolts and adjust so switch

actuates when roller contacts actuating channel and resets
when roller loses contact.

MOUNTING BOLTS

0144 ILLUSTRATION 26

RAS3 RCS1
RAS4 RCS2
Raise Switches (1.0SP Only)

These switches are located inside the lifting fork control

assembly. Depressing the raise buttons actuates RAS3 and
RAS4. The normally open contacts energize the pump-1
contactor which starts pump-1. Both raise buttons must be
depressed to energize the pump-1 contactor. These switches
require no adjustment.

RAS4 RAS3
3356
ILLUSTRATION 28

LOS4 LOS3

10855S
ILLUSTRATION 27

Crown 2003 PF13561-11 Printed in U.S.A.

M4.0–7530–242 M4.0–7530–242
 SWITCHES

RGS1 (Left) RS
RGS2 (Right) Reverse Switch
Rail Guide Switches
The reverse switch is located inside the control module
The rail guide switches are located on the aisle guide wheel assembly, left of the raise and lower buttons. When the twist
bracket mounted under the power unit. When the aisle guide grip is rotated toward the operator, the actuator arm of RS
wheels contact the rail, the normally closed contacts open. contacts a cam lobe, closing the normally open contact
When the wire is acquired, steering is automatic. The rail which completes the circuit to energize the reverse contactor.
guide bracket needs to be mounted to fit the rail guide width Adjustment of this switch is described in the control module
to actuate these switches. section.
RS
RGS1

3294 ILLUSTRATION 29
3295 ILLUSTRATION 30

Crown 2003 PF13561-12 Printed in U.S.A.

M4.0–7530–243 M4.0–7530–243
 SWITCHES

THS2 (Power Unit Heaters) ZSS

THS3 (Platform Heaters) Lift Zone Select Switch
Thermostat
The zone select switch is located on the switch panel of the
On freezer conditioned trucks, THS2 is located in the power control module. This switch, which includes a key, selects
unit and THS3 is located on the platform. THS3 has a the lift height cut out desired. ZSS requires no adjustment.
normally closed contact which closes at 50° C and opens at
60° C . THS2 has a normally open contact which closes at 5° ZSS
C and opens at 15° C . The switch heaters will turn ON when Zone Select
THS2 senses 5° C and turn OFF when THS3 senses 60° C. Switch

Located Next Control

USA
To Travel Alarm THS2 Module
Back Of
Power Unit

Brake Pedal
10852 ILLUSTRATION 32

THS3
BRS

Part Of Platfrom
Floorboard

10851 ILLUSTRATION 31

Crown 2003 PF13561-13 Printed in U.S.A.

M4.0–7530–244 M4.0–7530–244
 TRUCK MANAGEMENT MODULE (TMM)

Nine inputs of the truck management module are used to monitor the traction motor and both pump motors. Each motor
contains one temperature sensor and two brushwear sensors. The information from the TMM module is communicated to
the traction controller using two outputs; one for overtemperature (Pin 7) and one for brushwear (Pin 9). The information is
communicated to the steering module which in turn sends it to the display. The display will light the appropriate LED and tell
the operator which motor the overtemperature or the brushwear fault is occurring. A TMM fault will not inhibit any truck
functions. The traction controller will only check the status of TMM when passing through neutral.

DISPLAY

!W
AR
This
brak
truc
swit es ork doe
NIN
Steech is trav s
vehic ring in
Warn el not
the conhav
G
happe
cautiolethe
that may Tow trol e
pushi
n and
n. an ng not whe
to accid
or Pos n
towin wor
use ent itionTow
extrem
could
g k. .
e

Drive

TB601

Distribution Panel Motor Brushwear Indicator

3513
Motor Overtemperature Indicator

Transistor
Panel

! WA
This
brakes
truck
RN
switch or does IN
Steerinis travel
Warn
vehicle in
not
contro
thehave
G
happenthe g
caution.
that may Tow
pushing
and an
l when
not Positio
to accident
or
use towingwork.
extreme Tow
could n.

Drive

Truck Management
Module (TMM)

T
A1
B+
A2
B- C

C
AC

Steering A1
B+
A2

Module B-

Traction
Motor (M1)

Traction Panel

Lift Pump Motor (S)

(M3 One Speed Lift)
(M4 Two Speed Lift)
10565

4305

Crown 1994 PF10429-1 Rev. 11/02 Printed in U.S.A.

02 REV. 11/02
M4.2–7330–500 M4.2–7330–500
 TRUCK MANAGEMENT MODULE (TMM)

Overtemperature Sensors

To test the overtemperature sensor in the traction motor, clip one end of a jumper with the green striped/white wire of the
overtemperature sensor and the other end to TP4 on the distribution panel. Leave the jumper in place while cycling traction.
The overtemperature icon on the display will light up, the character display will read “Traction”, and a fault will be logged
in the fault history. Remove the jumper and the overtemperature indication will be removed after one minute. To test the
overtemperature sensors in the pump motors, move the jumper to the green striped/white wire of the overtemperature
sensor on one of the pump motors. Again, leave the jumper in place while cycling traction. The overtemperature icon will
light up, the character display will read “Lift 1” or “Lift 2”, and a fault will be logged in the fault history. The faults history table
follows.

Brushwear Sensors

To test the brushwear sensors in the traction motors, clip one end of a jumper to the brushwear sensor and the other end
to TP2 on the distribution panel. Leave the jumper in place while cycling traction. The brushwear icon will light up, the
character display will read “Traction”, the wrench icon will light up, and a fault will be logged in the fault history. Remove the
jumper and cycle the key from OFF to TEST to ON to clear the brushwear indication. To test the brushwear sensors in the
pump motors, move the jumper to the brushwear sensor on one of the pump motors. Again, leave the jumper in place while
cycling traction. The brushwear icon will light up, the character display will read “Lift 1” or Lift 2", the wrench icon will light
up, and a fault will be logged in the fault history. The faults history table follows. TMM
(TRUCK MANAGEMENT MODULE)
TB601

TABLES 1 OVER TEMP 1 IN 0V=OVER TEMP, 5V=OK

2 5V INPUT 0V=OFF 5V=OK

SENSOR INFORMATION 3 OVER TEMP 2 IN 0V=OVER TEMP, 5V=OK

4 OVER TEMP 3 IN 0V=OVER TEMP, 5V=OK

Sensor Location TMM TB601 5 BRUSH WEAR 1 24V=BRUSH WEAR, 0V=OK

6 BRUSH WEAR 1 24V=BRUSH WEAR, 0V=OK

Overtemperature 1 Traction Motor Pin 1 7 DATA OUT SEE TMM DIAGRAM
Overtemperature 2 Pump Motor 1 Pin 3
8 BRUSH WEAR 2 24V=BRUSH WEAR, 0V=OK
Overtemperature 3 Pump Motor 2 Pin 4
9 DATA OUT SEE TMM DIAGRAM
Brushwear 1A Traction Motor Pin 5
10 BRUSH WEAR 2 24V=BRUSH WEAR, 0V=OK
Brushwear 1B Traction Motor Pin 6
Brushwear 2B Pump Motor 1 Pin 8 11 BRUSH WEAR 3 24V=BRUSH WEAR, 0V=OK

Brushwear 2A Pump Motor 1 Pin 10 12 BRUSH WEAR 3 24V=BRUSH WEAR, 0V=OK

Brushwear 3A Pump Motor 2 Pin 11 13

Brushwear 3B Pump Motor 2 Pin 12 14

15 BATT NEG

FAULT HISTORY 3510V

Active sensor Character display Icon Fault History

Overtemperature 1 Traction Overtemperature 90

Overtemperature 2 Lift 1 Overtemperature 91
Overtemperature 3 Lift 2 Overtemperature 92
Brushwear 1A Traction Brushwear 93
Brushwear 1B Traction Brushwear 93
Brushwear 2A Lift 1 Brushwear 94
Brushwear 2B Lift 1 Brushwear 94
Brushwear 3A Lift 2 Brushwear 95
Brushwear 3B Lift 2 Brushwear 95

Crown 1994 PF10429-2 Rev. 11/02 Printed in U.S.A.

02 REV. 11/02
M4.2–7330–501 M4.2–7330–501
 C TUNE UP

Transistor Control EV-T100ZX

Panels are factory adjusted for a particular motor and truck SERVICE TERMINAL OPERATION
and should not require adjustment. On new or mistuned
cards, adjust functions to value listed in charts. Tune up adjustments are input to the traction control through
the use of the Crown Service Terminal. Interconnection of
the terminal to the truck electronic system is through a
CAUTION connector located on the platform wall directly below the
Care must be taken when replacing the EV100 control module.
control card. Installation of the wrong control card
may cause misoperation. Refer to subtitle and
parts breakdown for card type and part number.

WARNING
Failure to follow proper set-up instructions could
result in misoperation or damage to control sys-
tem. Settings must be changed by authorized
personnel only. Card type selection must be
made within the capabilities of the transistor
control used and the supporting electromechani-
cal devices. Failure to comply with proper appli-
cation standards could result in misoperation or
damage to the control and/or motors.
3372

Once the terminal is plugged in and truck is powered up,

select the CAL MODE of operation on the terminal. Use the
flowchart (chart 1) for keystrokes and resulting messages on
the display. Messages outlined by a box are displayed on the
terminal. An arrow leading from a display message to a term
(ie. FWD) represents the keystroke selected. The arrow
leading from the term to a box is the resultant message on the
display. Arrows leading from one message to another with-
out a term, are messages which automatically appear with-
out keypad input. Refer to charts 2 and 3 for the recom-
mended setting of each function. Function codes not listed in
the chart are not applicable regardless of setting, will not
affect truck operation. If in question, set these functions to
zero.

030501 6508

Crown 2003 PF13599-1 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
M4.2–7530–205 M4.2–7530–205
 C TUNE UP

EV-T100ZX Transistor Control Handset Flowchart

Main menu: Press Cal,

Disp, Erase, or Show.I
*NOTE
Whenever EXIT is a choice or the ABORT key is
used, terminal operation will return to this level.
CAL

Cal Mode: Truck Setups.

Modify? Yes or FWD/BACKI
*
Cal Mode: Exit to Main
Select? Yes or FWD/BACKI

FWD

Cal Mode: Traction Setups. Cal Mode: Wire Guidance

Modify? Yes or FWD/BACKI FWD Select? Yes or FWD/BACKI FWD

YES

Traction Setup: Load New Traction Setup: Load STD

Select? Yes or FWD/BACKI FWD Select? Yes or FWD/BACKI YES

Loading Std. Traction

YES Setups, Please Wait...I

FWD

Traction Setups: Input a Traction Setup: Exit Standard Traction

Function # & Enter:I Select? Yes or FWD/BACKI Setups LoadedI

Press the keys necessary to select

function number desired. Display will show:

Function _ _ Value is = _ _ _ For recommended values,

Enter Value (0-255): _ _ _I refer to Traction Tune Up.

Press the keys necessary to select

function value desired. The display
will momentarily show:

Writing New Value

Please Wait...I

Save New Traction Value? Replacing old RAM Value

Press Yes or AbortI ABORT Please Wait...I

NOTE: Truck is operational with new

YES value. Test, if necessary, for acceptable
performance.
Saving New Value
Please Wait...I

CHART 1

Crown 2003 PF13599-2 Printed in U.S.A.

M4.2–7530–206 M4.2–7530–206
 C TUNE UP

FUNCTION ADJUSTMENTS FOR TRUCK APPLICATION 1. Cycle the battery by disconnecting and then recon-
necting the emergency disconnect.
The following function settings may be modified if necessary,
to optimize truck performance to the application. When 2. Proceed with normal duty cycle operation until the BDI
modifying the function settings, the following procedures shows that the battery has discharged to the point that
must be used. between 2 to 5 bars are lit (22 to 61% charge if using
handset).
Battery Discharge Interrupt FUNCTION 14
3. This step should be completed within 5 to 10 minutes
This adjustment allows the battery discharge interrupt to after the completion of the duty cycle. Note the number
accurately compensate for the actual battery being used. of bars lit (% charge on handset). Cycle the battery
The preset value represents a typical battery for a particular using the battery disconnect, leaving the battery dis-
compartment size and is satisfactory in most cases. How- connected for at least 30 seconds.
ever, if the indicator is showing 100% discharge, or the
interrupt is locking out the lift function, at too high (greater 4. Connect the battery and note the number of bars lit (%
than 1175) or too low (less than 1140) specific gravity, the charge on handset).
compensation adjustment value is not suited to the actual
battery being used. 5. If the number of bars lit increased (% charge on
handset increased more than 6%) after connecting the
If several different batteries are used in the truck and the battery, the BDI is overcompensating and the truck will
range in capacity is greater than 800 AH, the largest battery lock out at too high a specific gravity. The value of
should be used for the adjustment procedure. Normally the Function 14 (IR compensation) should be lowered by
value for Function 14 will be set between 14 and 34 for 24 volt 1 set point; e.g. change from 31 to 30.
batteries.
6. If the number of bars lit decreased (% charge on
The truck should be operated under normal working condi- handset decreased more than 6%), the BDI is
tions to obtain an accurate indication. While performing undercompensating and will lock out at too low a
these steps, either observe the service terminal connected specific gravity. The value of Function 14 (IR compen-
to the platform terminal connector and entering the SHOW, sation) should be raised by 1 set point; e.g. change
truck monitors, mode of operation, or observe the bars in the from 31 to 32.
BDI display of the display panel. Start with a fully charged
and equalized battery of the size and condition that will 7. Repeat procedure to verify accuracy of new settings. If
normally be used in the truck. Function 14 has been adjusted per this procedure and
lock out still occurs at a too high specific gravity, the
value may need to be lowered further until lockout
occurs at the desired specific gravity. When this oc-
curs, it is possible that the duty cycle discharge rate is
too high for the battery size (AH capacity) being used.
It is also likely that this adjustment will cause lockout to
occur at discharge levels beyond 80%.

Crown 2003 PF13599-3 Printed in U.S.A.

M4.2–7530–207 M4.2–7530–207
 C TUNE UP

Plug Braking FUNCTIONS 5 and 16

The braking effort by the plug braking function is dependent

on plugging current limit (C/L), Function 5 and pedal plug,
Function 16. In certain applications it may be desirable to
either increase or decrease the braking effort from plug
braking.

Function 5 will determine maximum plugging effort when

throttle is rotated to full on. Function 16 will determine
minimum plugging effort when throttle is in creep position.
Throttle position between creep and full on will result in
plugging efforts from minimum to maximum.

1. Determine the present values of Functions 5 and 16.

Should match settings in charts for truck model and
drive tire.

2. To increase the braking effect (decrease stopping

distance), add 3 set points to function 5. Operate the
truck and determine if the performance is adequate.
Increase Function 5 in increments of 3 until desired
performance is achieved.

3. To decrease the braking effect (increase stopping

distance), subtract 3 set points from Function 5. Oper-
ate the truck and determine if the performance is
adequate. Decrease Function 5 in increments of 3 until
desired performance is achieved.

NOTE

Operating the truck in the forks first direction, with

a capacity load and too severe of a plug braking
setting may result in drive tire slide. It is recom-
mended that a setting be selected that results in
no tire slide. If Function 16 is set too low, a delay
will be experienced at elevated heights. Never
set Function 16 higher than Function 5.

Crown 2003 PF13599-4 Printed in U.S.A.

M4.2–7530–208 M4.2–7530–208
 C TUNE UP

Charts 2 and 3 list the standard EEC settings for Tune Up Functions on European trucks.
170 mm Diameter Motor
Mast Type Collapsed Height Collapsed Height
Function Code Description TL 2329 - 3330 mm
TT 2325 - 2720 mm
2 Creep Speed 220 220
3 Controlled Acceleration 15 15
4 Current Limit 255 255
5 Plug Current Limit 73 77
6 1A Drop Out Current Level 255 255
10 Speed 4 Lift >4500 mm 165 165
11 Speed 1 (Out Of Aisle) 100 99
12 Speed 2 Lift >1200 mm 122 121
13 Speed 3 Lift >2500 mm 152 151
14 Internal Resistance Compensation 31 31
15 Battery Voltage 24 24
16 Pedal Position Plug 43 47
17 Card Type 22 22
19 Maintenance Alert tens/units 255 255
20 Maintenance Alert thou/hund 255 255
25 Monitor Enable 0 0
26 Monitor Enable Address 0 0
27 Max Plug PWM 0 0
Chart 2

Crown 2003 PF13599-5 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
M4.2–7530–209 M4.2–7530–209
 C TUNE UP

Charts 2 and 3 list the standard EEC settings for Tune Up Functions on European trucks.
190 mm Diameter Motor
Collapsed
Mast Type Collapsed Height
Height
2260 -
Function Code Description TL Opt. "H - Series"
3330 mm
2260 - 2740 - 3350 -
TT
2720 mm 3330 mm 3940 mm
2 Creep Speed 120 120 120 120
3 Controlled Acceleration 15 15 15 15
4 Current Limit 255 255 255 255
5 Plug Current Limit 114 116 124 132
6 1A Drop Out Current Level 255 255 255 255
10 Speed 4 Lift >4500 mm 150 150 150 139
11 Speed 1 (Out Of Aisle) 92 91 90 73
12 Speed 2 Lift >1200 mm 127 111 110 94
13 Speed 3 Lift >2500 mm 139 137 137 124
14 Internal Resistance Compensation 31 31 31 31
15 Battery Voltage 24 24 24 24
16 Pedal Position Plug 84 86 94 102
17 Card Type 22 22 22 22
19 Maintenance Alert tens/units 255 255 255 255
20 Maintenance Alert thou/hund 255 255 255 255
25 Monitor Enable 0 0 0 0
26 Monitor Enable Address 0 0 0 0
27 Max Plug PWM 0 0 0 0
Chart 3

Crown 2003 PF13599-6 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
M4.2–7530–210 M4.2–7530–210
 C EVENT CODES

This section provides troubleshooting aids to facilitate analy-

sis of truck failures. By using the appropriate troubleshooting WARNING
aids (based on event codes displayed through the use of the
Service Terminal or display module), truck wiring diagram, Before troubleshooting, lift the drive wheel clear
and information provided in the Truck Service Manual; most of floor and place hardwood blocks under truck
problems should be easily detected and corrected. frame. Turn keyswitch "OFF", disconnect battery
and discharge capacitor 1C by connecting a 200
EVENT CODES ohm 2 watt resistor between the positive and
negative terminals.
EVENT CODES 1 through 76 are for the traction Transistor
control and EVENT CODES 90 through 95 are for the truck
management module (TMM). EVENT CODES 200 through
299 are for the steering module. EVENT CODES 300 through
399 are for the display module and EVENT CODES 400
through 499 are for wire guidance.

030501 7471

Crown 2003 PF13577-1 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–600 M4.2–7532–600
 C EVENT CODES

Test Points

Test points 1 through 25, referenced in the event code descriptions, are located on the distribution panel.

Note: TP1 on the distribution board is battery positive before ED.

TP2 on the distribution board is battery positive after ED and is to be used as battery positive reference unless
indicated.

TP3/TP4 on the distribution board is battery negative.

Battery discharge indicator (BDI) and event codes 01 through 95 are not displayed. EVENT CODE 0

Truck operation not effected.

Step 1: Check for loose or poor connections between CA404-4, -5, -13, -14 and CA406-1, -2, -10, -20.
If: Wiring problems exists.
Then repair wiring.
If: Wiring is okay and problem persists.
Then replace the traction control card.

Crown 2003 PF13577-2 Printed in U.S.A.

M4.2–7532–601 M4.2–7532–601
 C EVENT CODES

Traction control card TB403-5 (forward switch) is greater than 60% battery volts EVENT CODE 02
at initial power up. displayed as NEUTRAL

Traction disabled. Forward contactor will not energize. Static return to off (SRO) lock out.

Step 1: Using a DVOM check for the presence of 24 volt at TB403-5 during power up. Connect the negative lead to
TP3 on the distribution panel and positive lead to traction card TB403-5.
If: 24 volt is present.
Then check if the forward switch (FS) is closed or shorted.
If: The forward switch (FS) is shorted.
Then replace.
If: Zero volts at TB403-5 and the event code persists.
Then replace the traction card.

Distribution Panel

ED CA213 CA204 TB101 GTS4 GTS3

K3B
3 3 21
FU5
+

TP2 FS
TB403 (TB11) CA212 CA204
TP10
Fwd Sw Input 5 3 1 19
TP11
Rev Sw Input 6 4 2 20 RS

Traction Controller
MRC1
10887

Crown 2003 PF13577-3 Printed in U.S.A.

M4.2–7532–602 M4.2–7532–602
 C EVENT CODES

Traction control card TB403-6 (reverse switch input) is greater than 60% battery volts EVENT CODE 03
at initial power up. displayed as NEUTRAL

Reverse contactor will not energize. Static return to off (SRO) lock out.

Step 1: Using a DVOM check for the presence of 24 volt at TB403-6 during power up. Connect the negative lead to
TP3 on the distribution panel and positive lead to traction card TB403-6.
If: 24 volt is present.
Then check if the reverse switch (RS) is closed or shorted.
If: The reverse switch (RS) is shorted.
Then replace.
If: Zero volts at TB403-6 and the event code persists.
Then replace the traction card.

Distribution Panel

ED CA213 CA204 TB101 GTS4 GTS3

K3B
3 3 21
FU5
+

TP2 FS
TB403 (TB11) CA212 CA204
TP10
Fwd Sw Input 5 3 1 19
TP11
Rev Sw Input 6 4 2 20 RS

Traction Controller
MRC1
10887

Crown 2003 PF13577-4 Printed in U.S.A.

M4.2–7532–603 M4.2–7532–603
 C EVENT CODES

Traction card TB403-1 (traction command input) is less than 2.5 volts and TB403-2 EVENT CODE 05
(brake switch input) is less than 60% of battery volts at the same time. displayed as BRAKE

Traction disabled. Forward or reverse contactor will not energize.

Step 1: Using a DVOM check for the presence of traction command input (3.4 – 3.6 volts) at TB403-1. Connect the
negative lead to TP3 and the positive TB403-1.
Note: “Brake” will be displayed if the traction control twist grip is rotated prior to depressing the brake pedal.
If: TB403-1 is less than 2.5 volts.
Then check potentiometer (POT-1) as described in section M4.5 of the service manual.
If: The potentiometer is bad.
Then replace as described in section M4.5 of the service manual.
If: The voltage at TB403-1 is okay.
Then depress the brake pedal and check for 24 volts at TB403-2.
If: 24 volts is not present at TB403-2.
Then proceed to step 2.
If: 24 volts is present at TB403-2.
Then release the brake and check for zero volts.
If: 24 volts is still present after the brake is released.
Then check brake switch (BRS1) for a short.
If: Voltage drops to zero when the brake is released and the event code persists.
Then replace the traction card.

Crown 2003 PF13577-5 Printed in U.S.A.

M4.2–7532–604 M4.2–7532–604
 C EVENT CODES

Step 2: With the brake pedal depressed check for the presence of 24 volts at CA202-4. Connect the negative lead
to TP3 and the positive CA202-4.
If: 24 volts is not present at CA202-4 when the brake is depressed.
Then check for loose or bad connections between TB101-3, -5 and brake switch (BRS1).
If: Connections are okay.
Then check operation of brake switch (BRS1).
If: BRS1 is okay.
Then check continuity between TB102-5 and distribution panel CA202-4.
If: Wire continuity test fails.
Then replace mast cable 1.

Distribution Panel

ED CA213 TP1 K1B CA202 TB101

1 2 2 BRS1
FU2
+

4 3
TP8
POT1 Batt. Neg. 4 5
Accel Bus Bar
CA205 CA212 TB403 (TB11)
7 6 2 1 Command Input
5 5 6 2 Startswitch Input
TB102
10888

Crown 2003 PF13577-6 Printed in U.S.A.

M4.2–7532–605 M4.2–7532–605
 C EVENT CODES

Accelerator (twist grip) input to card changes before directional switch EVENT CODE 06
input is detected. displayed as GATE

Traction disabled.

Note: Relay K3 provides battery volts to the forward and reverse traction control circuit. Should K3 be opened
due to a fault that is unrelated to traction “Gate” would appear on the display when the twist grip is rotated.
Step 1: Check directional switch FS (forward) and RS (reverse) adjustment. Improperly adjusted switches will
cause event code 06 or “Gate” to appear on the display.
If: The switches are adjusted properly.
Then proceed to step 2.
If: The switches are improperly adjusted.
Then adjust the switches as described in M4.5 control module directional switches.
Step 2: With the truck powered up check for 24 volts between TB101-21 and TB101-11.
If: Zero volts.
Then proceed to step 4.
If: 24 volts present and event code persists.
Then proceed to step 3.
Step 3: Caution: Truck could move when performing this test.
Then check operation of gate switches GTS 3, 4 and directional switches. Move meter lead from TB101-21
to TB101-19. Close gates and rotate twist grip in forward direction. Meter should indicate 24 volts. Move
meter lead from TB101-19 to TB101-20. Close gates and rotate twist grip in reverse direction. Meter should
again indicate 24 volts.
If: 24 volts not present at either test point.
Then check for loose or poor wire connections between TB101-19 and GTS4 (LH), GTS3 (RH) and
forward switch, also connections between TB101-20 and GTS4 (LH), GTS3 (RH) and reverse switch.
Check switch operation. Repair or replace as necessary.
If: 24 volts present.
Caution: Truck could move when performing this test.
Then check for battery volts at TP10 and TP11. Connect negative lead to TP3.
FS, connect positive lead to TP10 and rotate the twist grip for forward.
RS, connect positive lead to TP11 and rotate twist for reverse.
If: There is zero volts at one or both test points
Then replace mast cable 3

Crown 2003 PF13577-7 Printed in U.S.A.

M4.2–7532–606 M4.2–7532–606
 C EVENT CODES

Step 4: With the truck powered up check for battery volts at CA204-3. Connect negative meter lead to TP3 and
positive lead to CA204-3.
If: There is zero volts.
Then check if relay K3 is closing.
If: Relay K3 is closing.
Then check fuse FU5.
If: Relay K3 is not closing.
Then check other event codes for faults related to lockout of relay K3.

Distribution Panel

ED CA213 CA204 TB101 GTS4 GTS3

K3B
3 3 21
FU5
+

TP2 FS
TB403 (TB11) CA212 CA204
TP10
Fwd Sw Input 5 3 1 19
TP11
Rev Sw Input 6 4 2 20 RS

Traction Controller
MRC1
10887

Crown 2003 PF13577-8 Printed in U.S.A.

M4.2–7532–607 M4.2–7532–607
 C EVENT CODES

Traction card accelerator input voltage at TB403-1 is higher than 3.7 volts
EVENT CODE 07
when a directional contactor is energized.

Traction disabled.

NOTE: The code will only be displayed when attempting travel in one direction. When opposite direction is se-
lected, code will disappear.
Step 1: Remove console and check the traction potentiometer (POT1) as described in section M4.5 of the service
manual.
If: The potentiometer (POT1) is defective.
Then replace.
If: The potentiometer is okay.
Then check wires #533 between POT1 and TB102-5 and wires #102/#105 between POT1 and TB102-
7 for shorts or opens.
If: A short or open exists.
Then repair.
If: The wires are okay.
Then check continuity of the blue wire on mast cable between TB102-7 and CA205-6.
If: The blue wire in mast cable #4 fails the continuity test.
Then replace mast cable #4.
If: Mast cable #4 is okay.
Then proceed to step 2.
Step 2: Check wire #101 between CA212-2 and TB403-1 for loose or bad connection.
If: Wire connection problem exists.
Then repair.
If: Wire connections are okay and the event code persists.
Then replace the traction control card.

Distribution Panel

ED CA213 TP1 K1B CA202 TB101

1 2 2 BRS1
FU2
+

4 3
TP8
POT1 Batt. Neg. 4 5
Accel Bus Bar
CA205 CA212 TB403 (TB11)
7 6 2 1 Command Input
5 5 6 2 Startswitch Input
TB102
10888

Crown 2003 PF13577-9 Printed in U.S.A.

M4.2–7532–608 M4.2–7532–608
 C EVENT CODES

Traction card accelerator input voltage at TB403-1 is less than 3.0 volts EVENT CODE 08
when traction is requested. displayed as NEUTRAL

Traction disabled.

Step 1: With the truck powered up check the voltage at TB403-1. Connect the negative lead of the meter to TP3
and the positive lead to traction control card TB403-1. The voltage should be greater than 3.0 volts.
If: The voltage is less than 3.0 volts.
Then remove the console and check the traction potentiometer (POT1) as described in section M4.5 of
the service manual.
If: The potentiometer (POT1) not adjusted correctly.
Then adjust as described in section M4.5 of the service manual.
If: The potentiometer is okay.
Then proceed to step 2.
Step 2: With the truck powered up check for battery volts at traction control card TB403-4. Connect the negative
meter lead to TP3 and positive to TB403-4.
If: Zero volts.
Then check fuse 5.
If: Fuse 5 is bad.
Then replace fuse 5.
If: 24 volts is present TB403-4.
Then check for battery volts at TB403-3.
If: Zero volts.
Then check wire connection between TB403-4 and TB403-3.
If: 24 volts is present and the event code persists.
Then replace the traction control card.

Distribution Panel

ED CA213 TP1 K1B CA202 TB101

1 2 2 BRS1
FU2
+

4 3
TP8
POT1 Batt. Neg. 4 5
Accel Bus Bar
CA205 CA212 TB403 (TB11)
7 6 2 1 Command Input
5 5 6 2 Startswitch Input
TB102
10888

Crown 2003 PF13577-10 Printed in U.S.A.

M4.2–7532–609 M4.2–7532–609
 C EVENT CODES

Traction card detected that battery volts are less than 1.95 volts per cell at initial power up. EVENT CODE 15

Traction disabled.

Step 1: Check battery state of charge.

If: Battery has a sufficient charge.
Then proceed to step 2.
If: The battery state of charge is low.
Then charge the battery.
Step 2: Connect the service terminal and check the traction control card function 15 setting as described in the
service terminal manual section 3 pages 3, 10 and 26.
If: The setting is incorrect.
Then correct function 15 setting per page 26.
If: The setting is okay.
Then change the battery.
If: Changing the battery corrected the problem.
Then have the original battery tested.
If: Changing the battery did not correct the problem and the event code persists.
Then replace the traction control card.

Crown 2003 PF13577-11 Printed in U.S.A.

M4.2–7532–610 M4.2–7532–610
 C EVENT CODES

Traction card detected that battery volts are greater than 2.40 volts per cell at power up. EVENT CODE 16

Traction disabled.

Step 1: Check for incorrect or overcharge battery.

If: Incorrect voltage battery installed.
Then change battery.
If: Battery voltage correct and state of charge is okay.
Then proceed to step 2.
If: The battery is overcharged.
Then contact a battery service center.
Step 2: Connect the service terminal and check the traction control card function 15 setting as described in the
service terminal manual section 3 pages 3, 10 and 26.
If: The setting is incorrect.
Then correct function 15 setting per page 26.
If: The setting is okay and the event code persists.
Then replace the traction control card.

Traction control card type selection value is invalid. EVENT CODE 17

Traction disabled.

Step 1: Connect the service terminal and check the traction control card function 17 setting as described in the
service terminal manual section 3 pages 3, 10 and 26.
If: The setting is incorrect.
Then correct function 17 setting per page 26.
If: The setting is okay and the event code persists.
Then replace the traction control card.

Crown 2003 PF13577-12 Printed in U.S.A.

M4.2–7532–611 M4.2–7532–611
 C EVENT CODES

Traction control card current draw in the forward or reverse contactor coil circuit is
EVENT CODE 23
less than 100 ma.

Traction disabled.

Step 1: Disconnect plug CA402 and check the resistance of the forward, reverse and 1A contactor coils.
Forward, connect the positive lead to the positive side of the coil and the negative lead to the female
connector on plug CA402-4.
Reverse, connect the positive lead to the positive side of the coil and the negative lead to the female
connector on plug CA402-5.
1A, connect the positive lead to the positive side of the coil and the negative lead to the female connector
on plug CA402-6.
Note: Resistance of each coil should be between 10 and 14 ohms.
If: Coil resistance is okay.
Then clean CA402 with a contact cleaner that is safe for plastics.
If: Coil resistance out of tolerance.
Then check wire connections between CA404-4, -5 the F/R coils.
If: Wiring is okay and the coil resistance is out of tolerance.
Then replace the coil(s).
If: Both wiring and coils are okay and the event code persists.
Then replace the traction control card.

Distribution Panel
CA213 CA202 TB101
K1B
+ 1 2 2 BRS1
FU2
TP1 3
ED TP8
4 5
CA212 TB403 (TB11)
1 4 Keyswitch Input
FU5
3 Seatswitch Input
6
2 Startswitch Input
CA402 (PCBT)
R 5 Reverse Contactor Output
F 4 Forward Contactor Output
1A 6 Bypass Contactor Output

10889

Crown 2003 PF13577-13 Printed in U.S.A.

M4.2–7532–612 M4.2–7532–612
 C EVENT CODES

Traction control card has detected a shorted forward directional coil driver. EVENT CODE 26

Traction disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then the truck is operation ready.
If: Event code persists.
Then replace the traction control card.

Traction control card supply voltage is less than 10 volts. EVENT CODE 27

Traction disabled (PMT trip).

Step 1: Check for battery volts at CA402-1. Connect the negative meter lead to “N” on the traction controller MRC1
and positive to CA402-1.
If: Battery volts present at CA402-1 and the event code persists.
Then replace the traction control card.
If: Less than 10 volts are present.
Then check fuse FU5.
If: Fuse FU5 is good.
Then check wire connections between CA402-1 and CA215-5.

Traction Controller
Distribution Panel MRC1

ED CA213 TP1 CA212 CA402 (PCBT)

Battery
1 5 1
+
Positive
FU2
Input
10890

Crown 2003 PF13577-14 Printed in U.S.A.

M4.2–7532–613 M4.2–7532–613
 C EVENT CODES

Traction control card voltage between PCZ-2 and PCZ-5 is greater than 0.8 volts. EVENT CODE 41

Traction speed reduced and/or disabled.

Note: In some heavy applications the traction control could reach a temperature level that the control would go
into thermal cutback. Should this occur allow the truck to cool.
Step 1: Check for loose connections the violet wire from PCZ-2 and the violet stripe/white wire from PCZ-5 to the
thermal protector. Refer to service manual section M4.2 for PCZ wire locations.
If: Connection okay.
Then remove plug PCZ. With the panel at room temperature (75F/25C) check the resistance between
PCZ plug pins 2 and 5.
If: The resistance is greater than 900 ohms at room temperature.
Then replace the MOSFET/IGBT module.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Crown 2003 PF13577-15 Printed in U.S.A.

M4.2–7532–614 M4.2–7532–614
 C EVENT CODES

Traction control card voltage between plug PCZ-12 and PCZ-13 is greater than 0.1 volt
EVENT CODE 42
with no current flowing in the motor circuit.

Traction disabled.

Step 1: Check for a loose or broken green wire between the current sensor and traction control card plug PCZ-12.
Refer to service manual section M4.2 for PCZ wire locations.
If: The wire connection is loose or broken.
Then repair.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Crown 2003 PF13577-16 Printed in U.S.A.

M4.2–7532–615 M4.2–7532–615
 C EVENT CODES

Traction card voltage between PCZ-12 and PCZ-13 is less than 0.1 volts with
EVENT CODE 43
no current flowing in motor circuit.

Traction disabled.

Step 1: Check for a loose or broken yellow wire between the current sensor and traction control card plug PCZ-13.
Refer to service manual section M4.2 for PCZ wire locations.
If: The wire connection is loose or broken.
Then repair.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Crown 2003 PF13577-17 Printed in U.S.A.

M4.2–7532–616 M4.2–7532–616
 C EVENT CODES

Traction panel transistor fails to turn off during operation or turn time is out of specification. EVENT CODE 44

Traction disabled (PMT trip).

Step 1: Check for a loose or broken red wire between the transistor gate and control card plug PCZ-4. Refer to
service manual section M4.2 for PCZ wire locations.
If: The red wire PCZ-4 connection is okay and the event code persists.
Then replace the transistor.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Crown 2003 PF13577-18 Printed in U.S.A.

M4.2–7532–617 M4.2–7532–617
 C EVENT CODES

Traction panel transistor fails to turn on. EVENT CODE 45

Traction disabled (PMT trip).

Step 1: Check for a loose or broken red wire between the transistor gate and control card plug PCZ-4. Refer to
service manual section M4.2 for PCZ wire locations.
If: The wire PCZ-4 connection is okay.
Then check for a loose or broken blue wire between T2 and control card plug PCZ-9.
If: The wire connection between T2 and PCZ-9 is okay and the event code persists.
Then replace the transistor.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Crown 2003 PF13577-19 Printed in U.S.A.

M4.2–7532–618 M4.2–7532–618
 C EVENT CODES

Traction panel voltage at T2 is less than 12% of battery volts. EVENT CODE 46

Traction disabled.

Step 1: Check for welded 1A contactor tips.

If: Tips are welded.
Then repair 1A contactor.
If: Tips are not welded.
Then check for shorted transistor as describe in section M4.2 of the service manual. Replace transistor
if defective.
If: The transistor is okay.
Then check the snubber as describe in section M4.2 of the service manual. Replace snubber if
defective.

Traction panel voltage at T2 is greater than 88% of battery volts. EVENT CODE 48

Traction disabled.

Step 1: Check for welded forward or reverse contactor tips.

If: Tips are welded.
Then repair contactor.
If: Tips are not welded.
Then check forward and reverse contactor operation. Sluggish pull-in speed will cause this event code.
If: Both forward and reverse contactors are okay.
Then check for a shorted 3 REC as describe in section M4.2 of the service manual. Replace 3
REC if defective.
If: The 3 REC is good.
Then check the snubber as describe in section M4.2 of the service manual. Replace snubber if
defective.

Crown 2003 PF13577-20 Printed in U.S.A.

M4.2–7532–619 M4.2–7532–619
 C EVENT CODES

Traction panel capacitor voltage is less than 85% of battery volts at initial start up. EVENT CODE 50

Traction disabled.

Step 1: Check fuse FU13.

Note: Ohms test may indicate that FU13 is good. Recommend voltage drop test.
If: Fuse FU13 is bad.
Then replace.
If: Fuse FU13 is good.
Then check for a loose or poor connection between FU13 and terminal “P” on MRC1.
If: Wire connections are good.
Then check for an open line capacitor as described in section M4.2 of the service manual.
If: Line capacitor is bad.
Then replace.

ED Traction
Controller
FU13
+
P MRC1
10619

Crown 2003 PF13577-21 Printed in U.S.A.

M4.2–7532–620 M4.2–7532–620
 C EVENT CODES

Traction panel capacitor volts less than 85% of battery volts at initial start up. EVENT CODE 51

Traction disabled (PMT trip).

Step 1: Check fuse FU5.

If: Fuse FU5 is bad.
Then replace.
If: Fuse FU5 is good.
Then check for a loose or poor connection between CA212-1 and traction card TB403-4.
If: Wire connections are good.
Then check for an open line capacitor as described in section M4.2 of the service manual.
If: Line capacitor is bad.
Then replace.

Distribution Panel

ED CA213 CA204 TB101 GTS4 GTS3

K3B
3 3 21
FU5
+

TP2 FS
TB403 (TB11) CA212 CA204
TP10
Fwd Sw Input 5 3 1 19
TP11
Rev Sw Input 6 4 2 20 RS

Traction Controller
MRC1
10887

Crown 2003 PF13577-22 Printed in U.S.A.

M4.2–7532–621 M4.2–7532–621
 C EVENT CODES

Traction panel transistor fails to turn off during plug cycle. EVENT CODE 53

Traction disabled (PMT trip).

Step 1: Check for a loose or broken red wire between the transistor gate and control card plug PCZ-4. Refer to
service manual section M4.3 for PCZ wire locations.
If: The red wire PCZ-4 connection is okay and the event code persists.
Then replace the transistor.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Traction control card forward, reverse or 1A contactor coil driver is shorted. EVENT CODE 54

Traction disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then the truck is operation ready.
If: Event code persists.
Then replace the traction control card.

Crown 2003 PF13577-23 Printed in U.S.A.

M4.2–7532–622 M4.2–7532–622
 C EVENT CODES

Traction panel voltage input to control card plug PCZ positions 13 and 12 are wrong polarity. EVENT CODE 57

Traction disabled (PMT trip).

Step 1: Using a meter check battery polarity at traction panel terminal P. Connect the negative meter lead to TP3
and positive lead to terminal P of the traction panel. Turn key “on”.
If: Negative 24 volts is present at terminal P.
Then check battery and truck connector for correct power cable polarity.
If: Battery and truck connector power cable polarity is correct.
Then make certain that motor A2 lead connects to traction panel A2 terminal.
If: Motor leads are correct.
Then check that the green wire from the current sensor is in position 12 of the traction control
card PCZ connector and the yellow wire is in position 13. Refer to service manual section M4.3
for PCZ wire locations.

(2) VIO
(3) BRN
(1) WHT/BRN
(4) RED VIO
PCZ (5) WHT/VIO

(9) BLU WHT/VIO

(12) GRN (14) WHT

(13) YEL BLU
GRN RED
WHT
BRN
YEL
WHT/BRN
10618

Crown 2003 PF13577-24 Printed in U.S.A.

M4.2–7532–623 M4.2–7532–623
 C EVENT CODES

TMM (truck management module) voltage at terminal 1 is at zero volts. EVENT CODE 90

Traction operation not effected. Event code flashes on and off.

Step 1: Check traction motor (M1) for an over-temperature condition.

If: An over temperature condition exist.
Then allow the motor to cool.
If: An over temperature condition does not exist.
Then check the temperature sensor circuit as described in section M4.2 of the service manual.
If: Temperature sensor is okay and the event code persists.
Then replace the TMM control card.

TMM (truck management module) voltage at terminal 3 is at zero volts. EVENT CODE 91

Lift operation not effected. Event code flashes on and off.

Step 1: Check lift pump motor 1 (M3) for an over-temperature condition.

If: An over temperature condition exist.
Then allow the motor to cool.
If: An over temperature condition does not exists.
Then check the temperature sensor circuit as described in section M4.2 of the service manual.
If: Temperature sensor is okay and the event code persists.
Then replace the TMM control card.

TMM (truck management module) voltage at terminal 4 is at zero volts. EVENT CODE 92

Lift operation not effected. Event code flashes on and off.

Step 1: Check lift pump motor 2 (M4) for an over-temperature condition.

If: An over temperature condition exist.
Then allow the motor to cool.
If: An over temperature condition does not exists.
Then check the temperature sensor circuit as described in section M4.2 of the service manual.
If: Temperature sensor is okay and the event code persists.
Then replace the TMM control card.

Crown 2003 PF13577-25 Printed in U.S.A.

M4.2–7532–624 M4.2–7532–624
 C EVENT CODES

TMM (truck management module) voltage at terminal 5 and 6 is battery volts. EVENT CODE 93

Traction operation not effected. Event code flashes on and off.

Step 1: Check for worn traction motor (M1) brushes as described in section M4.7 of the service manual and pages
6/7 of the motor analysis guide PF13361.
If: Brushes are worn.
Then replace.
If: Brushes are okay.
Then check the brush wear sensor circuit as described in section M4.2 of the service manual.
If: Brush wear sensor is okay and the event code persists.
Then replace the TMM control card.

TMM (truck management module) voltage at terminal 8 and 10 is battery volts. EVENT CODE 94

Lift operation not effected. Event code flashes on and off.

Step 1: Check lift motor 1 (M3) for worn brushes as described in section M4.7 of the service manual and pages 6/7
of the motor analysis guide PF13361.
If: Brushes are worn.
Then replace.
If: Brushes are okay.
Then check the brush wear sensor circuit as described in section M4.2 of the service manual.
If: Brush wear sensor is okay and the event code persists.
Then replace the TMM control card.

TMM (truck management module) voltage at terminal 11 and 12 is battery volts. EVENT CODE 95

Lift operation not effected. Event code flashes on and off.

Step 1: Check lift motor 2 (M4) for worn brushes as described in section M4.7 of the service manual and pages 6/7
of the motor analysis guide PF13361.
If: Brushes are worn.
Then replace.
If: Brushes are okay.
Then check the brush wear sensor circuit as described in section M4.2 of the service manual.
If: Brush wear sensor is okay and the event code persists.
Then replace the TMM control card.

Crown 2003 PF13577-26 Printed in U.S.A.

M4.2–7532–625 M4.2–7532–625
 C EVENT CODES

Steering feedback encoder (ECR2) count out of tolerance. EVENT CODE 201

Traction disabled.

Step 1: Check ECR2 wire connections between CA412 then from CA411 to CA406.
If: Encoder connections are bad.
Then repair/clean connections.
If: Encoder connections are okay.
Then adjust ECR2 as described in section 4.5 of service manual.
If: Encoder event codes persists.
Then replace and adjust ECR2 as described in section M4.5 of service manual.

Steering Module Connector Module

CA406 CA411 CA412
Channel A Input 5 028 1 1 BLU
L-Comm Output 3 532 2 2 BLK L-Comm CHA
CHB Steering
Channel B Input 14 029 3 3 ORG
+5V L ECR2 Feedback
5V Output 11 710 4 4 RED Encoder
Index 23 030 5 5 YEL Index

6 6

10620

Crown 2003 PF13577-27 Printed in U.S.A.

M4.2–7532–626 M4.2–7532–626
 C EVENT CODES

Steering feedback encoder (ECR2) raw counts are greater than 35 counts between reads. EVENT CODE 202

Traction disabled.

Step 1: Check condition and adjustment of encoder ECR2.

If: Encoder appears damaged.
Then replace encoder.
If: Encoder is okay and event codes persist.
Then adjust ECR2 as described in section M4.5 of service manual.
If: Encoder adjustment is okay.
Then replace and adjust ECR2 as described in section M4.5 of service manual.

Steering Module Connector Module

CA406 CA411 CA412
Channel A Input 5 028 1 1 BLU
L-Comm Output 3 532 2 2 BLK L-Comm CHA
CHB Steering
Channel B Input 14 029 3 3 ORG
+5V L ECR2 Feedback
5V Output 11 710 4 4 RED Encoder
Index 23 030 5 5 YEL Index

6 6

10620

Crown 2003 PF13577-28 Printed in U.S.A.

M4.2–7532–627 M4.2–7532–627
 C EVENT CODES

Steering feedback encoder (ECR2) shows no index. EVENT CODE 204

Traction disabled.

Step 1: Check the yellow wire between ECR2 and connection module CA412-5 also wire #030 between CA411-5
and steer module CA406-23.
If: Wiring is broken or a poor connection exists.
Then repair.
If: Encoder wire connections are okay and event code persist.
Then adjust ECR2 as described in section M4.5 of service manual.
If: Event code persists after adjustment.
Then replace and adjust ECR2 as described in section M4.5 of service manual.

Steering Module Connector Module

CA406 CA411 CA412
Channel A Input 5 028 1 1 BLU
L-Comm Output 3 532 2 2 BLK L-Comm CHA
CHB Steering
Channel B Input 14 029 3 3 ORG
+5V L ECR2 Feedback
5V Output 11 710 4 4 RED Encoder
Index 23 030 5 5 YEL Index

6 6

10620

Crown 2003 PF13577-29 Printed in U.S.A.

M4.2–7532–628 M4.2–7532–628
 C EVENT CODES

Steering selftest detects no movement. EVENT CODE 208

Steering and traction disabled.

Step 1: Check steering relay K5 power circuit. Check for poor or loose connections of wires #2941 between FU10
and CA407-2, wire #2911 between CA407-3 and K5, wire #2912 between CA407-1 and K5, wire #518
between CA407-4 and negative buss, wire #2930 and #2935 between relay K5 and steer motor.
If: Wiring problems exists.
Then repair wiring.
If: Wiring is okay.
Then visually check K5 relay for closure.
If: Relay K5 does close.
Then proceed to step 2.
If: Relay K5 does not close.
Then check FU6.
If: FU6 is okay.
Then check wires #5936 between CA406-8 and K5 coil also wire #2927 between FU6 and K5
coil.
Step 2: Check steering relay K5 tips.
If: K5 relay tips are worn and/or burnt.
Then replace relay.
If: K5 relay tips are good.
Then check the steering module for power output. Connect DVOM positive lead to TB407-2 and
negative lead to TB407-3. Power up the truck within a few seconds the meter should momentarily
indicate a voltage output.
If: There is power output.
Then proceed to step 3.
If: There is no power output.
Then check fuse FU10.
If: Fuse FU10 is good.
Then replace steering module.

Crown 2003 PF13577-30 Printed in U.S.A.

M4.2–7532–629 M4.2–7532–629
 C EVENT CODES

Step 3: With the truck powered down jack up the power unit until the steer wheel is off the floor. By hand, check the
drive unit for movement left to right. Drive unit should be able to be moved.
If: The drive unit cannot be moved.
Then check the associated mechanical components (i.e. steering gear box, gears, etc) as well as any
obstructions.
If: The drive unit moves freely.
Then check the steering gear box.

Steering Module

Distribution Panel TB407 K5A

1 2911 2935
ED CA213 CA210 CA406
2941 Bus Bar
2 5 K5 1 Steer 2
+
Enable FU10 +
Steer
FU6 3 ED-B M2
TP2 Relay Motor
Output 002 -
4 518 +
001
2912 2930
K5B
10621-01

Steering module logic positive 12 volt output is out of tolerance. EVENT CODE 209

Steering, traction and lift disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace steering module.

Steering module logic negative 12 volt is out of tolerance. EVENT CODE 210

Steering, traction and lift disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace steering module.

Crown 2003 PF13577-31 Printed in U.S.A.

M4.2–7532–630 M4.2–7532–630
 C EVENT CODES

Steering Module auxiliary logic 5 volt is out of tolerance. EVENT CODE 211

Steering, traction and lift disabled.

Step 1: Check wiring for loose or poor connections between encoder ECR2 and connector module CA412 and
connector module CA411 to steer module CA406.
If: Wiring connections are bad.
Then repair.
If: Wiring is okay.
Then adjust ECR2 as described in section M4.5 of the service manual.
If: Event code 211 persists.
Then replace the steering module.

Steering Module Connector Module

CA406 CA411 CA412
Channel A Input 5 028 1 1 BLU
L-Comm Output 3 532 2 2 BLK L-Comm CHA
CHB Steering
Channel B Input 14 029 3 3 ORG
+5V L ECR2 Feedback
5V Output 11 710 4 4 RED Encoder
Index 23 030 5 5 YEL Index

6 6

10620

Steering module positive 12 volt battery is out of tolerance. EVENT CODE 212

Steering, traction and lift disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace steering module.

Crown 2003 PF13577-32 Printed in U.S.A.

M4.2–7532–631 M4.2–7532–631
 C EVENT CODES

Steering fuse (FU10) is blown. EVENT CODE 213

Steering, traction and lift disabled.

Step 1: Check fuse FU10.

If: FU10 is bad.
Then replace.
If: FU10 is good.
Then check wire #2941 between FU10 and CA407-2 also wire #518 between CA407-4 and negative
bus for loose connections.
If: Connection is bad.
Then repair.

Steering Module

Distribution Panel TB407 K5A

1 2911 2935
ED CA213 CA210 CA406
2941 Bus Bar
2 5 K5 1 Steer 2
+
Enable FU10 +
Steer
FU6 3 ED-B M2
TP2 Relay Motor
Output 002 -
4 518 +
001
2912 2930
K5B
10621-01

Crown 2003 PF13577-33 Printed in U.S.A.

M4.2–7532–632 M4.2–7532–632
 C EVENT CODES

Steering is not responding properly to the left. EVENT CODE 215

Steering, traction and lift disabled.

Step 1: Check steer motor wiring for correct polarity (positive lead is #2935 and negative #2930).
If: Wiring is reversed.
Then correct wiring.
If: Wiring is okay.
Then proceed to step 2.
Step 2: Check for obstructions around steer wheel.
If: Obstruction exists.
Then clear the obstruction.

Steering Module

Distribution Panel TB407 K5A

1 2911 2935
ED CA213 CA210 CA406
2941 Bus Bar
2 5 K5 1 Steer 2
+
Enable FU10 +
Steer
FU6 3 ED-B M2
TP2 Relay Motor
Output 002 -
4 518 +
001
2912 2930
K5B
10621-01

Crown 2003 PF13577-34 Printed in U.S.A.

M4.2–7532–633 M4.2–7532–633
 C EVENT CODES

Steering is not responding properly to the right. EVENT CODE 216

Steering, traction and lift disabled.

Step 1: Check steer motor wiring for correct polarity (positive lead is #2935 and negative #2930).
If: Wiring is reversed.
Then correct wiring.
If: Wiring is okay.
Then proceed to step 2.
Step 2: Check for obstructions around steer wheel.
If: Obstruction exists.
Then clear the obstruction.

Steering Module

Distribution Panel TB407 K5A

1 2911 2935
ED CA213 CA210 CA406
2941 Bus Bar
2 5 K5 1 Steer 2
+
Enable FU10 +
Steer
FU6 3 ED-B M2
TP2 Relay Motor
Output 002 -
4 518 +
001
2912 2930
K5B
10621-01

Crown 2003 PF13577-35 Printed in U.S.A.

M4.2–7532–634 M4.2–7532–634
 C EVENT CODES

No steer wheel movement upon command. EVENT CODE 217

Steering, traction and lift disabled.

Step 1: Check wiring connection of steer motor and feedback encoder (ECR2).
If: Steer motor is not electrically connected.
Then connect wiring.
If: Steer motor wiring is okay.
Then check between ECR2 and CA412 for loose or poor connection.
If: Wiring problems exists.
Then repair.
If: Wiring is okay.
Then verify that the steer motor brushes and wiring are okay.
If: Brushes or wiring are bad.
Then replace as necessary.
If: Brushes and wiring are okay.
Then proceed with step 2.
Step 2: Check for obstructions around steer wheel.
If: Obstruction exists.
Then clear the obstruction.

Steering Module Connector Module

CA406 CA411 CA412
Channel A Input 5 028 1 1 BLU
L-Comm Output 3 532 2 2 BLK L-Comm CHA
CHB Steering
Channel B Input 14 029 3 3 ORG
+5V L ECR2 Feedback
5V Output 11 710 4 4 RED Encoder
Index 23 030 5 5 YEL Index

6 6

10620

Crown 2003 PF13577-36 Printed in U.S.A.

M4.2–7532–635 M4.2–7532–635
 C EVENT CODES

Raise cutout switches do not match truck setups. EVENT CODE 218

Lift disabled.

Step 1: Check for incorrect setups for raise cutouts. Connect service terminal and access “View Cutouts & Zones”.
If: The lift cutout setups do not match the truck configuration.
Then access “Calibration Truck Setups; Lift Cutouts & Zones” and modify setups.
If: The setups match the truck configuration.
Then using the service terminal access “View Truck Setups; Lift Cutouts & Zones” verify that raise
cutouts are enabled.
If: Raise cutouts is not enabled.
Then access “Calibration Truck Setups; Lift Cutouts & Zones” and enable cutouts.
If: Raise cutouts are enabled.
Then proceed to step 2.
Step 2: Check wire connections between raise cutout switches and CA216-6, -7, -, -9 also wire between CA210-
12, -13 and CA406-6, -25 for shorts or loose connections.
If: Wire problems exist.
Then repair.
If: Wires are okay.
Then proceed to step 3.
Step 3: If the truck is configured as single lift cutout with “no override” verify the jumper is in place between CA216-
6, -7.
If: The jumper is not present.
Then install a jumper.

Distribution
Panel Steering Module
CA216 CA210 CA406
BLK 6 13 6 Raise Cutout Switch 2
RCS2 Input 5V=Open 0V=Closed
WHT 7
BLK 8 12 25 Raise Cutout Switch 1
RCS1 TP3 Input 5V=Open 0V=Closed
WHT 9 CA213
Contactor Panel
4
Battery Negative
Bus Bar
10622

Crown 2003 PF13577-37 Printed in U.S.A.

M4.2–7532–636 M4.2–7532–636
 C EVENT CODES

Raise cutout switch sequence error. EVENT CODE 219

Lift disabled.

Step 1: Raise cutout switches RCS1 and RCS2 must be detected in numerical sequence. Check the adjustment
and wiring of RCS1.
If: RCS1 is out of adjustment and not actuated.
Then adjust RCS1.
If: RCS1 is adjusted properly.
Then check for loose or poor connections between CA210-12, -13 and CA406-6, -25 also the two
conductor cable between CA216-8, -9 and RCS1.
If: Wiring is okay.
Then proceed to step 2.
Step 2: If the truck is configured as single lift cutout with “no override” check that the jumper is in place between
CA216-6, -7.
If: The jumper is not present.
Then install a jumper.

Distribution
Panel Steering Module
CA216 CA210 CA406
BLK 6 13 6 Raise Cutout Switch 2
RCS2 Input 5V=Open 0V=Closed
WHT 7
BLK 8 12 25 Raise Cutout Switch 1
RCS1 TP3 Input 5V=Open 0V=Closed
WHT 9 CA213
Contactor Panel
4
Battery Negative
Bus Bar
10622

Crown 2003 PF13577-38 Printed in U.S.A.

M4.2–7532–637 M4.2–7532–637
 C EVENT CODES

Steering module general purpose driver test indicates a 6P driver output active prior to turn “ON”. EVENT CODE 221

Steering, traction and lift disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace steering module.

Steering module general purpose driver test detected a short during power up diagnostics. EVENT CODE 222

Steering, traction and lift disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace steering module.

Short detected in steering module K2 relay coil driver circuit. EVENT CODE 223

Steering, traction and lift disabled.

Step 1: Check negative coil wire #5925 between CA406-28 and CA210-6 for a short to battery negative or truck
frame.
If: Short exists.
Then repair wiring.
If: Wiring is not shorted to battery negative or truck frame.
Then check for a short in relay K2 coil and/or coil suppressor.
If: Relay K2 coil circuit is not shorted and event code persists.
Then replace steering module.

Steering
Module Distribution Panel

CA406 CA210 CA213

5925
Brake 28 6 K2 2
Relay FU6 TP2
3
Output TP23

ED
+

10891

Crown 2003 PF13577-39 Printed in U.S.A.

M4.2–7532–638 M4.2–7532–638
 C EVENT CODES

Short detected in steering module K4 relay coil driver circuit. EVENT CODE 224

Steering, traction and lift disabled.

Step 1: Check negative coil wire #5923 between CA406-18 and CA210-7 for a short to battery negative or truck
frame.
If: Short exists.
Then repair wiring.
If: Wiring is not shorted to battery negative or truck frame.
Then check for a short in relay K4 coil and/or coil suppressor.
If: Relay K4 coil circuit is not shorted and event code persists.
Then replace steering module.

Steering
Module Distribution Panel
CA406 CA210 CA213
Steer 5923
18 7 K4 2
Angle FU6 TP2
Relay 3
TP20
Output

ED
+

10892

Crown 2003 PF13577-40 Printed in U.S.A.

M4.2–7532–639 M4.2–7532–639
 C EVENT CODES

Short detected in steering module K7 relay coil driver circuit. EVENT CODE 225

Steering, traction and lift disabled.

Step 1: Check negative coil wire #5937 between CA406-19 and CA210-1 for a short to battery negative or truck
frame.
If: Short exists.
Then repair wiring.
If: Wiring is not shorted to battery negative or truck frame.
Then check for a short in relay K7 coil and/or coil suppressor.
If: Relay K7 coil circuit is not shorted and event code persists.
Then replace steering module.

Steering
Module Distribution Panel
CA406 CA210 CA213
Guidance 19 5937
1 K7 2
Speed FU6 TP2
Reduction 3
Relay
Output

ED
+

10625

Crown 2003 PF13577-41 Printed in U.S.A.

M4.2–7532–640 M4.2–7532–640
 C EVENT CODES

Short detected in steering module K7 relay coil driver circuit. EVENT CODE 226

Steering, traction and lift disabled.

Step 1: Check wire #013 between CA210-3 and CA406-9 for a short to battery negative or truck frame.
If: Short exists.
Then repair wiring.
If: Wiring is not shorted to battery negative or truck frame.
Then check for a short in relay K7 coil.
If: Relay K7 coil circuit is not shorted and event code persists.
Then replace steering module.

Steering
Module Distribution Panel
CA406 CA210 CA213
013
9 3 K7 2
FU6 TP2
Auto/Manual 3
Output

ED
+

10626

Crown 2003 PF13577-42 Printed in U.S.A.

M4.2–7532–641 M4.2–7532–641
 C EVENT CODES

Short detected in steering module K5 relay coil driver circuit. EVENT CODE 227

Steering, traction and lift disabled.

Step 1: Check negative coil wire #5936 between CA406-8 and K5 coil for a short to battery negative or truck frame.
If: Short exists.
Then repair wiring.
If: Wiring is not shorted to battery negative or truck frame.
Then check for a short in relay K5 coil and/or coil suppressor.
If: Relay K5 coil circuit is not shorted and event code persists.
Then replace steering module.

Steering
Module 5936 Distribution Panel
CA406 CA210 CA213
Steer 8 K5 5 2
Enable FU6 TP2
3
Relay
Output

ED
+

10627

Crown 2003 PF13577-43 Printed in U.S.A.

M4.2–7532–642 M4.2–7532–642
 C EVENT CODES

Short detected in steer module P1 and P2 contactor driver. EVENT CODE 228

Steering, traction and lift disabled.

Step 1: Check negative coil wire #5927 between CA406-7 and CA210-8 for a short to battery negative or truck
frame.
If: Short exists.
Then repair wiring.
If: Wiring is not shorted to battery negative or truck frame.
Then check for a short in contactor P1 and P2 coil.
If: Coil circuits of P1 and P2 are not shorted and event code persists.
Then replace steering module.

Distribution Panel
CA213 K1B CA202 TB101 GTS1 GTS2
+ 1 2 2
FU2
TP1 RAS1
ED CA208 CA203
TP15
P1 3 7 17
TP16 CA201
4 8 18 RAS2
P2
7 TP5
CA210 8 2 1
Lift CA406
Contactor 7 5927 HSRCS
Output
Steering Module
10628

Crown 2003 PF13577-44 Printed in U.S.A.

M4.2–7532–643 M4.2–7532–643
 C EVENT CODES

Display module service terminal initiate failure. EVENT CODE 300

Steering, traction and lift will be disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace display module.

Display module ECR1 clear count failed. EVENT CODE 301

Steering and traction will be disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace display module.

ECR1 voltage is out of tolerance. EVENT CODE 302

Steering and traction will be disabled.

Step 1: Check for the presence of 5 volts at CA302-2, -4.

If: 5 volts is present.
Then replace ECR1.
If: 5 volts is not present.
Then check wire continuity between CA302-4 and CA304-28 also wire between CA302-2 and CA304-18.
If: Wire checks bad.
Then repair wire.
If: Wire checks good.
Then replace display module.

Display Module
CA304 CA302
Channel A Input 26 1 BLU
L-Comm Output 18 2 BLK L-Comm CHA
CHB
Channel B Input 25 3 ORG Steering
+5V L ECR1
Encoder
5V Output 28 4 RED
5 YEL Index

6
10629

Crown 2003 PF13577-45 Printed in U.S.A.

M4.2–7532–644 M4.2–7532–644
 C EVENT CODES

Display module logic positive 12 volt output is out of tolerance. EVENT CODE 303

Steering, traction and lift will be disabled.

Step 1: Turn the key “off” then “on”.

If: The event code clears.
Then truck is operation ready.
If: The event code persists and the service terminal is connected to the truck.
Then disconnect the service terminal and power up the truck.
If: The event code clears.
Then check the service terminal.
If: The event code persists.
Then check wires between CA303-7 and CA301-20 also wire between CA303-4 and CA301-7 for
continuity or shorts to frame.
If: The wires are good and event code persists.
Then replace the display module.

Display Module
CA301 CA303
7 4 L-Comm
Service
Terminal
Connector
20 7 12 Volt

10630

Crown 2003 PF13577-46 Printed in U.S.A.

M4.2–7532–645 M4.2–7532–645
 C EVENT CODES

Display module logic negative 12 volt supply is out of tolerance. EVENT CODE 304

Steering, traction and lift will be disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace display module

Display module alarm driver output is shorted. EVENT CODE 305

No action taken truck will operate and alarm may sound.

Step 1: Check wire #5920 between CA304-19 and alarm (ALM1) also wire #2911 between alarm and TB102-3 for
continuity or shorts to truck frame.
If: Alarm and/or wiring shorts are found.
Then repair shorts.
If: Alarm and wiring look okay.
Then disconnect and insulate wire #5920 from the alarm and power up the truck.
If: The event code clears.
Then replace the alarm.
If: Event code persists.
Then replace display module.

Distribution Panel Display Module

ALM1
CA213 CA205 TB102 CA304
K1B 5920
+ 1 3 3 19 Status
FU2 Alarm
ED TP1
TP3 Output
4
Battery Negative
Bus Bar
10631

Crown 2003 PF13577-47 Printed in U.S.A.

M4.2–7532–646 M4.2–7532–646
 C EVENT CODES

Display module detected invalid lift setup configuration. EVENT CODE 306

Lift disabled.

Step 1: Programmed lift cutout or zone setups must match truck configuration. Connect service terminal and
access “View Truck Setups”. Press forward until “View Cutout & Zones”.
If: The set values do not match the truck configuration.
Then using the service terminal go to calibration of lift cutouts or zone and renter the correct value(s).
If: The values are correct.
Then proceed to step 2.
Step 2: If the truck is configured as single lift cutout with “no override” verify the jumper is in place between CA216-
6, -7.
If: The jumper is not present.
Then install a jumper.
If: The jumper is present.
Then replace the display module.

Distribution
Panel Steering Module
Note CA216 CA210 CA406
BLK 6 13 6 Raise Cutout Switch 2
RCS2 Input 5V=Open 0V=Closed
WHT 7
BLK 8 12 25 Raise Cutout Switch 1
RCS1 TP3 Input 5V=Open 0V=Closed
WHT 9 CA213
Contactor Panel
4
Battery Negative
Bus Bar
Note: Jumper terminals 6 and 7
with one lift cutout w/o override.
10632

Crown 2003 PF13577-48 Printed in U.S.A.

M4.2–7532–647 M4.2–7532–647
 C EVENT CODES

Zone select switch (ZSS) is broken. EVENT CODE 307

Lift disabled.

Step 1: Check zone select switch (ZSS).

If: Zone select is enabled in Truck Setups but switch is not physically present.
Then connect the service terminal, access calibration cutout & zones and disable zone select feature.
If: Zone select is enabled in Truck Setups and the zone switch (ZSS) is present.
Then check wire connections from zone switch to TB102-6, -20, -21 to CA304-13, -22, -23.
If: Wire connections and wires are okay.
Then make certain the switch is in “active” position and not between.
If: Switch position is correct and fault persists.
Then replace the display module.

Distribution
Battery Panel
Negative
CA213 CA205 TB102
Bus Bar
4 4 4

TP3 5 5

6
Display Module
CA304 ZSS
(ZONE SELECT)
ZSS 3 Input 23 12 (BLU) 7
6 (GRN)
(YEL) 5
(ORG) 4
ZSS 2 Input 13 20 (RED) 3
1 (BLK)
(WHT) 2
ZSS 1 Input 22 21
(BRN) 8
10633

Crown 2003 PF13577-49 Printed in U.S.A.

M4.2–7532–648 M4.2–7532–648
 C EVENT CODES

Zone select switch (ZSS) or wiring is short circuited. EVENT CODE 308

Lift disabled.

Step 1: Check condition of wiring between zone select switch (ZSS) and display module CA304-13, -22, -23.
If: Any of the wires are shorted.
Then repair.
If: Wires are okay.
Then proceed to step 2.
Step 2: Using a DVOM check zone select switch for shorts. Each individual internal switch must be isolated from
the other.
If: The switch is internally shorted.
Then replace zone select switch (ZSS).
If: The switch is okay and the fault persists.
Then replace the display module.

Distribution
Battery Panel
Negative
CA213 CA205 TB102
Bus Bar
4 4 4

TP3 5 5

6
Display Module
CA304 ZSS
(ZONE SELECT)
ZSS 3 Input 23 12 (BLU) 7
6 (GRN)
(YEL) 5
(ORG) 4
ZSS 2 Input 13 20 (RED) 3
1 (BLK)
(WHT) 2
ZSS 1 Input 22 21
(BRN) 8
10633

Crown 2003 PF13577-50 Printed in U.S.A.

M4.2–7532–649 M4.2–7532–649
 C EVENT CODES

Zone select switch (ZSS) is detected but not enabled in truck setups. EVENT CODE 309

Lift disabled.

Note: If the truck has the “Zone Select” option refer to step 1.
If the truck does not have the “Zone Select” option refer to step 2.
Step 1: Connect the service terminal to the truck and access calibration “Lift Cutout or Zones” and enable zone
select feature.
If: Fault persists.
Then replace display module.
Step 2: Connect the service terminal to the truck and access calibration “Lift Cutout or Zones”.
If: Zone select is enabled.
Then disable the feature.
If: Zone select is disabled.
Then connect a DVOM, negative lead to TP102-6 and with the positive lead check for the presence of
5 volts at TP102-12, -20, -21.
If: Any terminal is low (“0” volts) and there is no shorting of that terminal to negative.
Then replace the display module.
If: There is a short to negative on any terminal that has “0” volts.
Then repair the short.

Distribution
Battery Panel
Negative
CA213 CA205 TB102
Bus Bar
4 4 4

TP3 5 5

6
Display Module
CA304 ZSS
(ZONE SELECT)
ZSS 3 Input 23 12 (BLU) 7
6 (GRN)
(YEL) 5
(ORG) 4
ZSS 2 Input 13 20 (RED) 3
1 (BLK)
(WHT) 2
ZSS 1 Input 22 21
(BRN) 8
10633

Crown 2003 PF13577-51 Printed in U.S.A.

M4.2–7532–650 M4.2–7532–650
 C EVENT CODES

Lift setups are not detected by steering module. EVENT CODE 310

Lift disabled.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace display module.

Invalid zone select switch (ZSS) setup is detected. EVENT CODE 311

Lift disabled.

Step 1: Connect the service terminal to the truck. Access calibration “Truck Setups” then press forward until “Lift
Cutouts or Zones“ appear. Enter the correct configuration setups.
If: Fault persists.
Then replace display module.

Steering tiller encoder (ECR1) count out of tolerance. EVENT CODE 312

Traction disabled.

Step 1: Check condition of encoder ECR1 and mounting hardware.

If: Encoder appears damaged.
Then replace encoder.
If: Encoder is okay but mounting hardware is worn or loose.
Then repair mounting hardware.
If: Encoder and mounting hardware is okay.
Then replace encoder (ECR1).
If: Fault persists.
Then replace display module.

Crown 2003 PF13577-52 Printed in U.S.A.

M4.2–7532–651 M4.2–7532–651
 C EVENT CODES

Display module RS232 port failure. EVENT CODE 313

No action taken, truck will operate.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: The event code persists and the service terminal is plugged into the truck.
Then disconnect the service terminal.
If: The event codes clears.
Then check the service terminal.
If: The event code persists.
Then replace the display module.

Crown 2003 PF13577-53 Printed in U.S.A.

M4.2–7532–652 M4.2–7532–652
 C EVENT CODES

Guidance module fails to come out of reset upon power-up. EVENT CODE 411

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module fails to program upon power-up. EVENT CODE 412

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module CAN setup failed. EVENT CODE 413

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module CAN write message failed. EVENT CODE 414

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Crown 2003 PF13577-54 Printed in U.S.A.

M4.2–7532–653 M4.2–7532–653
 C EVENT CODES

Guidance module program interrupt. EVENT CODE 415

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module real time Interrupt occurs. EVENT CODE 416

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module analog to digital conversion failed. EVENT CODE 417

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module software error occurred. EVENT CODE 418

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Crown 2003 PF13577-55 Printed in U.S.A.

M4.2–7532–654 M4.2–7532–654
 C EVENT CODES

Truck tracking outside wire guidance slowdown limits. EVENT CODE 419

Traction will be disabled and brakes applied.

Step 1: Check load wheel and steer wheel sensor bars.

If: Bar height is not 3.25" from the floor (bottom of bar to floor surface).
Then adjust bar height.
If: Bar height okay.
Then proceed with step 2.
If: Load wheel sensor bar bracket is bent.
Then straighten mounting bracket.
If: Mounting okay.
Then proceed with step 2.
If: Sensor bar(s) are damaged.
Then replace sensor bar(s).
If: Condition okay.
Then proceed with step 2.
Step 2: Connect the service terminal and access “View Encoder Counts” “Wheel Angle”. With the wheel straight
ahead as indicated by the drive unit alignment marks verify that ECR2 is in “Index”.
If: ECR2 is in “Index”.
Then proceed to step 3.
If: ECR2 is not in “Index”.
Then adjust as described in section M4.5 of the service manual.
Step 3: Recalibrate guidance.
If: Tracking is okay.
Then truck is operation ready.
If: Event code persists.
Then proceed to step 4.
Step 4: Check floor condition as poor floors affect guidance. Operate the truck though out the warehouse noting
the areas that guidance is effected.
If: Guidance is being effected by poor floor conditions.
Then have the floor surface repaired.
If: Floor repair is not feasible.
Then alert operators to the condition and to use extreme care when in guidance.

Crown 2003 PF13577-56 Printed in U.S.A.

M4.2–7532–655 M4.2–7532–655
 C EVENT CODES

Wire guidance lost while tracking. EVENT CODE 421

Traction will be disabled and brakes applied.

Step 1: Driving the truck off the end of the wire before turning guidance off can cause this event.
If: Truck was driven off the end of the wire before turning guidance off.
Then there is nothing wrong with the guidance system.
If: The truck was not driven off the end of the wire.
Then proceed to step 2.
Step 2: Check load wheel and steer wheel sensor bars.
If: Bar height is not 3.25” from the floor (bottom of bar to floor surface).
Then adjust bar height.
If: Bar height okay.
Then proceed with step 2.
If: Load wheel sensor bar bracket is bent.
Then straighten mounting bracket.
If: Mounting okay.
Then proceed with step 2.
If: Sensor bar(s) are damaged.
Then replace sensor bar(s).
If: Condition okay.
Then proceed with step 2.
Step 3: Connect the service terminal and access “View Encoder Counts” “Wheel Angle”. With the wheel straight
ahead as indicated by the drive unit alignment marks verify that ECR2 is in “Index”.
If: ECR2 is in “Index”.
Then proceed to step 4.
If: ECR2 is not in “Index”.
Then adjust as described in section M4.5 of the service manual.
Step 4: Recalibrate guidance.
If: Tracking is okay.
Then truck is operation ready.
If: Event code persists.
Then proceed to step 5.

Crown 2003 PF13577-57 Printed in U.S.A.

M4.2–7532–656 M4.2–7532–656
 C EVENT CODES

Step 5: Center the truck over the wire and connect the service terminal and view wire guide sensors.
If: Sensor bar(s) signal is zero.
Then check line driver signal output.
If: There is no signal from the line driver.
Then proceed to step 7.
If: Line drive signal is okay.
Then proceed with step 7.
If: The sensor bar signal is okay.
Then proceed to step 8.
Step 6: Remove sensor connectors and check for +5V dc power to the sensor. LW connector CA418 and SW
connector CA419, pin 3 is battery negative and pin 5 is supply positive.
If: There is no voltage at CA418 or CA419.
Then check wire harness continuity. LW connector CA418-3 to guidance module CA417-4 and CA418-
5 to guidance module CA417-3. SW connector CA419-3 to guidance module CA417-16 and CA419-5
to guidance module CA417-15.
If: Continuity test failed.
Then replace harness.
If: Continuity test passed.
Then replace guidance module.
Step: 7 The line driver outputs the guidance signal. Should AC power to the line driver be lost it will continue to
operate off the backup batteries for approximately one hour (dependent on battery condition) after which
there will be no guidance signal to the truck.
If: AC power to the line driver lost.
Then alert all operators to stop operation of wire guided equipment until the line driver is repaired.
If: The line driver is not operational.
Then check AC power at J3.
If: There is no AC power at J3.
Then contact the appropriate personnel for repairs.
Step 8: Check floor condition as poor floors affect guidance. Operate the truck through out the warehouse noting
the areas that guidance is effected.
If: Guidance is being effected by poor floor conditions.
Then have the floor surface repaired.
If: Floor repair is not feasible.
Then alert operators to the condition and to use extreme care when in guidance.

Crown 2003 PF13577-58 Printed in U.S.A.

M4.2–7532–657 M4.2–7532–657
 C EVENT CODES

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-59 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–658 M4.2–7532–658
 C EVENT CODES

Steering module does not detect the guidance module. EVENT CODE 422

Traction will be disabled and brakes applied.

Step 1: Using a DVOM measure the voltage at the guidance module connector CA417-20, 21.
To measure CA417-20 connect the positive lead to CA417-20 and the negative lead to TP3 on distribution
panel. To measure CA417-21 connect the positive lead to TP1 on distribution panel and the negative lead
to CA417-21.
If: Battery volts present.
Then proceed to step 2.
If: Battery volts not present at CA417-20.
Then check fuse FU7.
If: Fuse FU7 is bad.
Then replace fuse.
If: Fuse FU7 is good.
Then check wire #2918 from FU7 to CA417-20.
If: Battery volts not present at CA417-21.
Then check wire #519 from the negative bus to CA417-21.
Step 2: Check CAN wire connections at guidance module CA417-1, -2 and distribution panel CA207-3, -4.
If: Wires are loose or damaged.
Then repair.
If: Wires are okay and the fault persists.
Then replace the guidance module.

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-60 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–659 M4.2–7532–659
 C EVENT CODES

No guidance module is detected at power up. EVENT CODE 423

Traction will be disabled and brakes applied.

Step 1: Using a DVOM measure the voltage at the guidance module connector CA417-20, 21.
To measure CA417-20 connect the positive lead to CA417-20 and the negative lead to TP3 on distribution
panel. To measure CA417-21 connect the positive lead to TP1 on distribution panel and the negative lead
to CA417-21.
If: Battery volts present.
Then proceed to step 2.
If: Battery volts not present at CA417-20.
Then check fuse FU7.
If: Fuse FU7 is bad.
Then replace fuse.
If: Fuse FU7 is good.
Then check wire #2918 from FU7 to CA417-20.
If: Battery volts not present at CA417-21.
Then check wire #519 from the negative bus to CA417-21.
Step 2: Check CAN wire connections at guidance module CA417-1, -2 and distribution panel CA207-3, -4.
If: Wires are loose or damaged.
Then repair.
If: Wires are okay and the fault persists.
Then replace the guidance module.

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-61 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–660 M4.2–7532–660
 C EVENT CODES

Auto guidance is requested but wire guidance has been disabled via the service terminal. EVENT CODE 424

Traction will be disabled and brakes applied.

Step 1: Connect the service terminal to the truck and access “Truck Options” press forward until the “Wire Guid-
ance” option appears.
If: Guidance is not active.
Then press “Yes” to activate guidance.
If: Guidance is active.
Then proceed to step 2.
Step 2: If the truck is to be configured as a non wire guided truck and event code 424 is logged then remove the
platform console to gain access to TB102.
If: The jumper wire from TB102-5 to TB102-17 is missing.
Then install a jumper.

TB102

17

10635

Crown 2003 PF13577-62 Printed in U.S.A.

M4.2–7532–661 M4.2–7532–661
 C EVENT CODES

Traction speed sensor SS1 is not counting. EVENT CODE 425

Traction will be disabled and brakes applied.

Step 1: Check for wire damage and proper connection of sensor SS1 to wire harness plug CA416 and from CA416
to guidance module CA417.
If: Wires are damaged or poor connections are found.
Then make repairs.
If: Wires and connections are okay.
Then connect the service terminal to the truck and access ”View Encoder Counts” press forward until
“Present Speed of Truck” appears. Operate truck in forward and reverse verify the travel speed is the
same in both directions.
If: Travel speed is different in one direction.
Then replace the sensor (SS1).

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-63 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–662 M4.2–7532–662
 C EVENT CODES

Guidance module sensor amplifier failed selftest. EVENT CODE 426

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Load wheel sensor bar failed selftest. EVENT CODE 427

Traction will be disabled and brakes applied.

Step 1: Check load wheel sensor bar for damage.

If: Load wheel sensor bar is damaged.
Then replace load wheel sensor bar.
If: Load wheel sensor bar appears okay.
Then proceed with step 2.
Step 2: Check connector and wiring from load wheel sensor bar CA418 to guidance module CA417.
If: Wiring or connections are bad.
Then repair.
If: Wiring and connections are good.
Then replace load wheel sensor bar.

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-64 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–663 M4.2–7532–663
 C EVENT CODES

Steer wheel sensor bar failed selftest. EVENT CODE 428

Traction will be disabled and brakes applied.

Step 1: Check steer wheel sensor bar for damage.

If: Steer wheel sensor bar is damaged.
Then replace steer wheel sensor bar.
If: Steer wheel sensor bar appears okay.
Then proceed with step 2.
Step 2: Check connector and wiring from steer wheel sensor bar CA419 to guidance module CA417.
If: Wiring or connections are bad.
Then repair.
If: Wiring and connections are good.
Then replace steer wheel sensor bar.

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-65 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–664 M4.2–7532–664
 C EVENT CODES

Guidance module traction speed sensor input failed. EVENT CODE 429

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module steering feedback sensor input failed. EVENT CODE 431

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module 5 volt supply is out of tolerance. EVENT CODE 432

Traction will be disabled and brakes applied.

Step 1: Check for shorts in the sensor bar and/or SS1 traction tach wiring.
If: Wiring is shorted or damaged.
Then replace wiring.
If: Wiring is okay and fault persists.
Then replace guidance module.

Guidance module load wheel sensor bar negative 5 volt supply is out of tolerance. EVENT CODE 433

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Crown 2003 PF13577-66 Printed in U.S.A.

M4.2–7532–665 M4.2–7532–665
 C EVENT CODES

Guidance module steer wheel sensor bar negative 5 volt supply is out of tolerance. EVENT CODE 434

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module positive 12 volt supply is out of tolerance. EVENT CODE 435

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then replace guidance module.

Guidance module invalid software instruction encountered. EVENT CODE 436

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then contact factory for recommendation.

Guidance module division by zero was attempted. EVENT CODE 437

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then contact factory for recommendation.

Crown 2003 PF13577-67 Printed in U.S.A.

M4.2–7532–666 M4.2–7532–666
 C EVENT CODES

Guidance module software interrupt. EVENT CODE 438

Traction will be disabled and brakes applied.

Step 1: Turn the key “off” then “on”.

If: Event code clears.
Then truck is operation ready.
If: Event code persists.
Then contact factory for recommendation.

Detected intermittent connection to the inner coils of the steer wheel sensor bar. EVENT CODE 439

Traction will be disabled and brakes applied.

Step 1: Check connector and wiring from the steer wheel sensor bar CA419 to guidance module CA417.
If: Wiring is damaged or connections are bad.
Then repair.
If: Wiring and connections are okay.
Then check sensor bar by part substitution.
If: Fault persists.
Then replace guidance module.

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Crown 2003 PF13577-68 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–667 M4.2–7532–667
 C EVENT CODES

Detected intermittent connection to the inner coils of the load wheel sensor bar. EVENT CODE 441

Traction will be disabled and brakes applied.

Step 1: Check connector and wiring from the steer wheel sensor bar CA418 to guidance module CA417.
If: Wiring is damaged or connections are bad.
Then repair.
If: Wiring and connections are okay.
Then check sensor bar by part substitution.
If: Fault persists.
Then replace guidance module.

DISPLAY DISTRIBUTION
MODULE TB102 PANEL

1 1 1 1
CA417 GUIDANCE MODULE
2 2 2 2
1 SERIAL +
CA303 CA205 CA207
CA418 2 SERIAL -
COIL 5 1 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
COIL 6 2 BLK 8 LOAD WHEEL SENSOR BAR COIL 6

BATT NEG 3 YEL 4 LOAD WHEEL SENSOR BAR BATT NEG

LOAD WHEEL 4
SENSOR BAR
+5V 5 BLU 3 LOAD WHEEL SENSOR BAR +5V

SELF TEST 6 ORG 5 LOAD WHEEL SENSOR BAR SELF TEST

COIL 7 7 RED 19 LOAD WHEEL SENSOR BAR COIL 7

COIL 8 8 BRN 18 LOAD WHEEL SENSOR BAR COIL 8

CA416

SENSOR RED 1 RED 22 TACHOMETER +5V

BEARING
WHT 2 WHT 14 TACHOMETER CH B (SENSOR SIGNAL A)

BLU 3 BLK 13 TACHOMETER CH A (SENSOR SIGNAL B)

BLK 4 BLK 23 TACHOMETER BATT NEG

+ ED FU7
N 20 BATTERY POSITIVE INPUT

CA419 21 BATTERY NEGATIVE INPUT

COIL 1 1 GRN 27 STEER WHEEL SENSOR BAR COIL 1

COIL 2 2 BLK 28 STEER WHEEL SENSOR BAR COIL 2

BATT NEG 3 YEL 16 STEER WHEEL SENSOR BAR BATT NEG
STEER WHEEL 4
SENSOR BAR
+5V 5 BLU 15 STEER WHEEL SENSOR BAR +5V
SELF TEST 6 ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 3 7 RED 17 STEER WHEEL SENSOR BAR COIL 3

COIL 4 8 BRN 7 STEER WHEEL SENSOR BAR COIL 4

9

10634-01

Guidance module software is not compatible with the display/steering module software. EVENT CODE 442

Traction will be disabled and brakes applied.

Step 1: Connect the service terminal to the truck and access system information. Press forward until “Software P/
N” is displayed.
If: The part number is 122690-001-02 or higher and fault persists.
Then contact factory for recommendations.
If: The part number is lower than 122690-001-02.
Then refer to TSB 402.

Crown 2003 PF13577-69 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M4.2–7532–668 M4.2–7532–668
 WIRE GUIDANCE

WIRE GUIDE SYSTEM

7819

The Wire Guidance System automatically steers the lift truck

down the aisle without the use of guide rails. A Line Driver
produces a set frequency of 5.2KHZ, 6.25KHZ, 7.0KHZ, or
10KHZ which is transmitted through wire embedded in the
Base of Main Frame
floor down the middle of each aisle. The generated signal is (Located under Platform)
transmitted through the embedded wire, as shown in Illustra- (Rotated for clarity)
tion 1.
RK
FO ND
E
Line Driver

Transmitted Transmitted
Signal Signal
Storage Racks

Storage Racks

Storage Racks

Storage Racks
Storage Racks

Storage Racks

Storage Racks

Load Wheel
Floor Floor
Sensor

Epoxy Wire Embedded

In Floor (Sawcut) Steered Wheel
Sensor
Embedded Wire

7747 ILLUSTRATION 1 7748 ILLUSTRATION 2

Sensor bars mounted on the centerline of both ends of the A guidance selector switch (GUS) in the switch panel on the
truck, near the floor, (See Illustration 2) contain coils which truck selects manual or automatic steering. When in the
act as antennas to receive the transmitted signal. The closer manual mode, truck steering is controlled by the operator.
a coil gets to being directly over the wire, the higher the Steering remains in the operator’s control when switching to
amplitude of signal received by the coil. Using the coil signal automatic until the guidance signal is detected. When the
amplitude comparisons, the truck will “sense” the signal guidance signal is detected, steering control is automatically
path. With this data, steering is electronically controlled to changed to the guidance system.
follow the signal.

991201 6231

Crown 1999 PF11767-1 Printed in U.S.A.

M4.3–7330–550 M4.3–7330–550
 WIRE GUIDANCE

To align a truck to the wire guide signal, the approach angle If there is loss of the guidance signal, or if signal strength is
must be within 35° and traction speed must be below 2.5 below the minimum required to guide the truck, the guidance
MPH (See Illustration 3). The brakes are automatically module will output signals to operate the alarm and apply the
applied when the approach angle and/or approach speed brake. It will also turn the “automatic” indicator off and turn
are not within limits, when in the automatic mode. Traction the “manual” indicator on. The guidance selector switch
speed is limited to 1.5 MPH in the automatic mode until the (GUS) must be placed in the “manual” position to release the
truck is aligned with the wire. When aligned, the acquisition brake.
speed limit is removed.
OPERATION MODES
Embedded Wire
MANUAL

Maximum approach When the guidance selector switch (GUS) is in the “manual”
angle can not exceed
35° 35° position, truck steering is in the operator’s control.
35 degrees

AUTOMATIC

When the guidance selector switch (GUS) is placed in the

“automatic” position, the electronics enter the Search mode.
At this time the guidance signal has not been detected by the
sensors. The “auto” and “manual” indicators are both on and
traction speed is limited to 1.5 MPH. Steering control re-
mains in the manual mode.

When either sensor bar detects the guidance signal, Auto

Acquisition mode will be indicated by a display change. If
7749 ILLUSTRATION 3 traction speed at this time is greater than 2.5 MPH or the
angle of the truck to the wire is greater than 35°, the brakes
Enabling of the "Auto Sense Mode" via the service terminal will be applied. To release the brakes, guidance selector
causes the audible alarm to sound three short "beeps" switch (GUS) must be placed in the manual position. If the
whenever either sensor bar detects the guide wire signal angle and speed of the truck are within the limits when the
and the guidance selector switch (GUS) is in the manual signal is detected the manual indicator is turned off and
mode. At this time the operator may choose to place the steering is controlled by the electronics. Traction speed is
truck in “automatic” to eliminate the alarm. still limited to 1.5 MPH.

Each sensor bar contains four (4) coils which act as separate When traveling in the forward direction, the guidance system
antennas. When the amplitude of guidance signals received will align the truck with the wire when all of the following
are compared, the higher amplitude signals are from the parameters have been met: truck less than 4 in. from wire,
coils in closer proximity to the embedded wire. The sensors truck angle less than 6° from wire and steer wheel less than
mounted on the truck, electronically “sense” where the truck 12° from center. When traveling in reverse direction the
is in reference to the guidance signal. When guidance guidance system will align the truck with the wire when all of
selector switch (GUS) is in the “automatic” mode, the steer- the parameters are met: truck less than 3/4 in. from wire,
ing module provides the correct polarity and amplitude of truck angle less than 1° and the steer wheel less than 6° from
voltage to the steering motor to keep the truck centered over center. When the truck is adequately aligned, the auto
the guidance signal. Feedback from the steering feedback tracking mode is indicated by a 1 second operation of the
encoder (ECR-2) verifies the steered wheel is turned in the alarm. In this mode the truck is automatically guided by the
direction and at the speed required. electronics and the traction speed limit is removed.

Whenever the guidance signal strength drops to near the Three (3) variations to normal operation are encountered
minimum required to guide the truck, the guidance module during the Auto Tracking mode: 1 ) Auto Field Strength; 2)
outputs a signal to illuminate the signal strength light (Sig- Auto Track Deviation; 3) Auto Wire Lost.
nal). The steering module sends the signal to the traction
controller for 1.5 MPH maximum traction speed. If signal
strength returns, the signal strength indicator is turned off
and the traction speed limit is removed.
Crown 1999 PF11767-2 Printed in U.S.A.

M4.3–7330–551 M4.3–7330–551
 WIRE GUIDANCE

Auto Field Strength variation is encountered when the CALIBRATION

guidance signal received by the sensors decreases to near
the minimum required to continue Auto Tracking Mode. Wire guidance calibration sets up components of the wire
When entering Auto Field Strength the alarm is sounded for guidance system to guide the truck automatically while
1 second, the field strength indicator is turned on and traction centered over the signal wire embedded in the floor. It is
speed is limited to 1.5 MPH. When the guidance signal important to calibrate the truck at the installation with the
received returns to above minimum levels the alarm is highest field reading. If the truck has been calibrated on wire
sounded for 1 second, the field strength indicator turned off at the lowest strength, on wire with a higher strength, the
and the speed limit removed. system can become saturated and allow the truck to weave.

Components which affect wire guidance calibration include

Auto Track Deviation is encountered if the center of the
the front and rear sensor bars, the guidance module, the
truck leaves the guidance signal by .75 - 1.50 inches, an
steering module and the steering angle feedback encoder
angle of 1 - 1.8 degrees or the steer wheel angle is 6 - 12°
(ECR-2).
from center. When this happens the alarm is sounded,
manual steering indicator is turned on and traction speed is NOTE
limited to 1.5 MPH. When the truck returns to acceptable
tracking characteristics, the alarm is sounded for 1 second, Whenever any of these components are changed
the manual steering indicator is turned off and the traction or adjusted, the wire guidance system must be
speed limit is removed. recalibrated.

Auto Wire Lost will occur if one or more of four (4) situations Wire guidance calibration consists of four (4) parts: 1 ) Peak
are present; 1) guidance signal lost; 2) centerline of truck sensor coil search; 2) Center wheel position; 3) Vehicle
leaves signal path is more than 1.5 inches; 3) angle of truck angle; and 4) X-offset position.
to guidance signal is more than 1.8 degrees; 4) steer wheels
are turned more than 12 degrees during Auto Track. The Peak sensor coil search determines the maximum coil value
truck is allowed to deviate more immediately following a of each coil when passed over an active guide wire. The
travel direction change. When in Auto Wire Lost, the alarm maximum values are compared and each channel is given a
is operated continuously and the brake is applied. Guidance value to be multiplied by so all coils will appear equal (at least
selector switch (GUS) must be placed in the “manual” 95). This is electronic correction for weak coils.
position to release the brakes after this situation occurs.
Steer wheel position calibration determines the steer wheel
SENSORS center position which will provide straight line travel.

The sensor bars are fastened to adjustable brackets which Vehicle angle calibration determines angular deviation of the
permit adjusting the distance between the sensor bars and truck assembly which would cause “dog-tracking”.
the floor. When the line driver current output is set as
specified by M4.3-7330-702, the sensor bar should be level X-offset position calibration positions the mechanical center
and 3.25 inches (82 mm) from the floor. (See Illustration 4) of the truck over the guidance signal.
Voltage required by the sensor bar to operate is 5 volts,
between terminals 5 (positive) and 3 (negative). To perform the wire guidance calibration procedures, the
Service Terminal must be used. Refer to the Service Termi-
nal Instruction Book for a detailed step by step procedure.
Sensor Bar Height Adjustment

Sensor Bar
Truck
3.25 to 3.38 Inches
Centerline
Floor Floor

Guidewire

7750 ILLUSTRATION 4
Crown 1999 PF11767-3 Printed in U.S.A.

M4.3–7330–552 M4.3–7330–552
 WIRE GUIDANCE

TROUBLESHOOTING

Components concerned only with wire guidance are func-

tionally checked by the software diagnostics and are cov-
ered by service numbers 411 thru 442. Refer to the Service
Terminal Handbook (PF10462) for all troubleshooting and
diagnostic information.

Two (2) conditions can exist which would cause unsatisfac-

tory wire guidance performance by not tracking properly: 1.
Incorrect feedback information from the steering feedback
assembly; and 2. Saturated sensor bar coils.

The incorrect feedback information in the first condition can

occur if the wheels move slightly without turning the encoder
input shaft or from a misaligned feedback encoder. Refer to
M4.0-7330-080 Encoders for information and alignment
procedures.

To check if the coils in the sensor bars are saturated as

stated in the second condition, with truck centered over the
guide wire, use the Service Terminal to check the RAW
values of each coil as described in the SHOW-8 mode of
operation in the Service Terminal Instruction Book. The
outboard sensor raw and scaled values will be substantially
lower than the inboard sensor values, due to signal appear-
ance.

When each individual coil is directly over the guide wire (see
Service Terminal Operator Book for determining when a coil
is directly over the guide wire) and the RAW values are
above 90% and the wire amplitude can not be adjusted
down, the sensor bar should be raised to bring the RAW
values into the 70% to 80% range. Typically this will not be
required since the sensor height described earlier in this
section is correct for the line amplitude, measured with field
strength meter (112953), as referenced in M4.3-7330-702.
Always maintain a level relationship between the sensor bar
and the floor.

Crown 1999 PF11767-4 Printed in U.S.A.

M4.3–7330–553 M4.3–7330–553
 WIRE GUIDANCE
Connector CA417
9 8 7 6 5 4 3 2 1

19 18 17 16 15 14 13 12 11 10

28 27 26 25 24 23 22 21 20

7820

PIN COLOR FUNCTION VOLTAGE LEVEL CONNECTION

1. Black Serial + 0-5V CA207-3

2. White Serial - 0-5V CA207-4
3. Blue Load Wheel Sensor Bar +5V 5V CA418-5
4. Yellow Load Wheel Sensor Bar Batt.- Batt. Negative CA418-3
5. Orange Load Wheel Sensor Bar Self-test 5vp-p Max. AC CA418-6
6. - not used - -
7. Brown Steer Wheel Sensor Bar Coil 4 2Vp-p Max. AC CA419-8
8. Black Load Wheel Sensor Bar Coil 6 2Vp-p Max. AC CA418-2
9. Green Load Wheel Sensor Bar Coil 5 2Vp-p Max. AC CA418-1
10. - not used - -
11. - not used - -
12. - not used - -
13. Black Traction Tachometer CHA 0-5V CA416-3
14. White Traction Tachometer CHB 0-5V CA416-2
15. Blue Steer Wheel Sensor Bar +5V 5V CA419-5
16. Yellow Steer Wheel Sensor Bar Batt.- Batt. Negative CA419-3
17. Red Steer Wheel Sensor Bar Coil 3 2Vp-p Max. AC CA419-7
18. Brown Load Wheel Sensor Bar Coil 8 2Vp-p Max. AC CA418-8
19. Red Load Wheel Sensor Bar Coil 7 2Vp-p Max. AC CA418-7
20. R / White Batt.+ input to Guidance Module 24V FU7
21. Green Batt.- input to Guidance Module Batt. Negative Negative Buss.
22. Red Traction Tachometer +5V 5V CA416-1
23. Black Traction Tachometer Batt.- Batt. Negative CA416-4
24. - not used - -
25. - not used - -
26. Orange Steer Wheel Sensor Bar Self-test 5Vp-p Max. AC CA419-6
27. Green Steer Wheel Sensor Bar Coil 1 2Vp-p Max. AC CA419-1
28. Black Steer Wheel Sensor Bar Coil 2 2Vp-p Max. AC CA419-2

7821

Crown 1999 PF11767-5 Printed in U.S.A.

M4.3–7330–554 M4.3–7330–554
 C WIRE GUIDANCE

TRUCK CONSIDERATIONS

The truck steering system should be thoroughly checked before the alignment procedure is attempted. The system operates
through the existing truck steering mechanism. Slack, lag or excessive wear within this system will prevent guidance within
specifications.

Verify the following:

• Steering feedback encoder is set to index (I) when • Load wheel condition, including bearings.
drive unit alignment marks are aligned. • Look for load wheel debris such as shrink wrap.
• Steering gears-condition and lubrication. • Steer wheel sensor condition, orientation and height
• Steering servo motor and brushes. adjustment.
• Steering gearbox-condition and lubrication. • Load wheel sensor condition, orientation and height
• Drive unit stud and mounting bolts. adjustment.
• Drive unit thrust bearing and lubrication. • Speed sensor, SS1, condition, orientation and height
• Drive tire condition and type (poly only). adjustment.
• Look for drive tire debris such as shrink wrap.

6762-03
991101 2265

Crown 1999 PF11766 Rev. 2/02 Printed in U.S.A.

01 REV. 2/02
M4.3–7330–802 M4.3–7330–802
 CONTACTOR

10554

The purpose of this information is to instruct the technician CONTACTS

on proper care and maintenance to obtain satisfactory
service from these devices. Crown has tested and applied • In normal operation, the contacts will become black-
these contactors according to the requirements of our ve- ened, discolored, and roughened. This will not interfere
hicle. No modifications or changes should be made in the with proper operation and cleaning is not necessary.
layout, physical arrangement or electrical connections with-
out permission from Crown. • The contacts should be replaced before the silver
contact facing is completely eroded through to the
CAUTION backing material. The silver contact facing may trans-
Before any inspection, adjustments, servicing, fer to either the moving or stationary contact and cause
parts replacement or any other act is performed buildup on one contact. This can be expected under
requiring physical contact with the electrical work- certain conditions and does not require contact dress-
ing components or wiring of these contactors, ing or filing.
disconnect battery, raise drive wheels clear of
floor and place blocks under truck frame. • It is recommended that contacts always be replaced in
mating pairs.
Inspection
COIL
The following information is intended to assist during periods
of normal maintenance and to provide checks for maintain- • Remove all electrical connections.
ing adjustments. As these devices are tested and adjusted
at the factory, they should not normally require further • Resistance reading of the coil should be between 15 -
adjustments. However, if factory adjustments are tampered 19 ohms.
with or otherwise changed, the checks contained in the
following information may be made. • If reading does not fall within the limits, replace.

Curtis-Albright 4236

Crown 1992 PF9313-1 Rev. 11/02 Printed in U.S.A.

02 REV. 11/02
M4.4–04.2–001 M4.4–04.2–001
 CONTACTOR

Component Replacement CONTACT REPLACEMENT

Refer to Illustration 4.4-1 and parts breakdown in Parts 1. Remove electrical connections to contacts (coils do not
Section of manual when replacing components. have to be disconnected for this procedure).

4 2. Remove two (2) screws (Index 4) from top of contacts

and lift contact assembly from truck.
1
3. Disassemble and replace contacts.

4. Place contact assembly on coils and fasten securely

with two (2) screws (Index 4).
3
5. Connect cables.
8 5
COIL REPLACEMENT

1 1. Disconnect all electrical wiring.

2. Remove four (4) mounting bolts from mounting bracket

and lift entire contactor from truck.
2
3. Remove two (2) screws (Index 4) and separate contact
assembly from coil assembly.
9
4. Select replacement coil and transfer plunger (Index 2)
6 from coil being replaced to replacement coil.

5. Reassemble contact assembly to coil assembly and

secure with two (2) screws (Index 4).

7 6. Mount contactor on truck and reconnect all electrical

wiring.

1158-01 ILLUSTRATION 4.4-2

Crown 1992 PF9313-2 Rev. 11/02 Printed in U.S.A.

02 REV. 11/02
M4.4–04.2–002 M4.4–04.2–002
 MAINTENANCE

116794-001 & 116794-002 CONTACTOR 24 Volt

DIRECTIONAL “F & R”

The purpose of these instructions is to instruct the user on Inspection

proper care and maintenance to obtain satisfactory service
from these devices. Crown has tested and applied these The following information is intended to assist during periods
contactors according to the requirements of our vehicle. No of normal maintenance and to provide checks for maintain-
modifications or changes should be made in the layout, ing adjustments. As these devices are tested and adjusted
physical arrangement or electrical connections without per- at the factory, they should not normally require further
mission from Crown. adjustments. However, if factory adjustments are tampered
with or otherwise changed, the checks contained in the
DANGER following information may be made.
Before any inspection, adjustments, servicing,
parts replacement or any other act is performed CONTACTS
requiring physical contact with the electrical work-
ing components or wiring of these contactors; In normal operation, the contacts will become blackened,
disconnect battery, raise drive wheels clear of discolored, and roughened. This will not interfere with proper
floor and place blocks under truck frame. operation and cleaning is not necessary. The contacts
should be replaced before the silver contact facing is com-
pletely 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
expected under certain conditions and does not require
contact dressing or filing. It is recommended that contacts
always be replaced in mating pairs.

To inspect the normally closed (N.C.) contacts, manually

push the contacts apart. Use an inspection mirror to inspect
the contacts to the rear of the contactors.

COILS

Remove all electrical connections from coils. Resistance

reading of the coils should be between 17.6 - 18.4 ohms. If
3250P 116794-001
reading does not fall within the limits, replace.

2530P 116794-002

ILLUSTRATION 4.4-1
931201 4295NE - 39406

Crown 1993 PF9987-1 Rev. 8/94 Printed in U.S.A.

01 REV. 8/94
M4.4–6535–001 M4.4–6535–001
 MAINTENANCE

Component Replacement CONTACT REPLACEMENT

Refer to parts breakdown in Illustration 4.4-2 when replacing Disconnect all electrical wiring from contactor. Remove
components. mounting bolts from mounting bracket and lift entire contactor
from truck. Remove three (3) screws (Index 1) and while still
1 holding assembled contactor, place upside down to rest on
2 its fixed contacts. Separate coil assembly from the rest of the
contactor assembly.

Remove the two insulators (Index 7) and the fixed contact

3 (Index 6) from the top cover assembly. Using a thin screw-
driver, depress the return spring. Remove the moving con-
tact sideways from the top cover assembly.

Select a replacement moving contact (Index 5). Depress the

return spring again as previously. Slide the replacement
moving contact in from the side so that the top of the plunger
engages with the return spring insulator. Ensure that the
4 insulator and the return spring are correctly located. Repeat
these steps for the other moving contact assembly. As-
semble the fixed contact (Index 6) to one of the insulators
6
(Index 7). Place the fixed contact and its insulator into the top
cover assembly. Place the other insulator into the top cover
assembly.

Carefully place coil assembly onto the contact assembly.

7
7 Locate the moving contact plungers (Index 5) into the holes
5
in the top of the replacement coil. Position the pegs of the
insulators (Index 7) to holes in the frame. While holding
correctly assembled contactor, carefully turn top side up.
Secure with screws (Index 1) tightening up to a torque of 2.4
Nm. Install contactor on mounting bracket of truck with
mounting bolts. Connect electrical wiring.

COIL REPLACEMENT
8
Disconnect all electrical wiring from contactor. Remove
mounting bolts from mounting bracket and lift entire contactor
from truck. Remove three (3) screws (Index 1) and while still
holding assembled contactor, place upside down to rest on
its fixed contacts. Separate coil assembly from the rest of the
contactor assembly.
2255
ILLUSTRATION 4.4-2
Select replacement coil and carefully place on the contact
Index Part Name assembly. Locate the moving contact plungers (Index 5) into
the holes in the top of the replacement coil. Position the pegs
1 Screw of the insulators (Index 7) to holes in the frame. While holding
2 Screw M8 correctly assembled contactor, carefully turn top side up.
Lockwasher Secure with screws (Index 1) tightening up to a torque of 2.4
3 Cover Top Includes Index 4 & 5 Nm. Install contactor on mounting bracket of truck with
4 Spring Return mounting bolts. Connect electrical wiring.
5 Contact Moving
6 Contact Fixed
7 Insulator
8 Coil
Crown 1993 PF9987-2 Printed in U.S.A.

M4.4–6535–002 M4.4–6535–002
 BRAKE SYSTEM

The brake system consists of an electric brake and a brake

module mounted to the traction panel on the power unit. Part Of Platform

When the operator depresses the brake pedal, a switch

(BRS) located below the platform is actuated. Switch con-
tacts close, thereby allowing power to be supplied to the
brake. The brake is then electromagnetically released. When
the operator releases the pedal, the brake magnets are de-
energized. Springs force armatures within the brake to press
BRS
the brake pads against the rotor, applying the brake.
Brake Module
Depending on the truck steer angle and platform height, one
of three levels of brake force will be applied. The applied Brake
braking force is controlled by the brake module. These three
levels of braking force are listed in the charts. TP
TP
YE
GRL F
1
N AU L
PO T
W
ER
2
TP
3
TP

The brake contains two armatures, inner and outer, which

4
TP
8
TP

are controlled by two electromagnets. When 33% of full Drive Motor

5
BR
P AK
RE/ N 1E M
V.– 17 OD
59 U
8 LE

braking is required, the module allows only the inner magnet TP

TP
6

coil to be de-energized. Springs force the inner armature to

press the pads against the rotor while the outer armature
remains electromagnetically attracted to the magnet. Thus
33% of full braking occurs. When 67% of full braking is
required, only the outer armature is used for braking and at
100%, both armatures are used.

When in a reduced braking mode, the inner or outer armature 3216-01

ILLUSTRATION 1
(depending on braking level required) remains released for
4 - 8 seconds after brakes are requested. This time is MODEL SP 3000
referred to as time out. Time out allows the truck to stop in a
reduced braking mode, then applies full brakes to reduce Steer Angle Free Ranging
heat build up in the brake and conserve truck battery life.
Fork Height
mm Braking Force

75 To 1200 100%
1200 To 2500 67%
2500 To 4500 33%
4500 To 7010 33%

Steer Angle Guided (Wire or Rail)

500 To 1200 100%

1200 To 2500 67%
2500 To 4500 33%
4500 To 7010 33%

030501 5556

Crown 2003 PF13578-1 Printed in U.S.A.

M5.0–7530–009 M5.0–7530–009
 BRAKE SYSTEM

BRAKE ADJUSTMENT 1. Chock load wheels. Open power unit doors to access
brake assembly.
Air Gap Adjustment
2. Release brake, using tow switch.
The "air gap" is the distance between the brake pad and
rotor. As the brake pads and rotor wear normally, the air gap 3. Using low pressure air, remove any dirt between
will increase and should be readjusted when it exceeds 1.0 armatures and magnet body.
mm.
4. With a 20 mm open end wrench, loosen the top nut.
NOTE
5. Using a 30 mm open end wrench, turn the 30 mm hex
If the air gap measures more than 1.0 mm , the nut down until the air gap is 0.13 mm at its tightest
brake may not release properly. If the brake location. One complete turn of the nut will change the
pad thickness is less than 2.8 mm, the brake gap 0.13 mm or 1/6 (60 degrees) turn will change gap
pads and rotor should be replaced. 0.13 mm.

6. Torque the 20 mm hex nut to 122 Nm.

7. Apply brake, using tow switch.

8. Remove chocks and check operation.

Torque To
122 Nm

0
Motor Shaft 20 mm
Hex Nut
Rotor

30 mm
Hex Nut

Brake Pads
Air Gap Armature
Electromagnet
Electromagnet

Torque
Adjuster
Gap
Torque
Adjuster
Plate

Drive
Motor

10894
ILLUSTRATION 2

Crown 2003 PF13578-2 Printed in U.S.A.

M5.0–7530–010 M5.0–7530–010
 BRAKE SYSTEM

STOPPING DISTANCE ADJUSTMENT Stopping Distance Procedure

GENERAL NOTES Check stopping distance with the platform height below 610
mm, no load, and on a level surface typical for the application.
The brake system is adjusted at the factory to provide Travel at maximum acceleration from 0 to 15 meters in the
optimal braking performance for smooth dry concrete floors power unit first direction. Apply the brake and measure the
and standard tire conditions. Upon installation, the brake stopping distance. Approximate stopping distance for smooth,
adjustment should be checked. It may be necessary to dry concrete is 2660 to 3050 mm.
modify the factory setting to properly accommodate the
particular floor conditions.

Brake Adjustment

Using the stopping distance procedure that follows, adjust

the torque adjuster plate to produce the desired stopping
distance. Rotate the torque adjuster plate up to SHORTEN
the stopping distance or down to LENGTHEN the stopping
distance. After this initial adjustment, the stopping distance
of the truck should require minimal adjustment. However,
this distance should be checked with each planned mainte-
nance.

Torque To
122 Nm

0
Motor Shaft 20 mm
Hex Nut
Rotor

30 mm
Hex Nut

Brake Pads
Air Gap Armature
Electromagnet
Electromagnet

Torque
Adjuster
Gap
Torque
Adjuster
Plate

Drive
Motor

10894
ILLUSTRATION 3

Crown 2003 PF13578-3 Printed in U.S.A.

M5.0–7530–011 M5.0–7530–011
 BRAKE SYSTEM

Manual Release
Flatwasher (AR) Roll Pin
If necessary (due to low voltage, magnet malfunction,
30 mm etc.) the brake assembly can be manually released. To
20 mm Torque To
Hex Nut Hex Nut release, insert two 1/4 in. - 20 screws approximately 41
122 Nm mm long in the brake assembly from under the brake pad

0
assembly. Tighten screws just enough to spread the
brake pad mounting plate and rotor apart.
Brake Pad Rotor
Assembly

Ma a
u
n
Re
eHelsao
Compression
Spring
Outer
Armature

10896 ILLUSTRATION 5
Inner
Armature Rotor and Brake Pad Replacement
Springs Tools are available from Crown to permit replacement of the
10:00 pads on the brake pad assembly. When used with a press,
Position these tools allow the correct positioning of the pads and
correct setting of the rivets. A press is required to insure the
rivets provide the compression strength needed to keep
Magnet brake pads stationary.
Body
Torque
Adjuster RIVETER BASE
119343
Plate

RIVETER
114518
Drive 0996-01 ILLUSTRATION 6
Motor (M1)
To disassemble rotor and brake pad assembly:

1. Block load wheels, disconnect battery and open power

unit doors.
2. Disconnect brake connector from brake module.
3. Remove roll pin and two hex nuts.
4. Remove rotor and brake pad assembly.
10895 ILLUSTRATION 4
5. Measure torque adjuster gap for reference during
reassembly.
When assembling, be sure the manual release holes are
aligned.
Crown 2003 PF13578-4 Printed in U.S.A.

M5.0–7530–012 M5.0–7530–012
 BRAKE SYSTEM

Brake Assembly
Flatwasher (AR) Roll Pin
Before assembling brake, inspect all components for wear,
grooves, nicks or other damage. If any abnormal wear or 30 mm 20 mm
Hex Nut Torque To
damage appears that may affect brake operation, replace Hex Nut 122 Nm
with new parts. Assemble brake as follows:

0
1. Turn torque adjuster plate down as far as possible to
reduce spring force. Brake Pad Rotor
Assembly
2. Position wire harness in an approximate 10 o'clock
position.

3. Secure magnet body to motor housing using three

5/16" screws. Compression
Spring
4. Assemble springs, inner & outer armatures and brake Outer
pad assembly to magnet body. Be sure the holes used Armature
for manual release are aligned (See Manual Release).

5. Slip rotor on motor shaft, hub first. Thread 30 mm hex

Inner
nut onto motor shaft. Turn the nut down until the rotor Armature
moves down and almost touches the brake pads.
Proper air gap adjustment will be made later. Springs
10:00
6. Thread 20 mm hex nut onto motor shaft and torque to Position
122 Nm. Add flatwasher(s) and insert roll pin into motor
shaft.
Magnet
Body
7. Set torque adjuster gap to its original setting.
Torque
Adjuster
8. Connect brake connector to module. Plate
9. Connect battery to apply brake.

10. Adjust air gap. See AIR GAP ADJUSTMENT proce-

dures.

11. Check brake operation and stopping distance. See

STOPPING DISTANCE ADJUSTMENT procedures. Drive
Motor (M1)

10895 ILLUSTRATION 7

Crown 2003 PF13578-5 Printed in U.S.A.

M5.0–7530–013 M5.0–7530–013
 BRAKE SYSTEM

Troubleshooting

Problem Probable Cause Remedy

Brakes will not release • Air gap more than 1.0 mm Adjust

• Open circuit in brake module circuitry or Make voltage checks at test points
wiring of the brake module (see chart 2)

• Armatures movement restricted by dirt, Clean with low pressure air

foreign material

Brakes drag • Air gap less than 0.13 mm Adjust

• Brake pad mounting plate or rotor distorted Replace

• Armatures movement restricted by dirt, Clean with low pressure air

foreign material

Brakes grab • Incorrect stopping distance adjustment Adjust

• Brake pad mounting plates or rotor distorted Replace

Stopping distance too long • Incorrect stopping distance adjustment Adjust

• Brake pads loose or soiled with grease Replace

Abnormal noise and chatter • Brake pad mounting plate or rotor distorted Replace
when brakes applied
• Brake pads worn out, loose, soiled with Replace
grease, foreign material embedded

• Rotor thin, cracked, or spline worn Replace

* Abnormal braking force • WIRE GUIDE TRUCKS: Guide wire Troubleshoot wire guidance
for lift height or brakes lost power or truck off guide wire system
applied without request
• Open circuit in brake module circuitry or Make voltage checks at test
wiring points of the brake module
(see chart 2)

* The brake module allows 1/3 braking only if TP1 (CA414-8) goes to +24 volts after TP3 (CA414-5) once truck is powered
up. If TP1 is +24 volts when TP3 goes to +24 volts, 2/3 braking will automatically be applied and the yellow LED on the
brake module will illuminate. Brakes will not release until the truck is powered down and powered back up.

CHART 1

Crown 2003 PF13578-6 Printed in U.S.A.

M5.0–7530–014 M5.0–7530–014
 BRAKE SYSTEM

LED INDICATORS

Green Indicator - When illuminated, the brake module internal DC - DC Converter is operating. If this indicator is not
illuminated when truck is powered up, verify if battery volts are present between TP4 (battery negative) and CA403-4 (battery
positive).

Yellow Indicator - When illuminated, a fault has been detected. Incorrect sequence of input signals due to open circuit or
an internal module fault can cause this condition. Verify input signals at test points prior to replacing module.

TEST POINTS

Brake module test points are listed in Chart 2 and shown in illustration 5.0-7. At various levels of braking, battery voltage
should be present at test points indicated with an "X" in Chart 2. The monitored signals are as follows:

Test Points SP 3000 Monitored Signals Input/Output

TP1 HTS2500 Input

TP2 Not Used
TP3 HTS1200 Input
TP4 Battery Negative Input
TP5 Brake Release Input
TP6 33% of Full Braking (inner coil) Output
TP7 67% of Full Braking (outer coil) Output
TP8 Brake Pedal (BRS) Input

TP1, 2, 3, 5 and 8 are test points for input signals to the brake module. Battery voltage not present at these test points as
indicated in Chart 2 will indicate a poor connection, faulty switch, etc. in the circuit before the brake module. TP6 and 7 are
test points for outputs from the brake module. Battery voltage, after time out, present at these test points when the brakes
are to be applied will indicate a faulty brake module.

To make voltage checks, block load wheels and actuate brake switch to release brake. Connect negative meter lead to TP4
and actuate pump contactor to obtain correct lift height (connecting a jumper from TP15 to TP1, located on the distribution
panel, will actuate the pump contactor). When lift height is obtained, release brake. Check voltage at TP6 and TP7.

NOTE

Voltages must be checked within 4 - 8 seconds after brake is released. After 5 - 8 seconds, time-out will occur
and voltages at TP6 and TP7 will be 0 volts.

Crown 2003 PF13578-7 Printed in U.S.A.

M5.0–7530–015 M5.0–7530–015
 BRAKE SYSTEM

Brake Module YE

on Contactor Panel TP
GRL F
1
N AUL
PO T

in Power Unit
W
ER
TP
2
TP
3
TP
4
TP
8
TP
5
BR
P AK
RE/ N 1E M
V.– 17 OD
59 U
8 LE

TP
6
TP
7

3221-01
ILLUSTRATION 8

MODEL SP 3000

Steer Angle Free Ranging

Fork Height Test Points

mm TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8
75 To 1200 X NOTE 1 NOTE 1
1200 To 2500 X X
2500 To 4500 X X
4500 To 7010 X X X

Steer Angle Guided (Wire or Rail)

75 To 1200 X NOTE 1 NOTE 1

1200 To 2500 X X
2500 To 4500 X X X
4500 To 7010 X X

CHART 2
X = 24 Volts

NOTE 1: When the brake is released (energized), battery voltage should be present at TP5, 6, 7 and 8.

Crown 2003 PF13578-8 Printed in U.S.A.

M5.0–7530–016 M5.0–7530–016
 C FORK INSPECTION

The following causes of fork failure may mean loss of

equipment, damaged materials, bodily injury or loss of life. At
each planned maintenance interval an inspection and mea-
surement of the forks must be made to check for wear,
overload, fatigue, bends, etc.

WARNING

Use the proper fork for which it is designed.

Avoid using fork extensions. 6335 ILLUSTRATION 1

Do not modify forks. Only qualified personnel To set the outside jaws, measure the thickness of the middle
should make such repairs. of the shank (this point receives almost no wear). Set the
calipers to the “feel” of the shank by lightly tapping on them
Inspect forks visually each work day. with a metal object.

Abrasion Care should be taken when using the calipers to hold them
square across the shank or an incorrect reading will result.
Abrasion gradually reduces the thickness of the fork. Be sure
the fork thickness is up to standard. Do not allow forks to rub
the floor during normal operation (if forks do rub floor, check
lift chain adjustment). Fork wear at the heel must not exceed
10 percent of the original thickness. At this point forks are
adequate for approximately 80 percent of rated capacity
(refer to Chart 2). Crown has a fork wear calipers (part
no.107330) available for use or a measuring instrument such
as a vernier or good six inch scale may be used. For
allowable fork wear thickness refer to Chart 1.

Standard Fork Allowable 10% Wear

6336
Thickness Fork Thickness
mm in. mm in.
31.5 1.25 28.5 1.12
38.0 1.50 35.0 1.38
44.5 1.75 39.5 1.56
51.0 2.00 46.0 1.81
57.0 2.25 51.0 2.00
63.5 2.50 57.0 2.25

CHART 1 6337 ILLUSTRATION 2

If using the fork wear calipers refer to the following:

The fork wear calipers has two measuring points

or jaws. The inside jaws measure 10 percent less
than the outside jaws.

7951

Crown 1988 PF7393-1 Rev. 4/04 Printed in U.S.A.

02 REV. 4/04
M7.8–04.2–001 M7.8–04.2–001
 C FORK INSPECTION

Once the outside jaws are set, check to see if the inside jaws
of the calipers pass over the flanks of the fork blade at any
point between the end of the taper and the heel of the fork
blade. After checking the blade, recheck the caliper setting
by measuring the shank again making sure the setting was
not inadvertently changed.

6338 ILLUSTRATION 3

PERCENTAGE REMAINING OF SPECIFIED FORK CAPACITY

6339 CHART 2

Overloading

Know the capacity of the forks and truck. The fork capacity
and load center is stamped on the fork (see Illustration 4).
Overloading can cause permanent deformation or serious
fatigue conditions.

6340 ILLUSTRATION 4

Crown 1988 PF7393-2 Rev. 4/04 Printed in U.S.A.

02 REV. 4/04
M7.8–04.2–002 M7.8–04.2–002
 C FORK INSPECTION

Fatigue

A fatigue crack will normally start in the heel area of the fork. To check the fork, a carpenters square can be used, refer to
Cracks can usually be detected in the early stages by Illustration 7. Hold the square against the shank staying
inspection of the heel area. Check for cracks that transverse above the radius of the heel as shown. Measure the distance
the fork in an area up to 130 mm (5 inches) either side of the closest to the radius of the heel of the fork blade and square.
outer heel radius. These cracks are a sign that the area has Add 31.8 mm (1.25 in.) to this measurement and record. If
weakened and the fork needs to be replaced. A visual the distance between the end of the square and blade is
inspection for cracks should be made each work day. If a greater than this calculation, replace blade (fork is deformed
more accurate inspection is necesary, dye penetrants can more than 93°).
be used or magnaflux fork.
60.9cm
(2 ft.)

130mm (5 in.)

"x" "x" + 31.8mm (1.25 in.)

6343-01 ILLUSTRATION 7

Hanger
130mm (5 in.)
Check for cracks or damage to the fork pins and the area of
fork attachment. Check carriage for excessive wear or
6341-01 ILLUSTRATION 5
cracks. Repair or replace parts if necessary.
Bent or Twisted Forks
Check condition of fork locking pin, spring, cam, etc. for
proper operation (if forks are so equipped).
Overloading, glancing blows against solid objects, or picking
up loads unevenly can bend or twist a fork, making fork
replacement necessary. The maximum allowable difference
in fork tip elevation from one fork to another is 3% of the fork
length.

The angle between the top of the fork (blade) to the back
surface of the vertical leg (shank) shall be less than 93°. Any
angle greater will require fork repair or replacement. The fork
manufacturer or repairman with the expertise of equal
comptetence are the only parties that should attempt to
make such repairs.

6344 ILLUSTRATION 8

6342 ILLUSTRATION 6
Crown 1988 PF7393-3 Rev. 4/04 Printed in U.S.A.
02 REV. 4/04
M7.8–04.2–003 M7.8–04.2–003
 MAINTENANCE

PLATFORM
From time to time maintenance and/or repair of the platform A special tool 103792 will greatly aid in the installation of the
and components may be necessary to keep the truck oper- wedge locking strips. To use the tool, the strip must be fed
ating properly. Use the following information as an aid in through the throat of the tool head (as shown in Illustration
maintaining proper platform condition and operation. 9-3), leaving approximately 1 in. (25mm) of strip exposed
beneath the head. The tool should then be inserted into the
FLOOR MAT REPLACEMENT “V” slot in the main molding body. Once started with both the
strip and body ends flush, clamp the end with your thumb
Should a mat need replace- and push the tool through the slot. If the tool seems to push
ment, thoroughly clean the relatively hard, heat should be applied to the molding. This
platform’s floor surface. Apply will liquefy the film which covers the molding and act as a
a thin coat of cement lubricant.
(#061007-001) to the back side
of the mat and to the platform
floor. Do not apply cement to
the back side of the mat if it is
a sponge type surface, rather
apply a heavier coat to the FLOOR
platform floor. Allow the ce- MATS
ment to dry until it becomes 3789
ILLUSTRATION 9-1
tacky (approximately 10 to 15
minutes). Place the mat in position and apply pressure to
insure good contact between surfaces.

SAFETY SHIELD

To perform mainte-
nance to certain areas
of the mast or platform
assembly, it may be
necessary to remove
the safety shield. The SAFETY
SHIELD
safety shield is mounted
in rubber molding so that
it is fully suspended. The
molding and safety
glass should be as-
sembled as shown in il-
4018 ILLUSTRATION 9-2
lustration 9-3. The
wedge locking strip must be pressed into the open groove
to secure the glass in place. 2942S ILLUSTRATION 9-3

950612 6784

Crown 1995 PF10649-1 Rev. 9/00 Printed in U.S.A.

01 REV. 9/00
M9.0–7530–001 M9.0–7530–001
 MAINTENANCE

FORKS NOTE

Fork Inspection Shorter tapered fork lengths will tend to be heavier

in the heel area. Care must be taken to handle
Visually inspect forks for cracks, deformation, proper instal- fork safely after removal.
lation, etc. The platform needs to be raised accordingly to
inspect the portion of fork beneath the platform. See section Fork installation requires a balanced fork hook-up to the
M7.8 for additional information. hoist with a basket type sling arrangement that allows for the
fork to be raised safely into position. Install fork pin and
CAUTION retaining ring to fork pin.
When performing any type of inspection, adjust-
ment, maintenance, etc. beneath the platform, Shims are used in the heel area of the fork to obtain the
blocks should be positioned under each side of proper position of the fork tip. The fork tip height should be
the platform, along the mast channel. Refer to the same as fork height at the rear edge of the platform. Be
Illustration 9-4. sure measurement is taken on a level surface. Apply thread
locking adhesive to the screws securing shims to platform.
FORK OPERATOR FORK
PLATFORM PALLET After forks have been properly inspected, replaced etc.
GRAB
remove chain from around floor of platform and blocks from
under platform. Raise the platform clear of blocks for easier
block removal. Lower platform completely and measure fork
height from floor. Fork height should be approximately 3 in.
(75mm) from top of fork to floor at maximum lowered posi-
tion. The lift chain will have to be lengthened to lower fork
height or shortened to raise fork height.

TT MAST
CHAIN
ANCHOR

TL MAST
CHAIN
ANCHOR
HARDWOOD BLOCKS
4 in. X 4 in.
(100mm X 100mm)

3274 ILLUSTRATION 9-4 3788 ILLUSTRATION 9-5

Fork Replacement Refer to Illustration 9-5. On the TL mast, fork height is
adjusted at the chain anchors located close to the top of the
Raise platform approximately 2 ft. (0.5m) and block securely main frame on both sides. Adjustment for fork height on the
with hardwood blocks. Wrap a chain as tight as possible TT mast is made at the chain anchors located on the free lift
around floor of platform. As the fork pins are removed this cylinder. With the platform totally lowered, adjust the forks so
chain will help support the heel of the fork. Form a basket that the top of the forks is a maximum of 3 in. (75mm) from
hook-up with a sling about the area of the fork that will the floor. If possible, allow 1/4 in. (5mm) clearance between
balance the fork weight evenly. Remove retaining ring from underside of operator platform and top of outrigger.
end of fork rod. Raise the hoist to assume the fork weight and
carefully remove fork pin.

Crown 1995 PF-10649-2 Printed in U.S.A.

M9.0–7530–002 M9.0–7530–002
 MAINTENANCE

PALLET GRAB
Horizontal
(Refer to Illustration 9-6.)
The pallet grab is located beneath the operator platform. Release
Mechanical linkage connects the mounting plate located Handle
beneath the platform to the operator release handle located
Release Foot Pedal
below the control module. The pallet grab is foot applied and Adjustment
Handle
hand released. The platform must be blocked securely with Adjustment (Jam Nuts)
hardwood 4 x 4’s (100 x 100mm) during any maintenance
procedure related to the pallet grab. Foot Pedal
Cable (F) (G)
RELEASE HANDLE ADJUSTMENT

The release handle is in a near horizontal position and should

be parallel to cutout in console when the pallet grab is not Poly
being used (foot pedal in the “up” position). To maintain this Poly Cable (F)
Stop
position an adjustment can be made to the push rod connect- Stop Cable (E) Anchor Points
ing the handle to the latch located on the power unit side of Anchor Points
the platform. Remove the pin from the connecting rod and 3296-01 ILLUSTRATION 9-6
latch. Loosen “jam” nut securing the push rod end to the push
rod. Turn rod end counter-clockwise to lengthen push rod and
The foot pedal position, in the released position, can be
this will rotate the release handle down. Turn rod end clock-
adjusted somewhat to make sure it latches properly. During
wise to shorten push rod and this will rotate the handle up.
normal operation a slightly lower, released pedal position
may develop that could make a pedal latch impossible. Refer
FOOT PEDAL ADJUSTMENT
to Illustration 9-6. To adjust pedal height slightly, loosen the
jam nuts and turn nut clockwise until pedal height and
The foot pedal has spring tension applied to it constantly
operation is correct. The adjustment must be made from
during normal released and applied conditions. When the
beneath the floor of the platform. Be sure platform is blocked
pedal is in the “up” or released position, the backside of the
securely with hardwood blocks before performing work un-
pedal is contacting a poly stop. The poly stop prevents metal
der platform. If correct pedal height can not be achieved,
to metal contact between the pedal and the platform frame-
through this adjustment, component parts have worn and
work. The poly stop has a center mount bolt that can be
replacement is recommended.
removed with a 5/32 in. hex key wrench. Slide the poly stop
off the bolt and install a new replacement poly stop if worn.

Crown 1995 PF10649-3 Rev. 9/00 Printed in U.S.A.

01 REV. 9/00
M9.0–7530–003 M9.0–7530–003
 MAINTENANCE

PALLET GRAB REMOVAL A poly stop is located at the rear of the right pallet grab arm
and should be inspected for wear, damage, etc. The stop is
Should cable “E” or “F”, springs, pulleys, etc. need replace- secured in position with two bolts for simple installation or
ment the pallet grab can be removed from the floor of the removal as necessary. Be sure all springs, retainers, rollers,
platform by removing the two hex socket head bolts near the etc. are positioned and working properly before installing
rear of the platform with a 3/8 in. hex key wrench. Hold the mounting plate with associated parts to the underside of the
pallet grab in position until both bolts are removed. The grab platform.
can be rotated down on the “L” shaped mounting bracket
located on underside of platform floor. Be careful that the OPERATOR COMPARTMENT GATES
grab does not slip from this bracket. Remove cotter pin,
flatwasher and cable from point (G). The pallet grab can now The stockpicker platform has operator compartment gates
be moved to a suitable work area. that can be rotated “up” to allow for easy entry or exit when
the platform is in the “lowered” position. The truck will not
When reassembling pallet grab the override spring, in the travel or raise until the gates are in the “down” position. The
grab released position should measure 5.62 in. (140mm) sidegate upper pivot shaft actuates switches as it is rotated.
overall length. Refer to Illustration 9-7. When raising the sidegates, the lower pivot shaft has a coil
spring attached that aids the operator. A poly stop, located
on the floor of the platform directly below each gate upright,
acts as a rest when the gates are “down”.

CONSOLE
MOUNTING
SCREWS

SIDE GATES
UPRIGHT POSITION
REAR GATES
UPRIGHT POSITION

CONSOLE

SIDE GATES
DOWN POSITION
REAR GATES
DOWN POSITION

2945S ILLUSTRATION 9-7 3861 ILLUSTRATION 9-8

Attach cable (F) to the 1st hole in the end of the retainer. If
To gain access to the sidegate upper pivot shaft, switches,
the cable has stretched slightly or a replacement cable has
etc. the console must be removed from the platform. Refer
been installed, the 2nd or 3rd hole can be used to maintain
to section M4.0 Electrical Maintenance for switch informa-
the proper spring length and cable tension etc. Two cables
tion.
are used in the pallet grab mechanism, they are referred to
as cable (E) and (F). Cable (E) is the shorter of the two
To remove the console remove the 6 console mounting
(approximately 14.5 in. [368mm] overall length) and cable
screws shown in Illustration 9-8. On 54 in. (1370mm), 60 in.
(F) is the longer cable (approximately 53 in. [1346mm]
(1525mm), and 64 in. (1625mm) wide platforms two addi-
overall length). Refer to Illustration 9-6 for cable connec-
tional covers must be removed. They are located on both
tions, routing, etc.
sides of the console and are held in place by four screws, two
on top and two on the bottom of each cover.

Crown 1995 PF-10649-4 Printed in U.S.A.

M9.0–7530–004 M9.0–7530–004
 MAINTENANCE

SPRING
SPRING REPLACEMENT
STOP TORSION
SPRING
To replace a weak or broken coil spring on the bottom pivot ROLL PIN BUSHING
shaft, either left or right, the following information must be SHAFT
used. BUSHING "V" SLOT
SHIM
Use a face spanner wrench 104712 that has two 5/32 in.
pins, at a spread of 15/16 in. Refer to Illustration 9-9.

104712
RELEASE
Spanner Tool, Special
APPLY SPRING
FORCE

GATE

3301 ILLUSTRATION 9-10

After all parts are in proper position and the gate is held in the
“up” position, use spanner wrench to turn the pivot shaft to
increase spring force until the roll pin can be installed through
2946 ILLUSTRATION 9-9 the lower gate and the pivot shaft. The pivot shaft will need
to be turned approximately 40° to 45° to allow for roll pin
The lower pivot shaft is designed to accept the spanner installation with the gate in the “up” position.
wrench 104712. With the gate in the down position, place
spanner wrench on the lower pivot shaft. Using a hammer
and 3/16" dia. punch to drive the roll pin partially out (1/2 to OPERATOR EGRESS SYSTEM
3/4 in.). Keep spanner wrench on the shaft, remove punch
and rotate gate to up position. Pull roll pin from shaft making The Operator Egress Sys-
sure that spanner wrench is still on shaft. Using spanner tem consists of a harness &
wrench rotate shaft until all spring tension is relieved. As the rope assembly. This unit is
roll pin is removed the spring tension will be transferred to for use by the operator in the
OPERATOR
the spanner wrench. You will have to assume the load when event of his being trapped EGRESS SYSTEM
the roll pin is pulled out. Remove shaft and note the position on an elevated platform in STORED HERE
of spacers, bearings, etc. for correct position at assembly. an emergency situation. The
Operator Egress System is
Refer to Illustration 9-10. Position coil spring with outer packed in a clear plastic bag
flange next to small stop welded to platform wall that keeps and is stored in the tray be-
the coil spring from rotating when all parts are assembled neath the console. Instruc-
properly. tions for use are attached to
the assembly.

4017 ILLUSTRATION 9-11

Crown 1995 PF-10649-5 Printed in U.S.A.

M9.0–7530–005 M9.0–7530–005
 MAINTENANCE

SHIM BASICS 3. Measure the distance between the channel and the
roller, 3/8 in. (10mm) from the channel face. Always
The mast on the SP 3000 is measure the side the roller is canted toward. A clear-
designed to be at its tightest ance of 0 in. to 0.030 in. (0mm to 0.75mm) should be
point when fully extended and at obtained. Check the center and lower platform rollers
its loosest when fully lowered. only since the top rollers are not adjustable. If the
This allows the mast and plat- dimension is greater than 0.030 in. (0.75mm), another
form rollers to move freely as the shim will need to be added behind the roller. It will be
mast extends while providing necessary to remove the platform from the mast to
maximum stability when fully shim platform rollers. If the dimension is zero and it
extended. Each mast is designed does not appear to be tight, proceed to check the
to be wider at the bottom than remaining platform column rollers.
the top. If the mast were shimmed
so that it was tight when fully NON - ADJUSTABLE
collapsed, it would not fully ex- COLUMN ROLLERS
SHIM 0.031 in.
tend because of mast channel to (0.8 mm)
roller binding causing detrimen- THICK
tal effects to the mast channel. 3307
ILLUSTRATION 9-12
The mast should only be checked
for tightness when near or at full
extension.

The shim size used on the SP 3000 truck is 0.031 in. (0.8mm)
thick. Refer to section M7.0 of this manual for mast shim
procedures.

PLATFORM REMOVAL & SHIMMING TL MAST

In order to shim the platform rollers it is necessary to remove

the platform from the mast.
ADJUSTABLE
COLUMN ROLLERS
WARNING
3790 ILLUSTRATION 9-13
Wear appropriate protective items, such as safety
glasses, steel toe shoes, etc. whenever perform-
ing maintenance work. To avoid injury, do not
place fingers, hands, or arms through mast or
position them at a pinch point.

1. Raise platform to full extension.

2. Use a man up vehicle to get into position to measure

the platform roller clearance. Use a pry bar to shift the
platform to one side, this will force the opposite side
tight against the mast channel. This is necessary to
seat each platform roller against the roller stud shoul-
der to allow for an accurate measurement. Once the
platform has shifted, retain slight pressure to hold the
platform in position.

Crown 1995 PF-10649-6 Printed in U.S.A.

M9.0–7530–006 M9.0–7530–006
 MAINTENANCE

4. Lower the second stage and block both sides of the 5. Disconnect the battery.
mast when it is a minimum of 30 in. (760mm) above the
floor. Use hardwood blocks that are a full 2 in. x 4 in. 6. With a hoist raise the platform approximately 3 in.
(50mm x 100mm). (75mm) to allow the mast chains to slack. Note that the
combined weight of the platform and forks will be
approximately between 1069 lbs. (484kgs.) and 1358
lbs. (616kgs.).

WARNING
Make sure lifting device is sufficiently rated to lift
various parts of the mast sections and platform
either individually or as a group. Make sure that
the blocking material is strong enough to with-
stand the weight. Never work under or around a
truck that is not properly blocked.

7. Remove the four control cable pulleys located at the

bottom of the platform. Remove the two pulleys shown
in Illustration 9-15 from the pulley plate assembly.
BLOCK BOTH SIDES
SECOND STAGE MAST
30 in. (762mm) HIGH

)
100mm 2 in
4 in. ( . (50
mm
)

3793 ILLUSTRATION 9-14

CABLE GUIDE

3794 ILLUSTRATION 9-15

Crown 1995 PF-10649-7 Printed in U.S.A.

M9.0–7530–007 M9.0–7530–007
 MAINTENANCE

8. Disconnect the mast lift chains from the platform by UNEVEN SHIMMING
removing the chain pins and secure with tie straps. CORRECT METHOD

9. With hoist lower platform to floor making sure that NON-ADJUSTABLE

cables, hoses, or lift chains do not become tangled with
platform to prevent any damage to them.

10. Slide platform away from mast approximately 5 in.

(125mm), to fully expose platform rollers.

11. Remove rollers and note shims on each stud. Remove

the rollers carefully, many times the shims will cling to
the back of the roller and fall off after removal.

12. Shim the platform rollers as required. Please note that

it is best to shim the platform rollers evenly. That is, an
equal number of shim(s) on each roller. However, if this
is not possible follow the shim procedures as described 2 SHIMS
in section M7.0. Example: Two shims on both left side
platform rollers and one shim on both of the right side 1 SHIM
rollers.

UNEVEN SHIMMING
INCORRECT METHOD

NON-ADJUSTABLE

2 SHIMS
IN
C
O
R
R
EC
T

1 SHIM

2 SHIMS

1 SHIM

3795 ILLUSTRATION 9-16

Crown 1995 PF-10649-8 Printed in U.S.A.

M9.0–7530–008 M9.0–7530–008
 MAINTENANCE

13. Install platform back into mast carefully. With hoist 4. Raise the mast until the third stage is a minimum of
extend platform to full height and check for tight spots. 30 in. (760mm) from the floor, the second stage should
Make sure that all cables hoses and chains are not be approximately 15 in. (380mm) from the floor. Block
pinched, cut, or damaged in any way while hoisting the the second stage using 4 in. x 4 in. x 15 in. (100mm x
platform up the mast. If any tight spots are found make 100mm x 380mm) minimum hardwood blocks.
corrections to shims as required.

14. If no tight spots are found, lower platform with hoist and
reassemble chains, pulleys, etc. in reverse order of
removal.

15. Connect battery and check truck operation.

PLATFORM REMOVAL & SHIMMING TT MAST

In order to shim the platform rollers it is necessary to remove

the platform from the mast.

WARNING
Wear appropriate protective items, such as safety
glasses, steel toe shoes, etc. whenever perform- BLOCK BOTH SIDES
ing maintenance work. To avoid injury, do not SECOND STAGE MAST
place fingers, hands, or arms through mast or 15 in. (380 mm)
position them at a pinch point. MINIMUM HEIGHT
m)
1. Elevate carriage through free lift and stop platform 2 in. (100 m 4 in
. (10
.
(50mm) short of spring loaded stops making contact 4 in 0m
m)
with stop bar on third stage mast.
3796 ILLUSTRATION 9-17
2. Use a man “up” vehicle to get into position to measure
the platform roller clearance. Use a pry bar to shift the 5. Disconnect the battery.
platform to one side, this will force the opposite side
tight against the mast channel. This is necessary to 6. With a hoist raise the platform approximately 3 in.
seat each platform roller against the roller stud shoul- (75mm) to allow the free lift chain to slack. Note that the
der to allow for an accurate measurement. Once the combined weight of the platform and forks will be
platform has shifted, retain slight pressure to hold the approximately between 1069 lbs. (484kgs.) and 1358
platform in position. lbs. (616kgs.).

3. Measure the distance between the channel and the

roller, 3/8 in. (10mm) from the channel face. Always WARNING
measure the side the roller is canted toward. A clear- Make sure lifting device is sufficiently rated to lift
ance of 0 in. to 0.030 in. (0mm to 0.75mm) should be various parts of the mast sections and platform
obtained. If the dimension is greater than 0.030 in. either individually or as a group. Make sure that
(0.75mm), another shim will need to be added behind the blocking material is strong enough to with-
the roller. It will be necessary to remove the platform stand the weight. Never work under or around a
from the mast to shim platform rollers. If the dimension truck that is not properly blocked.
is zero and it does not appear to be tight, proceed to
check the remaining platform column rollers. 7. Disconnect the free lift chains from platform and secure
to mast with tie straps. Secure chain slack mechanism
in place so that it does not fall out.

Crown 1995 PF-10649-9 Printed in U.S.A.

M9.0–7530–009 M9.0–7530–009
 MAINTENANCE

UNEVEN SHIMMING
CHAIN SLACK/ CORRECT METHOD
BREAK MECHANISM

CABLE
GUIDE

FREE
LIFT
CHAINS
2 SHIMS

1 SHIM
3797 ILLUSTRATION 9-18

8. Remove cable guide assembly from platform. Support

the cable guide from a couple of the eye bolts that are
used for the cable grips and springs.
UNEVEN SHIMMING
9. With a hoist lower the platform to floor making sure that INCORRECT METHOD
cables, hoses, or lift chains do not become tangled with
platform to prevent any damage to them.

10. Slide platform away from mast approximately 5 in.

(125mm), to fully expose platform rollers.
2 SHIMS
11. Remove rollers and note shims on each stud. Remove
the rollers carefully, many times the shims will cling to
the back of the roller and fall off after removal.

12. Shim the platform rollers as required. Please note that

IN
C

it is best to shim the platform rollers evenly. That is, an

O
R
R

equal number and size of shim on each roller. However 1 SHIM

EC
T

if this is not possible follow the shim procedures as

described in section M7.0. Example: Two shims on
both left side platform rollers and one shim on both of
the right side rollers. 2 SHIMS

1 SHIM

3798 ILLUSTRATION 9-19

Crown 1995 PF-10649-10 Printed in U.S.A.

M9.0–7530–010 M9.0–7530–010
 MAINTENANCE

13. Install platform back into mast carefully. Remove yoke

from free lift cylinder and suspend it from the third stage
mast so that it will be moved toward the power unit a
minimum of 1 1/2 in. (40mm) to prevent any damage to
the yoke assembly while raising or lowering the plat-
form. With hoist, extend platform to full height and
check for tight spots. Make sure that all cables, hoses,
and chains are not pinched, cut, or damaged in any
way while hoisting the platform up the mast. If any tight
spots are found make corrections to shims as required.

14. If no tight spots are found lower platform with hoist and
reassemble chains, pulleys, etc. in reverse order of
removal.

15. Connect battery and check truck operation.

Crown 1995 PF-10649-11 Printed in U.S.A.

M9.0–7530–011 M9.0–7530–011
 C GLOSSARY

Components of the SP 3000 truck have been listed in chart truck such as on platform or in power unit. The FUNCTION
form to assist the maintenance mechanic in locating these column then explains the function or circuit of that device.
components on the Electrical Diagrams and Parts Break- The DIAGRAM column gives the page number of the dia-
down forms. gram on which the component can be found. The callout in
parenthesis following the page number corresponds to the
The chart is in columns: COMPONENT; LOCATION; FUNC- grid callouts on that diagram, locating that component. The
TION; DIAGRAM; PARTS BREAKDOWN. The COMPO- PARTS BREAKDOWN column includes the parts break-
NENT column contains the abbreviation of the component down page number on which the component is located along
as it appears on the Diagrams in the Maintenance Section. with the index number, in parenthesis, if applicable.
The LOCATION column gives the general location on the

AUDIBLE INDICATORS
Location Function Diagram Parts Breakdown

ALM1 Steering Status Alarm DIA–7530–037 (A-4) 06.0–7330–001 (14)

Command DIA–7530–038 (A-4)
DIA–7530–042 (B-3)
HN1 Platform Horn DIA–7530–037 (C-1)
(Below Floorboard) DIA–7530–038 (C-1) 09.0–7530–052 (2)
DIA–7530–039 (B-3) 09.0–7530–104 (2)
HN2 Power Unit Travel Alarm DIA–7530–044 (A-3) 04.0–7532–001 (11)
(Platform Side)

BATTERY
Location Function Diagram Parts Breakdown

Battery Battery Power DIA–7530–037 (B-4) 01.2–7532–001 (20)

Compartment DIA–7530–038 (B-4)
DIA–7530–050 (A-1)

CONNECTIONS
Location Function Diagram Parts Breakdown

CA201 Distribution Panel Height Switches DIA–7530–044 (A-1) 04.8–7330–172

CA202 Distribution Panel Mast Cable 1 DIA–7530–044 (A-1) 04.8–7330–172
CA203 Distribution Panel Mast Cable 2 DIA–7530–044 (B-1) 04.8–7330–172
CA204 Distribution Panel Mast Cable 3 DIA–7530–044 (B-1) 04.8–7330–172
CA205 Distribution Panel Mast Cable 4 DIA–7530–044 (B-1) 04.8–7330–172
CA206 Distribution Panel Communications to Steer Module DIA–7530–044 (C-1) 04.8–7330–172
CA207 Distribution Panel Communications to Guidance DIA–7530–044 (C-2) 04.8–7330–172
CA208 Distribution Panel Lift/Lower Panel DIA–7530–044 (C-2) 04.8–7330–172
CA209 Distribution Panel Braking DIA–7530–044 (C-3) 04.8–7330–172
CA210 Distribution Panel Steering DIA–7530–044 (B-4) 04.8–7330–172
CA211 Distribution Panel Guidance DIA–7530–044 (B-4) 04.8–7330–172
CA212 Distribution Panel Traction DIA–7530–044 (A-4) 04.8–7330–172
CA213 Distribution Panel Power DIA–7530–044 (A-4) 04.8–7330–172
CA214 Distribution Panel Travel Alarm DIA–7530–044 (A-3) 04.8–7330–172
CA215 Distribution Panel Freezer Conditioning DIA–7530–044 (A-2) 04.8–7330–172
CA216 Distribution Panel Options DIA–7530–044 (A-2) 04.8–7330–172
CA301 Platform Service Terminal Port DIA–7530–042 (A-1) 04.8–7330–172
CA302 Steering Command Steering Encoder DIA–7530–042 (B-4) 04.8–7330–172
CA303 Display Module Communications DIA–7530–042 (B-2) 04.8–7330–172
CA304 Display Module Inputs/Outputs DIA–7530–042 (B-2) 04.8–7330–172

001001 5796

Crown 2000 PF11945-1 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–015 M10–7530–015
 C GLOSSARY

CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown

CA401 Traction Controller Speed Limits Inputs DIA–7530–045 (B-1) 04.8–7330–172

CA402 Traction Controller Traction Coil Inputs DIA–7530–045 (B-1) 04.8–7330–172
CA404 Traction Controller Communications/TMM DIA–7530–045 (B-2) 04.8–7330–172
CA405 Steering Module Communications DIA–7530–046 (B-1) 04.8–7330–172
CA406 Steering Module Inputs/Outputs DIA–7530–046 (B-1) 04.8–7330–172
CA411 Connector Module Steer Module Output DIA–7530–046 (A-3) 04.8–7330–172
CA412 Connector Module Encoder Input DIA–7530–046 (A-3) 04.8–7330–172
CA413 Connector Module Encoder Output DIA–7530–046 (B-3) 04.8–7330–172
CA414 Brake Module Coil/Thermostat Inputs DIA–7530–047 (B-1) 04.8–7330–172
CA415 Brake Module Height Switches/Power Inputs DIA–7530–047 (B-3) 04.8–7330–172
CA416 Traction Motor Traction Tachometer DIA–7530–046 (B-4)
CA417 Wire Guide Module Inputs/Outputs DIA–7530–046 (B-3) 04.8–7330–172
CA418 Load Wheel Sensor Inputs/Outputs DIA–7530–046 (A-3) 04.8–7330–172
CA419 Steer Wheel Sensor Inputs/Outputs DIA–7530–046 (A-4) 04.8–7330–172
CA501 Overhead Power Supplies DIA–7530–043 (B-1) 04.8–7330–172
Console Left
CA503 Overhead Fan DIA–7530–043 (B-3) 04.8–7330–172
Console Right
CA807 F/C Distribution Heater Power DIA–7530–049 (B-1) 04.8–7330–172
Panel
CA808 F/C Distribution Input Power to F/C Panel DIA–7530–049 (A-1) 04.8–7330–172
Panel
TB101 Platform Control Pod DIA–7530–039 (A-1) 09.0–7530–003 (15)
(Power Unit Side) DIA–7530–049 (B-2)
TB102 Platform Miscellaneous DIA–7530–040 (B-2) 09.0–7530–003 (15)
(Power Unit Side) DIA–7530–041 (A-4)
DIA–7530–049 (B-3)
TB403 Traction Controller SRO Inputs DIA–7530–045 (B-2)
TB407 Steering Module Power DIA–7530–046 (C-2)
TB502 Overhead Dome Light DIA–7530–043 (B-3) 04.9–7330–050 (9)
Console Left
TB601 Truck Man. Module TMM DIA–7530–048 (B-1)

CONTACTORS
Location Function Diagram Parts Breakdown

ED Lift/Power Panel Emergency Disconnect DIA–7530–037 (C-4) 04.4–7330–050

DIA–7530–038 (C-4)
DIA–7530–044 (C-3)
DIA–7530–046 (C-2)
DIA–7530–050 (B-1)
F Traction Panel Forward DIA–7530–037 (B-2) 04.4–7330–002
DIA–7530–038 (B-2)
DIA–7530–045 (B-1)
DIA–7530–050 (A-2)
P1 Lift/Power Panel Pump 1 DIA–7530–050 (B-2) 04.4–6535–050
DIA–7530–037 (B-3)
DIA–7530–038 (B-3)
DIA–7530–044 (C-2)
DIA–7530–050 (B-2)

Crown 2000 PF11945-2 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–016 M10–7530–016
 C GLOSSARY

CONTACTORS(Continued)
Location Function Diagram Parts Breakdown

P2 Lift/Power Panel Pump 2 DIA–7530–037 (B-3) 04.4–6535–050

DIA–7530–044 (C-2)
DIA–7530–050 (B-2)
R Traction Panel Reverse DIA–7530–037 (B-2) 04.4–7330–002
DIA–7530–038 (B-2)
DIA–7530–045 (B-2)
DIA–7530–050 (A-2)
1A Traction Panel Bypass Traction DIA–7530–037 (B-2) 04.4–04.2–020
DIA–7530–038 (B-2)
DIA–7530–045 (B-2)
DIA–7530–050 (A-2)

FUSES
Location Function Diagram Parts Breakdown

FU1 Distribution Panel Light/Fan DIA–7530–037 (A-1) 04.3–7530–001 (5)

DIA–7530–038 (A-1)
DIA–7530–044 (A-3)
FU2 Distribution Panel Control DIA–7530–037 (A-4) 04.3–7530–001 (5)
DIA–7530–038 (A-4)
DIA–7530–044 (A-3)
FU3 Distribution Panel Spare DIA–7530–044 (A-3) 04.3–7530–001 (5)
FU4 Distribution Panel Brake Module DIA–7530–037 (A-2) 04.3–7530–001 (5)
DIA–7530–038 (A-2)
DIA–7530–044 (A-3)
FU5 Distribution Panel Traction Controller DIA–7530–037 (A-3) 04.3–7530–001 (5)
DIA–7530–038 (A-3)
DIA–7530–044 (A-3)
FU6 Distribution Panel Steer Relays DIA–7530–037 (A-3) 04.3–7530–001 (5)
DIA–7530–038 (A-3)
DIA–7530–044 (A-3)
FU7 Lift/Power Panel Wire Guidance Module DIA–7530–037 (A-3) 04.3–7530–100 (33)
DIA–7530–050 (B-1)
FU8 Lift/Power Panel Pump Motor 1 DIA–7530–037 (A-1) 04.3–7530–100 (11)
DIA–7530–038 (A-1)
DIA–7530–050 (B-1)
FU9 Lift/Power Panel Pump Motor 2 DIA–7530–037 (A-1) 04.3–7530–100 (26)
DIA–7530–050 (B-1)
FU10 Lift/Power Panel Steer Module DIA–7530–037 (A-4) 04.3–7530–100 (13)
DIA–7530–038 (A-3)
DIA–7530–046 (C-2)
DIA–7530–050 (B-1)
FU11 F/C Distribution F/C Power Unit DIA–7530–049 (B-1) 04.9–7330–100 (2)
Panel
FU12 F/C Distribution F/C Platform DIA–7530–049 (B-1) 04.9–7330–100 (2)
Panel
FU13 Lift/Power Panel Traction Motor DIA–7530–037 (A-3) 04.3–7530–100 (12)
DIA–7530–038 (A-3)
DIA–7530–045 (C-4)
DIA–7530–050 (B-1)

Crown 2000 PF11945-3 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–017 M10–7530–017
 C GLOSSARY

LIGHTS
Location Function Diagram Parts Breakdown

LGT1 Power Unit Strobe DIA–7530–037 (A-1) 04.9–10.0–550

Flashing DIA–7530–038 (A-1) 04.9–7330–001
DIA–7530–044 (A-1)
LGT2 Overhead Console Work Left DIA–7530–043 (C-1) 04.9–7330–052 (22)
LGT3 Overhead Console Dome Left DIA–7530–043 (B-2) 04.9–7330–052 (20)
LGT4 Overhead Console Spot Left DIA–7530–043 (C-2) 04.9–7330–052 (17)
LGT5 Overhead Console Work Right DIA–7530–043 (C-4) 04.9–7330–052 (22)
LGT6 Overhead Console Dome Right DIA–7530–043 (B-4) 04.9–7330–052 (20)
LGT7 Overhead Console Spot Right DIA–7530–043 (C-3) 04.9–7330–052 (17)

MISCELLANEOUS
Location Function Diagram Parts Breakdown

BRK1 Traction Motor Travel Brake DIA–7530–037 (B-1) 05.3–7330–007

DIA–7530–038 (B-4)
DIA–7530–047 (B-4)
DB1 Platform Lower Override DIA–7530–040 (C-2) 09.0–7530–001 (6)
DIA–7530–041 (C-2)
FAN Overhead Console Fan DIA–7530–043 (C-3) 04.9–7330–052 (27)
PS1 Overhead Console Light Power Supply DIA–7530–043 (C-1) 04.9–7330–052 (6)
PS2 Overhead Console Light Power Supply DIA–7530–043 (C-2) 04.9–7330–052 (7)

MOTORS
Location Function Diagram Parts Breakdown

M1 Power Unit Traction DIA–7530–037 (C-3) 03.1–7330–001

DIA–7530–038 (C-2) 03.1–7330–050
DIA–7530–045 (C-4)
DIA–7530–048 (A-2)
DIA–7530–050 (B-2)
M2 Power Unit Power Steering DIA–7530–037 (C-3) 06.2–7330–003
DIA–7530–038 (C-3)
DIA–7530–046 (C-2)
DIA–7530–050 (C-2)
M3 Power Unit Lift Pump 1 DIA–7530–037 (B-1) 02.2–07.3–001
DIA–7530–038 (B-1)
DIA–7530–048 (A-2)
DIA–7530–050 (C-2)
M4 Power Unit Lift Pump 2 DIA–7530–037 (A-1) 02.2–7330–050
DIA–7530–048 (A-3)
DIA–7530–050 (C-2)

RELAYS
Location Function Diagram Parts Breakdown

K1 Distribution Panel Power Up DIA–7530–037 (C-4) 04.3–7530–001 (2)

DIA–7530–038 (C-4)
DIA–7530–044 (A-2)
K2 Distribution Panel Diagnostic Travel Inhibit DIA–7530–037 (C-1) 04.3–7530–001 (14)
DIA–7530–038 (C-1)
DIA–7530–044 (B-4)

Crown 2000 PF11945-4 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–018 M10–7530–018
 C GLOSSARY

RELAYS (Continued)
Location Function Diagram Parts Breakdown

K3 Distribution Panel Stop DIA–7530–037 (C-1) 04.3–7530–001 (2)

DIA–7530–038 (C-1)
DIA–7530–044 (C-3)
K4 Distribution Panel Steer Angle DIA–7530–037 (B-3) 04.3–7530–001 (14)
DIA–7530–038 (B-3)
DIA–7530–044 (B-4)
K5 Traction Panel Steer Motor DIA–7530–037 (B-3) 04.1–7330–009 (40)
DIA–7530–038 (B-3)
DIA–7530–046 (B-1)
K7 Distribution Panel Auto/Manual Speed DIA–7530–037 (A-4) 04.3–7530–001 (14)
DIA–7530–044 (C-3)
K8 Distribution Panel Acquisition Speed DIA–7530–037 (A-3) 04.3–7530–001 (14)
DIA–7530–038 (A-3)
DIA–7530–044 (C-4)
K9 Platform Gate Switches 1.25 DIA–7530–040 (C-1) 09.0–7530–003 (4)
K10 Platform Two Hand Control DIA–7530–037 (A-3) 09.0–7530–003 (5)
DIA–7530–038 (A-3)
DIA–7530–039 (C-4)
K11 F/C Distribution F/C Power Up DIA–7530–049 (B-2) 04.9–7330–100 (3)
Panel
K12 F/C Distribution F/C Heater Power DIA–7530–049 (B-2) 04.9–7330–100 (4)
Panel

RESISTORS
Location Function Diagram Parts Breakdown

RES1 Overhead Console Fan Speed Reduced DIA–7530–043 (B-3) 04.9–7330–050 (30)
RES2 P.U. Guide RGS1 Heater DIA–7530–049 (C-1) 04.9–7330–100 (11)
Wheel Bracket
RES3 P.U. Guide RGS2 Heater DIA–7530–049 (C-1) 04.9–7330–100 (11)
Wheel Bracket
RES4 Power Unit BRES1 Heater DIA–7530–049 (C-1) 04.9–7330–100 (14)
(Skirt - Left Side)
RES5 Power Unit BRES2 Heater DIA–7530–049 (C-1) 04.9–7330–100 (15)
(Skirt - Right Side )
RES6 Power Unit CHS1 Heater DIA–7530–049 (C-1)
RES7 Power Unit CHS2 Heater DIA–7530–049 (C-2)
RES8 Platform Gate Switch 1 & 3 Heater DIA–7530–049 (C-3) 04.9–7530–202 (3)
RES9 Platform Gate Switch 2 & 4 Heater DIA–7530–049 (C-2) 04.9–7530–202 (4)
RES10 Control Module EDS Heater DIA–7530–049 (C-2) 04.9–7530–150 (3)
RES11 Control Module Raise & Lower Switches Heater DIA–7530–049 (C-2) 04.9–7530–150 (5)
RES12 Control Module Horn Switch Heater DIA–7530–049 (C-2) 04.9–7530–150 (7)
RES13 Control Module Forward Switch Heater DIA–7530–049 (C-2) 04.9–7530–150 (9)
RES14 Control Module Reverse Switch Heater DIA–7530–049 (C-2) 04.9–7530–150 (10)
RES15 Platform CHS3 Heater TT DIA–7530–049 (C-3)
(Power Unit Side)
RES16 Platform Brake Switch Heater DIA–7530–049 (C-3) 04.9–7530–202 (6)
(Below Floorboard)
RES18 Platform HTS1200 Heater DIA–7530–049 (C-3)
RES19 Platform CHB6 Heater DIA–7530–049 (C-3)
(Power Unit Side)

Crown 2000 PF11945-5 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–019 M10–7530–019
 C GLOSSARY

RESISTORS (Continued)
Location Function Diagram Parts Breakdown

RES20 Platform DMS1 DIA–7530–049 (B-4) 04.8–7530–450 (14)

RES21 Platform CHB7 Heater DIA–7530–049 (B-4)
RES22 Platform GTS3 or R3, L3 DIA–7530–049 (B-4) 09.1–7530–250 (22)
RES23 Platform GTS4 or R4, L4 DIA–7530–049 (B-4) 09.1–7530–250 (22)
RES24 Power Unit CHB4 Heater DIA–7530–049 (B-4)
RES25 Power Unit CHB5 Heater DIA–7530–049 (B-4)
RES26 Platform LOS3 Aux. Forks DIA–7530–049 (B-4) 04.6–7530–500 (29)
RES27 Platform LOS4 Aux. Forks DIA–7530–049 (B-4) 04.6–7530–500 (29)
RES28 Platform RAS3 Aux. Forks DIA–7530–049 (B-4) 04.6–7530–500 (29)
RES29 Platform RAS4 Aux. Forks DIA–7530–049 (B-4) 04.6–7530–500 (29)

SENSORS
Location Function Diagram Parts Breakdown

ECR1 Steering Command Steering DIA–7530–037 (B-4) 06.0–7330–001 (1)

DIA–7530–038 (B-4)
DIA–7530–042 (A-4)
ECR2 Steering Feedback Steering Feedback DIA–7530–037 (B-3) 04.8–7330–200 (3)
DIA–7530–038 (B-3)
DIA–7530–046 (B-3)
POT1 Control Module Traction Accelerator DIA–7530–037 (C-2) 04.6–7330–003 (30)
DIA–7530–038 (C-2)
DIA–7530–040 (B-2)
DIA–7530–041 (B-2)
SS1 Traction Motor Traction Tachometer DIA–7530–046 (B-4) 05.3–7332–001 (24)

SOLENOID VALVES
Location Function Diagram Parts Breakdown

SV1 Lift/Lower Manifold Low Speed Lower DIA–7530–037 (B-1) 02.4–7330–001 (8)
DIA–7530–038 (B-1) 02.4–7330–052 (12)
DIA–7530–044 (C-2) 02.4–7530–500 (8)
02.4–7530–552 (12)
SV2 Lift/Lower Manifold High Speed Lower DIA–7530–037 (B-1) 02.4–7330–052 (5)
DIA–7530–044 (C-2) 02.4–7530–500 (24)
02.4–7530–552 (5)
SV3 Lift/Lower Manifold Raise DIA–7530–037 (B-3) 02.4–7530–500 (23)
DIA–7530–044 (C-2) 02.4–7530–552 (29)
SV4 Lift/Lower Manifold Auxiliary Raise DIA–7530–037 (B-3) 02.4–7530–552 (28)
DIA–7530–044 (C-2)
SV5 Platform Auxiliary Lower DIA–7530–037 (B-3) 02.0–7530–700 (8)
DIA–7530–039 (C-2)

SUPPRESSOR BLOCKS
Location Function Diagram Parts Breakdown

SB10 Platform Horn DIA–7530–037 (C-1) 09.0–7530–052 (4)

DIA–7530–038 (C-1) 09.0–7530–104 (4)
DIA–7530–039 (B-2)
SB11 Steering Command Platform Communications DIA–7530–040 (B-1) 06.0–7330–001 (12)
DIA–7530–041 (B-1)

Crown 2000 PF11945-6 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–020 M10–7530–020
 C GLOSSARY

SUPPRESSOR BLOCKS (Continued)

Location Function Diagram Parts Breakdown

SB12 Platform SV5 (1.0SP) DIA–7530–039 (C-2)

SB20 Lift/Lower Manifold SV3 & SV4 DIA–7530–044 (C-2) 04.0–7532–001 (28)
SB21 Below Strobe Light Strobe Light DIA–7530–044 (A-1) 04.0–7532–001 (3)
SB22 Traction Panel Power Unit Communications DIA–7530–044 (C-1) 04.1–7530–001 (10)
SB30 Overhead Console Fan DIA–7530–043 (C-3) 04.9–7330–050 (28)

SWITCHES
Location Function Diagram Parts Breakdown

BRES1 Power Unit Battery Restraint Left DIA–7530–037 (C-3) 01.2–7532–001 (13)
DIA–7530–044 (A-2)
BRES2 Power Unit Battery Restraint Right DIA–7530–037 (C-3) 01.2–7532–001 (13)
DIA–7530–044 (A-2)
BRS1 Platform Brake DIA–7530–037 (A-2) 05.1–7330–001 (1)
DIA–7530–038 (A-2)
DIA–7530–039 (B-1)
DIA–7530–049 (C-3)
BRS2 Platform Brake (Optional) DIA–7530–037 (A-3)
DIA–7530–040 (B-4)
DIA–7530–041 (B-4)
DIA–7530–049 (C-3)
CHB4 Main Frame R.H. Chain Break DIA–7530–037 (B-3) 04.8–7530–058 (D)
DIA–7530–038 (B-3) 04.8–7530–059 (B)
DIA–7530–044 (A-1) 07.6–7530–005 (6)
DIA–7530–049 (C-2) 07.6–7530–054 (5)
CHB5 Main Frame L.H. Chain Break DIA–7530–037 (B-3) 04.8–7530–058 (E)
DIA–7530–038 (B-3) 04.8–7530–059 (C)
DIA–7530–044 (A-1) 07.6–7530–005 (5)
DIA–7530–049 (C-2) 07.6–7530–054 (4)
CHB6 Platform L.H. Chain Break TT DIA–7530–037 (A-3) 04.8–7530–059 (M)
DIA–7530–038 (A-3) 09.0–7530–104 (32)
DIA–7530–040 (B-4)
DIA–7530–041 (B-4)
DIA–7530–049 (C-3)
CHB7 Platform R.H. Chain Break TT DIA–7530–037 (A-3) 04.8–7530–059 (L)
DIA–7530–038 (A-3) 09.0–7530–104 (33)
DIA–7530–040 (B-4)
DIA–7530–041 (B-4)
DIA–7530–049 (C-3)
CHS1 Main Frame L.H. Chain Slack DIA–7530–037 (C-1) 04.8–7530–058 (E)
DIA–7530–038 (C-1) 04.8–7530–059 (C)
DIA–7530–044 (A-2) 07.6–7530–005 (5)
DIA–7530–049 (C-1)
CHS2 Main Frame R.H.Chain Slack DIA–7530–037 (C-1) 04.8–7530–058 (D)
DIA–7530–038 (C-1) 04.8–7530–059 (B)
DIA–7530–044 (A-2) 07.6–7530–005 (6)
DIA–7530–049 (C-1)
CHS3 Platform(Bottom) L.H. Chain Slack TT DIA–7530–037 (C-1) 04.8–7530–059 (M)
DIA–7530–038 (C-1) 09.0–7530–104 (32)
DIA–7530–040 (B-3)
DIA–7530–041 (B-3)

Crown 2000 PF11945-7 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–021 M10–7530–021
 C GLOSSARY

SWITCHES (Continued)
Location Function Diagram Parts Breakdown

CHS4 Platform(Bottom) R.H.Chain Slack TT DIA–7530–037 (A-2) 04.8–7530–059 (L)

DIA–7530–038 (A-2) 09.0–7530–104 (33)
DIA–7530–040 (B-3)
DIA–7530–041 (B-2)
DIA–7530–049 (A-3)
DMS1 Platform Two Hand Control DIA–7530–037 (A-3) 04.8–7530–450 (6)
DIA–7530–038 (A-3)
DIA–7530–040 (C-3)
DIA–7530–041 (C-2)
DIA–7530–049 (B-2)
DSP Switch Panel Display Mode Select DIA–7530–037 (C-4) 04.8–7330–100 (3)
DIA–7530–038 (C-4)
DIA–7530–040 (B-4)
DIA–7530–041 (B-3)
DTS1 Distribution Panel Drive/Tow DIA–7530–037 (C-4) 04.3–7530–001 (12)
DIA–7530–038 (C-4)
DIA–7530–044 (B-3)
EDS Control Module Emergency Disconnect DIA–7530–037 (A-4) 04.6–7530–020 (7)
DIA–7530–038 (A-4)
DIA–7530–039 (B-1)
DIA–7530–049 (C-2)
FNS Switch Panel Fan DIA–7530–040 (B-3) 04.8–7330–100 (6)
DIA–7530–041 (B-3)
FS Control Module Forward DIA–7530–037 (B-2) 04.6–7330–003 (37)
DIA–7530–038 (B-2)
DIA–7530–039 (B-2)
DIA–7530–049 (C-2)
GTS1 Platform Gate Left DIA–7530–037 (A-3) 09.0–7530–150 (7)
DIA–7530–038 (A-3)
DIA–7530–039 (B-1)
DIA–7530–040 (B-1)
DIA–7530–049
GTS2 Platform Gate Right DIA–7530–037 (A-3) 09.0–7530–150 (7)
DIA–7530–038 (A-3)
DIA–7530–039 (B-1)
DIA–7530–040 (B-1)
DIA–7530–049
GTS3 Platform Gate Right 1.0SP DIA–7530–037 (B-2) 09.0–7530–150 (7)
DIA–7530–038 (B-2)
DIA–7530–039 (C-1)
DIA–7530–040 (B-1)
DIA–7530–049
GTS4 Platform Gate Left 1.0SP DIA–7530–037 (B-2) 09.0–7530–150 (7)
DIA–7530–038 (B-2)
DIA–7530–039 (C-1)
DIA–7530–040 (B-1)
DIA–7530–049
GUS Control Module Guidance DIA–7530–037 (B-2) 04.6–7330–003 (25)
DIA–7530–040 (B-3)
DIA–7530–041 (B-2)

Crown 2000 PF11945-8 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–022 M10–7530–022
 C GLOSSARY

SWITCHES (Continued)
Location Function Diagram Parts Breakdown

HNS1 Control Module Horn DIA–7530–037 (C-1) 04.6–7530–020 (20)

DIA–7530–038 (C-1)
DIA–7530–039 (B-1)
HSLCS Platform High Speed Lower Cutout DIA–7530–037 (B-1) 04.8–7530–058 (K)
(Power Unit Side) DIA–7530–039 (B-2) 04.8–7530–059 (K)
HSRCS Main Frame High Speed Raise Cutout DIA–7530–037 (A-3) 04.8–7530–058 (A)
DIA–7530–044 (A-1) 04.8–7530–059 (A)
HTS1200 Platform 1200 mm Height Limit Switch DIA–7530–037 (C-2) 04.8–7530–058 (H)
(Power Unit Side) DIA–7530–038 (C-2) 04.8–7530–059 (F)
DIA–7530–039 (B-2)
DIA–7530–044 (B-1)
DIA–7530–049 (C-4)
HTS2500 Main Frame 2500 mm Height Limit Switch DIA–7530–037 (C-2) 04.8–7530–058 (G)
DIA–7530–038 (C-2) 04.8–7530–059 (E)
DIA–7530–039 (B-2)
DIA–7530–044 (B-1)
HTS4500 Main Frame 4500 mm Height Limit Switch DIA–7530–037 (C-2) 04.8–7530–059 (D)
DIA–7530–038 (C-2)
DIA–7530–044 (B-1)
KYS Control Module Key DIA–7530–037 (A-4) 04.6–7330–003 (31)
DIA–7530–038 (A-4)
DIA–7530–039 (B-1)
LCS1 Platform Lower Cutout DIA–7530–037 (A-2,C-4) 04.8–7530–058 (C)
(Power Unit Side) DIA–7530–040 (A-3) 04.8–7530–059 (E)
DIA–7530–041 (A-2)
LGS1 Switch Panel Dome Light (LGT3 & 6) DIA–7530–040 (B-3) 04.8–7330–100 (7)
DIA–7530–041 (B-3)
LGS2 Switch Panel Work Light (LGT2 & 5) DIA–7530–040 (B-3) 04.8–7330–100 (7)
DIA–7530–041 (B-3)
LGS3 Switch Panel Spot Light (LGT4 & 7) DIA–7530–040 (B-4) 04.8–7330–100 (7)
DIA–7530–041 (B-3)
LMS1 Platform Lift Limit 1.0SP DIA–7530–039 (C-1) 04.8–7530–058 (B)
04.8–7530–059 (J)
LOS1 Control Module Low Speed Lower DIA–7530–037 (A-1) 04.6–7530–020 (20)
DIA–7530–038 (A-1)
LOS2 Control Module High Speed Lower DIA–7530–037 (A-1) 04.6–7530–020 (25)
DIA–7530–039 (B-2)
LOS3 Lifting Forks Auxiliary Lower DIA–7530–037 (A-3) 04.6–7530–500 (27)
DIA–7530–039 (C-2)
DIA–7530–049
LOS4 Lifting Forks Auxiliary Lower DIA–7530–037 (A-3) 04.6–7530–500 (25)
DIA–7530–039 (C-2)
DIA–7530–049
ORS1 Switch Panel Override DIA–7530–037 (A-2, C-4) 04.8–7530–100 (4)
DIA–7530–040 (B-3)
DIA–7530–041 (B-3)

Crown 2000 PF11945-9 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–023 M10–7530–023
 C GLOSSARY

SWITCHES (Continued)
Location Function Diagram Parts Breakdown

RAS1 Control Module Low Speed Raise DIA–7530–037 (A-3) 04.6–7530–020 (20)
DIA–7530–038 (A-3)
DIA–7530–049
RAS2 Control Module High Speed Raise DIA–7530–037 (A-3) 04.6–7530–020 (25)
DIA–7530–039 (B-2)
DIA–7530–049
RAS3 Lifting Forks Auxiliary Raise DIA–7530–037 (A-3) 04.6–7530–500 (26)
DIA–7530–039 (C-1)
DIA–7530–049
RAS4 Lifting Forks Auxiliary Raise DIA–7530–037 (A-3) 04.6–7530–500 (15)
DIA–7530–039 (C-1)
DIA–7530–049
RCS1 Main Frame Raise Cutout DIA–7530–037 (C-3) 04.8–7530–058 (J)
DIA–7530–044 (A-2) 04.8–7530–059 (I)
RCS2 Main Frame Raise Cutout DIA–7530–037 (C-3) 04.8–7530–058 (I)
DIA–7530–044 (A-2) 04.8–7530–059 (I)
07.2–7530–003 (29)
RGS1 P.U. Guide L.H. Rail Guide DIA–7530–037 (C-3) 10.0–7530–001 (4)
Wheel Bracket DIA–7530–044 (A-2)
DIA–7530–049
RGS2 P.U. Guide R.H. Rail Guide DIA–7530–037 (C-3) 10.0–7530–001 (4)
Wheel Bracket DIA–7530–044 (A-2)
DIA–7530–049
RS Control Module Reverse DIA–7530–037 (B-2) 04.6–7330–003 (37)
DIA–7530–038 (B-2)
DIA–7530–039 (B-2)
DIA–7530–049 (C-2)
THS1 Power Unit F/C Thermostat DIA–7530–049 (B-1) 04.9–7330–100 (7)
(Platform Side)
THS2 Platform F/C Thermostat DIA–7530–049 (B-2) 04.9–7330–202 (9)
(Below Floorboard)
ZSS Switch Panel Lift Cutout Zone Select DIA–7530–037 (C-4) 04.8–7330–100 (5)
DIA–7530–040 (B-3)
DIA–7530–041 (B-3)

SYSTEM/MODULES
Location Diagram Parts Breakdown

Brake Module Lift/Lower Panel DIA–7530–037 (B-1) 04.3–7530–100 (17)

DIA–7530–038 (B-1)
DIA–7530–047
DIA–7530–050 (B-1)
Connector Module Steering Feedback DIA–7530–046 (A-3) 04.8–7330–200 (16)
Display Module Platform DIA–7530–037 (B-1) 09.0–7530–003 (20)
DIA–7530–038 (B-1)
DIA–7530–042
Distribution Panel Traction Panel DIA–7530–044 04.3–7530–001
DIA–7530–049 (A-2)
DIA–7530–050 (A-1)

Crown 2000 PF11945-10 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–024 M10–7530–024
 C GLOSSARY

SYSTEM/MODULES
Location Diagram Parts Breakdown

Distribution Panel F/C Traction Panel DIA–7530–049 (A-2)

Service Terminal Service Tool DIA–7530–037 (B-4)
DIA–7530–042 (A-2)
Steering Module Traction Panel DIA–7530–037 (B-3) 04.1–7330–009 (31)
DIA–7530–038 (B-3)
DIA–7530–046
DIA–7530–050 (A-2)
Traction Controller (MRC1) Transistor Panel DIA–7530–037 (B-2) 04.2–7330–001 (14)
DIA–7530–038 (B-2)
DIA–7530–045
DIA–7530–050 (A-2)
Truck Management Module (TMM) Traction Panel DIA–7530–048 04.1–7330–009 (13)
DIA–7530–050 (A-2)
Guidance Module Steering Panel DIA–7530–037 (B-3) 04.3–7330–502 (8)
DIA–7530–046
DIA–7530–050 (A-3)
Steer Wheel Sensor Power Unit DIA–7530–046 (A-4) 04.3–7330–502 (1)
(Wire Guidance)
Load Wheel Sensor Power Unit DIA–7530–046 (A-3) 04.3–7330–502 (4)
(Wire Guidance)
Time Delay Module (TDM) Reservoir DIA–7530–037 (B-1) 04.0–7532–001 (30)
DIA–7530–044 (C-2)

Crown 2000 PF11945-11 Rev. 5/03 Printed in U.S.A.

01 REV. 5/03
M10–7530–025 M10–7530–025
 ELECTRICAL DIAGRAMS INDEX

This electrical diagram index for European SP 3000 Stockpickers lists the wiring diagrams with the area or
component(s) of the truck covered by each diagram.

Title Page Number Revision

Block Diagram DIA–7530–036 01 - 4/03

Schematic with Options DIA–7530–037 01 - 4/03

Schematic without Options DIA–7530–038 01 - 4/03

Pictorial Platform DIA–7530–039 02 - 8/03

Pictorial Platform 1.25SP DIA–7530–040 02 - 8/03

Pictorial Platform 1.0SP DIA–7530–041 02 - 8/03

Pictorial Display Module DIA–7530–042

Pictorial Lights/Fan DIA–7530–043

Pictorial Distribution Panel DIA–7530–044 03 - 8/04

Pictorial Traction Controller DIA–7530–045 01 - 4/03

Pictorial Steering Module/Guidance System DIA–7530–046

Pictorial Brake Module DIA–7530–047 01 - 4/03

Pictorial Truck Management Module TMM DIA–7530–048

Pictorial Freezer Conditioning DIA–7530–049 01 - 4/03

Pictorial Power Cables DIA–7530–050

Wire Harnesses † DIA–7530–051 01 - 4/03

† Includes Supplemental Information

001001 8882 (IRE)

Crown 2000 PF11940-1 Rev. 8/04 Printed in U.S.A.

03 REV. 8/04
DIA–7530–035 DIA–7530–035
 BLOCK DIAGRAM
A B C

GTS4
PROGRAM
ANALYSIS 2
CARTRIDGE
SERVICE
TERMINAL

GTS3
5
1 3

EDS
ALM1

LOS2
DISPLAY

RAS4
CHB7
GTS2
ORS1B
LCS1B
MODULE

RAS1
LOS1

GUS
DPS

ZSS

KYS
ECR1 4

RS
FS
1 1

ORS1A

HSLCS
LCS1A

GTS1

RAS3
CHS3

CHB6
DMS1

RAS2

BRS1

POT1
THS3

HTSAUX

HTS1200

HTS2500
FAN/LGT PACKAGE

LOS3
HN1 K10

LGS1

LGS2

LGS3

FNS

HNS1
3 6

LOS4
K12
F/C
THS2
PACKAGE PLATFORM
K11
SV5

POWER UNIT 3

BRAKE
MODULE BRAKE
K3
2 2
DTS1

R
TRACTION
NOTES:
MODULE 1A
1 SIDE GATES - 1.0 & 1.25

M1 2 REAR GATES - 1.25

10 3 1.0 ONLY
5 6
4 TT PLATFORM ONLY
30 CONTROL WIRING

HTS2500
5 1.25 TL ONLY
2 COMMUNICATIONS

HTS1200 5
6 HEIGHT DETERMINED ON A TT MAST
HTS4500

K1
7

ED

3 DISTRI- 3
CHS1 CHS2 SV1
BUTION
PANEL
SV2

SV3

CHB4 CHB5 P1

13 4
RS232 P2 HSRCS

4X 8-COND
MAST CABLE
RGS2
RCS1

RCS2

BRES2

2 LOAD WHEEL
SENSORS 5
RGS1

7
BRES1

K2 STR'D WHEEL
SENSORS
STEERING 7
MODULE K5

4 K4 GUIDANCE 4
MODULE CONNECTOR
K7 MODULE

K8
5

M2 ECR2

A B C
5500 - EO10100/EO10468 131568 A

Crown 2000 PF11940-2 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–036 DIA–7530–036
 ELECTRICAL SCHEMATIC
A B C

M4
WITH OPTIONS
FU9 P2 2
PUMP MOTOR 2
M3
FU8 P1 PUMP MOTOR 1
F/C
PLATFORM

F/C
POWER UNIT

LT/FAN
1 2 PACKAGE 2 1
FILTER
FU1 LGT1
(STROBE LIGHT)
-

+
HNS1
HSLCS HN1
TDM SV2 CHS2 CHS1
LOS2 2 (Right) (Left)
SV1
LOS1 K10 TP20

CA415-5 CA414-6 K3

CA414-3
CA415-6
BRAKE
CA415-1
CA415-2
P-COMM BRK1
CA415-3
BRAKE
CA415-4 MODULE
+

CA414-4
FU4 K3A
CA414-1 CA414-5
(REDUCE 2)

CA414-2 CA414-8 TP13

(1LEVSEL)
BRS1 DTS1 K2A 9
4 K7
(DRIVE/TOW)
TP8 CA401-6
CHS4

(SL1) HTS1200
R CA402-5 7

2 CA401-4
2
CHS3

F CA402-4 (SL2)
MRC1 TP14
TB403-2 K8
CA401-5
(SL3) K7 TP12
1A CA402-6
CA401 = PCAT
TB403-3 CA402 = PCBT CA401-3
TB403 = TB11 (SL4) HTS2500
5 TB403-4 CA404 = PCYT K4

1.25 HTS4500
LCS1A

TRACTION TP7
TB403-1
GTS4 GTS3 TP11 CONTROLLER CA404-13 TP6
(Right) (Left) RECEIVE POT1
ORS1A

RS CA404-14 TRANSMIT
TP2 TB403-6 CA404-5 5V 4
K3B REAR GATES TP10 CA404-4 L-COMM
FS
TB403-5
FU5 N

10 10 CONTENTS OF DASHED BOXES ARE OPTIONAL.

T2
R R
SV5
LOS3 LOS4 A1
FU13 S2
P A2 M1

6 ALL TEST POINTS ARE LOCATED ON

8 ENERGIZED WHEN STEER ANGLE IS

7 SPEED LIMITS ARE ACTIVE WITH AN
CA402-1
TRAC F S1 F 1A

9 HTS1200 WIRED TO POWER UNIT

MOTOR
TP19
K10 SV4

THE DISTRIBUTION PANEL.

RAS3 RAS4

LESS THAN 10 DEGREES.

L-COMM WITH TL MAST.

FU7 CA417-21

OPEN CIRCUIT (>2.0V).

CA417-20

POWER UNIT P-COMM (POWER)

GUIDANCE 3

PLATFORM L-COMM (LOGIC)

PLATFORM P-COMM (POWER)

TP24
CHB5 CHB4 TP17 STEERING
SYSTEM
DMS1

(Left) (Right) MOTOR

3 STEERING K5 - 3
+

4 TP5 TP16 FEEDBACK

CA407-1 M2
AUTO/MAN

RAS2 ENCODER
CA406-5

BATT NEG
CA406-9

HSRCS K5
CA406-14
K9A

P2 ECR2 CA407-3
2 CA406-23
(Right)
CHB7

1.25

CA406-3 CA406-1 RECEIVE

CA406-11 CA406-10 TRANSMIT
P1 RAISE CA406-7 CA406-20 5V 4
RAS1 K10 TP15
STEERING CA406-2 L-COMM

STEERING WITH STEER WHEEL CENTERED,

TP21
CHB6

ZONE SELECT OR RAISE CUTOUT OPTION.)

SV3
(Left)

ACQUISITION CA406-27
MODULE
(Right)
GTS2

K8

PRESENT WITH LOWER CUTOUT ONLY.

TP23
TRUCK IS SHOWN IN A STATIC (HOME)
SIDE GATES
1.0 & 1.25

(ORSB1 MAY ALSO BE PRESENT WITH

BRES1(Left) BRES2(Right)

USED FOR GUIDANCE OPTION ONLY.

LOWERED,GATES DOWN,IN MANUAL

K2 BRAKE CA406-28
POSITION - KEY OFF,TRUCK FULLY

CA406-15
BRS2

2 AUTO SPD CA406-19 RGS1(Left) RGS2(Right)

GTS1
(Left)

CURVES
K5 STR EN/DIS CA406-8 CA406-24 RESENT WITH TT MAST ONLY.
2
NO OPERATOR PRESENT.

CA406-6
K4 STR ANGLE/ CA406-18 RCS2
CA405-3

CA405-1

CA405-2

CA405-4

2-HAND CA406-25
FU6 8 TP22 RCS1

CA407-2 CA407-4
FU10
OPTIONAL
+

L-COMM
CA304-23
SERIAL+

ZSS 2
L-COMM
CA303-8

CA303-1

CA303-2

CA303-9

CA304-16
SERIAL-

K4
CA304-6 CA304-13
CA304-22
+BV

CA304-15 TP4
5
2
3
NOTES: 1

CA304-24
GUS 3
CA304-7 CA304-21
CA304-19 DISPLAY TP3
+BV

CA304-10
CA304-26 MODULE
+BV(K1B)

ALM1 K7 ECR1 CA304-25 CA304-20

AUTO SPEED CA304-28 DPS LCS1B
4 4
CA303-3
CA303-4
CA303-5
CA303-6
CA303-7
+BV(ED)

CA304-18 CA304-12
STEERING
ENCODER ORS1B
CA304-14 CA304-11
ED K1B KYS 5
START
RECEIVE
CA503-22

TRANSMIT

CA503-20
CA503-7
L-COMM

SERVICE
CA503-3
CA503-2

A B ACC
TERMINAL TP18 ED
12V

IGN
5V

EDS TP9
FU2 OFF K1
TP1 K1A
2 4

N
BATT

A B C 5500 - EO10100 131361 A SH1

Crown 2000 PF11940-3 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–037 DIA–7530–037
 ELECTRICAL SCHEMATIC
A B C
WITHOUT OPTIONS
M3
FU8 P1 PUMP MOTOR 1

FILTER
FU1 LGT1
(Strobe Light)
+ -

HNS1
HN1
1 K10
CHS2
(Right)
CHS1
(Left)
1
SV1
TP20

CA414-6 K3
CA415-5

CA415-6 CA414-3
LOS1 BRAKE
CA415-1
CA415-2
P-COMM BRK1 BRAKE
CA415-3
CA415-4 MODULE
+
CA414-4
FU4 K3A
CA414-1 CA414-5
(REDUCE 2)

CA414-2 CA414-8 TP13

(1LEVSEL)
BRS1 DTS1 K2A 6
2 K7
(DRIVE/TOW)
TP8 CA401-6
CHS4 (SL1) HTS1200
R CA402-5 4

F CA402-4
MRC1 CA401-4
(SL2)
CHS3 TP14
TB403-2
CA401-5
(SL3) K8 K7 TP12
1A CA402-6
CA401 = PCAT
2 TB403-3 CA402 = PCBT
TB403 = TB11
CA401-3
(SL4) HTS2500
2
TB403-4 K4
CA404 = PCYT
1.25 HTS4500
TRACTION TP7
TP6
TB403-1
GTS4
(Right)
GTS3
(Left)
TP11 CONTROLLER CA404-13 RECEIVE POT1
CA404-14 TRANSMIT
TP2 TB403-6 CA404-5 5V 4
RS
K3B REAR GATES TP10 CA404-4 L-COMM

FS TB403-5
FU5 N

T2
R R
A1
FU13 S2
P A2 M1
CA402-1 TRAC 1A
F F

Contents Of Dashed Boxes Are Optional.

MOTOR S1

K10

Speed Limits Are Active With An

Energized When Steer Angle Is

HTS1200 Wired To Power Unit

POWER UNIT P-COMM (POWER)
PLATFORM L-COMM (LOGIC)
TP24

PLATFORM P-COMM (POWER)

L-COMM With TL Mast.

Less Than 10 Degrees.
CHB5 CHB4 TP17
(Left) (Right) STEERING

Open Circuit (>2.0V)

DMS1

MOTOR
STEERING K5
FEEDBACK
2
AUTO/MAN

ENCODER CA407-1 M2
CA406-5
CA406-9

CA406-14 K5

BATT NEG
ECR2 CA406-23 CA407-3
(Right)
CHB7

3 K10
CA406-3 CA406-1 RECEIVE 3
CA406-11 CA406-10 TRANSMIT
P1 CA406-7 CA406-20 5V 4
RAS1

7
TP15 TP21 CA406-2 L-COMM
CHB6
(Left)

SV3
ACQUISITION CA406-27

Steering With Steer Wheel Centered,

(Right)
GTS2

K8 TP23
SIDE GATES

Truck Is Shown In A Static (Home)

STEERING

Lowered,Gates Down,In Manual

K2 BRAKE CA406-28
1.0 & 1.25

Position - Key OFF,Truck Fully

MODULE

Present With TT Mast Only.

AUTO SPD CA406-19

On The Distribution Panel.

All Test Point Are Located
GTS1
(Left)

CURVES
K5 STR EN/DIS CA406-8

No Operator Present.
K4 STR ANGLE/ CA406-18
CA405-3

CA405-1

CA405-2

CA405-4

FU6 5 2-HAND
TP22
CA407-2 CA407-4
FU10
NOTES:
+

L-COMM
1

2
3
SERIAL+

L-COMM

TP4
CA303-8

CA303-1

CA303-2

CA303-9
SERIAL-

K4 CA304-16
CA304-6
+BV

CA304-15
CA304-24
CA304-7
+BV(K1B)

TP3
CA304-19
+BV

CA304-10
CA304-26
ALM1 ECR1 CA304-25 CA304-20
CA304-28 DPS
CA304-18
STEERING DISPLAY
+BV(ED)

ENCODER
4 MODULE 4
CA304-14
ED K1B KYS
START
A B ACC
TP18 ED
EDS IGN TP9
FU2 OFF K1
TP1 K1A
2 4

N
BATT

A B C 5500 - EO10100 131361 A SH2

Crown 2000 PF11940-4 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–038 DIA–7530–038
 PLATFORM
A B C

GTS1 (L) GTS2 (R)

TB101 2923 2989 TB102-11 3
1 BLK CA202-1 +BV TO K1A 1 2919 BLK (TB102) GTS3 4
1 1 WHT CA202-2 +BV(K1B) FROM K1B 2 2936 1
2914
3 2922 HNS1
BRS1 KYS OFF
1 RED CA202-3 +BV FROM FU2 4 203 2902 IGN
ACC 2977
EDS
1 GRN CA202-4 +BV(K1B) TO DIST PNL 5 2928 START (TEST)

1 ORG CA202-5 +BV(ED) FROM FU1 6 2958 (TB102) LGS2 COMM +BV TO LGS2

1 BLU CA202-6 +BV(ED) FROM FU1 7 2964 (TB102) FNS COMM +BV TO FNS
559 TB501-1 P-COMM TO PS1,LF WORK LGT
1 WHT/BLK CA202-7 P-COMM 8 561 CA503-2 P-COMM TO FAN,RT SPT LGT
FROM DIST PNL 562 CA503-1 P-COMM TO RT DOME,RT WORK LGT
1 RED/BLK CA202-8 P-COMM 9 528 709 716
FROM DIST PNL 1 560 CA501-2 P-COMM TO PS2,LF DOME,SPT LGT
2 BLK CA203-1 +BV TO K1+ 10 2903 2968
29109 CA304-14 +BV TO DISPLAY TB102-11 RAS3 RAS4 LMS1
2 WHT CA203-2 P-COMM FROM DIST PNL 11 506 710
2969 310 311
2 RED CA203-3 AUX RAISE 12 710
- SB12
2 GRN CA203-4 +BV(ED) 13 TO OVERHEAD GUARD
+ 1
FUSED SPARE FROM FU3 LOS3 LOS4
29146
2 ORG CA203-5 +BV(K1B) TO SV1- 14 528 2
2907 2991
2 15 LOS2 1
WHT RED 3
20 SV5
3
2 BLU CA203-6 +BV(K1B) TO SV2- 16 BLK
2 HSLCS
1
1.0 SP ONLY GRN 2
2 WHT/BLK CA203-7 +BV(K1B) TO P1+ 17 29164
2906 2908
2 RED/BLK CA203-8 +BV(K1B) 18 1 RAS2
TO HSRCS COM 2 29105 29105 CA304-16 +BV(ED) TO DISPLAY
3 BLK CA204-1 +BV(ED) TO TRAC, GUID 19 2947
FS
2948 2904 2905
3 WHT CA204-2 +BV(ED) TO TRAC, GUID 20 RS
29106 29106 CA304-6 +BV(ED) TO DISPLAY
3 RED CA204-3 +BV(ED) FROM K3B 21 2929 2932 3
GTS4 (L) GTS3 (R)
3 GRN CA204-4 L-COMM TO POWER UNIT 22 BLK WHT TB102-5 L-COMM
6 HTS2500
29
3 ORG CA204-5 L-COMM TO POWER UNIT 23 BLK WHT TB102-4 L-COMM
17 HTS1200
3 BLU CA204-6 L-COMM TO POWER UNIT 24 5

3 WHT/BLK CA204-7 +BV(K1B) 25 SEE FREEZER

FROM F/C PNL CONDITIONING
3 RED/BLK CA204-8 +BV(K1B) TO F/C PNL 26 (CA807)
SB10 HN1
3
27 2921 29178 -
+

IN OUT
28 2977
29108 CA304-15 +BV(RAS1) TO DISPLAY 29 29154

29107 CA304-24 +BV(LOS1) TO DISPLAY 30 29153

3 3
NOTES:
2952 TB102-15
2954 TB102-13

1 OPTIONAL
2 JUMPER REQUIRED IF TRUCK IS NOT
EQUIPPED WITH HIGH SPEED LOWER
CUT-OUT SWITCH (HSLCS) OPTIONS.

3 1.0 SP ONLY
4 PRESENT WITH 1.25 ONLY
5 PRESENT ON PLATFORM FOR 1.0 TL AND ALL TT MAST. LOS1 RAS1
6 HEIGHT DETERMINED ON A TT MAST
29153

29146

29164
29154
2917

2913
2991

2908

1 2 3 4

29166 (TB102) DMS1-N.C. 5

570 TB102-4 6
4 K10 4

A B C 6363 - EO10789 131362 B Sh1

Crown 2000 PF11940-5 Rev. 8/03 Printed in U.S.A.

02 REV. 8/03
DIA–7530–039 DIA–7530–039
 PLATFORM 1.25 TT & TL
A B C

2905 (TB101) FS COMM

29157 TB101-21
1 1
GTS3 GTS4

WHT
1 2 3 4
2989

29168

29159
BLK

BLK 5
GTS1 GTS2
569 TB101-9 6
2923 K9
SB11
2936 TB101-2
023 1 1.25 SP ONLY

2
29445
024 3
TB102
001 001 CA303-1 SERIAL + DISPL/STEER
4 BLK CA205-1 SERIAL+ DISPLAY/STEER 1
002 002 CA303-2 SERIAL - DISPLAY/STEER
4 WHT CA205-2 SERIAL- DISPLAY/STEER 2 29110 29110 (CA304) +BV(K1B) TO ALM1
2938 2938 CA303-8 +BV(K1B) TO DISPLAY
4 RED CA205-3 +BV(K1B) FROM DIST PNL 3
WHT WHT (TB101) HTS1200 N.O.
2 546 546 CA303-9 L-COMM TO DISPLAY 2
4 GRN CA205-4 L-COMM FROM DIST PNL 4
570 570 (TB101) K10-6
WHT WHT (TB101) HTS2500 N.O.
5 556
4 ORG CA205-5 L-COMM FORM DIST PNL
566
553
5 6 565
563
512
4 BLU CA205-6 0 TO 3.7V TO TRAC 7
102 POT1
(TRAC)
4 WHT/BLK CA205-7 +BV(ED) 8 ACCEL
FROM DIST PNL 105 DB1 1
SEE FREEZER
9 CONDITIONING 1
(CA807)
4 RED/BLK CA205-8 P-COMM 10 29167 2
FROM DIST PNL 29445
4
11 GRN 3
4 5908
5909 CA304-23 L-COMM TO DISPLAY 12
2954 2954 (TB101) LOS1 COMM
(LEFT) (RIGHT)
WHT 13 WHT BLK 29166 (TB101) K10-5
4 2973 CHS3 CHS4 NO
2 29151 CA304-7 +BV
14 29159
RED WHT TO DISPLAY
ORS1A DMS1 NC
3 29168
LCS1 1 2974
GRN 15 1
GRN ORS1B
566
BLK
3 19
16 2952 2952 (TB101) RAS1 COMM 3
5907 5907 CA304-12 L-COMM TO DISPLAY
5910 CA304-21 L-COMM TO DISPLAY 17 5903 556
1 GUS (GUIDANCE)
5912 CA304-20 L-COMM TO DISPLAY 18 5911
7 (BLU)

5913 CA304-11 L-COMM TO DISPLAY 19 5906 5 (YEL) 512

ZSS
(ZONE SELECT) 4 (ORG) 6 (GRN)
5916 CA304-13 L-COMM TO DISPLAY 20 5905 3 (RED)
2 (WHT) 563
5917 CA304-22 L-COMM TO DISPLAY 21 5904 8 (BRN) 1 (BLK)
LO FNS (FAN) 1
2963 CA503-6 +BV(ED) TO LOW SPD FAN 22 2961 2964 TB101-7 +BV(ED) FROM FU1
2972
2962 CA503-4 +BV(ED) TO HIGH SPD FAN 23 2965
HI 2958 TB101-6 +BV(ED) FROM FU1
2960 CA501-3 +BV(ED) TO WORK LIGHTS 24 2966
1 LGS2 (WORK)
2925 CA501-5 +BV(ED) TO DOME LIGHTS 25
2970 2975
306 CA501-6 +12V FROM PS2 26 1 LGS1 (DOME)
305 CA503-5 +12V TO RT DOME LIGHT
303 CA501-4 +12V FROM PS1 27 NO2 NOTES:
DSP (DISPLAY)
304 CA503-3 +12V TO RT WORK LIGHT
565 1 OPTIONAL
5934 CA304-10 L-COMM TO DISPLAY 28 5902
NO1
2 CHS3,CHB4,CHB6 & CHB7 ARE
4 2942 CA501-7 +BV(ED) TO LF SPOT LIGHT 29 2976 2972 PRESENT WITH TT MAST. 4
2944 CA503-7 +BV(ED) TO RT SPOT LIGHT 1 LGS3 (SPOT) 3 JUMPER REQUIRED IF TRUCK IS
30
NOT EQUIPPED WITH LOWER CUTOUT
1 SWITCH (LCS) OR OVERRIDE
GRN SWITCH (ORS1) OPTIONS.
BRS2 4 JUMPER REQUIRED FOR TL MAST.

(RIGHT) (LEFT) 5 JUMPER REQUIRED IF TRUCK IS NOT

EQUIPED WITH WIRE GUIDANCE.
GRN RED RED
CHB7 2 CHB6 2

A B C 6363 - EO10789 131362 B Sh2

Crown 2000 PF11940-6 Rev. 8/03 Printed in U.S.A.

02 REV. 8/03
DIA–7530–040 DIA–7530–040
 PLATFORM 1.0 TT & TL
A B C

SB11
1 023 1 1
2

024 3
TB102
001 001 CA303-1 SERIAL + DISPL/STEER
4 BLK CA205-1 SERIAL+ DISPLAY/STEER 1
002 002 CA303-2 SERIAL - DISPLAY/STEER
4 WHT CA205-2 SERIAL- DISPLAY/STEER 2 29110 29110 (CA304) +BV(K1B) TO ALM1
2938 2938 CA303-8 +BV(K1B) TO DISPLAY
4 RED CA205-3 +BV(K1B) FROM DIST PNL 3
WHT WHT (TB101) HTS1200 N.O.
546 546 CA303-9 L-COMM TO DISPLAY
4 GRN CA205-4 L-COMM FROM DIST PNL 4
570 570 (TB101) K10-6
WHT WHT (TB101) HTS2500 N.O.
556
4 ORG CA205-5 L-COMM FORM DIST PNL 5
566
553
5 6 565
563
512
4 BLU CA205-6 0 TO 3.7V TO TRAC 7
102 POT1
8 (TRAC)
4 WHT/BLK CA205-7 +BV(ED)
FROM DIST PNL 105 ACCEL DB1 1
SEE FREEZER
2 9 CONDITIONING 1 2
(CA807)
4 RED/BLK CA205-8 P-COMM 10 29167 2
FROM DIST PNL 4
2989 (TB101) GTS-2 N.O. 11 WHT 3
4 5908
5909 CA304-23 L-COMM TO DISPLAY 12
2954 2954 (TB101) LOS1 COMM
5
WHT 13 BLK BLK 29166 (TB101) K10-5
2973 CHS3 CHS4 NC
4 2 29151 CA304-7 +BV
14 29168
RED WHT TO DISPLAY
3 ORS1A DMS1 NO
LCS1 29168 2974
GRN 15 1
WHT ORS1B
566
BLK
16 2952 2952 (TB101) RAS1 COMM
19
5907 5907 CA304-12 L-COMM TO DISPLAY
5910 CA304-21 L-COMM TO DISPLAY 17 5903 556
1 GUS (GUIDANCE)
5912 CA304-20 L-COMM TO DISPLAY 18 5911
7 (BLU)
5913 CA304-11 L-COMM TO DISPLAY 19 5906 5 (YEL) 512
ZSS
(ZONE SELECT) 4 (ORG) 6 (GRN)
5916 CA304-13 L-COMM TO DISPLAY 20 5905 3 (RED)
2 (WHT) 563
3 5917 CA304-22 L-COMM TO DISPLAY 21 5904 8 (BRN) 1 (BLK) 3
LO FNS (FAN) 1
2963 CA503-6 +BV(ED) TO LOW SPD FAN 22 2961 2964 TB101-7 +BV(ED) FROM FU1
2972
2962 CA503-4 +BV(ED) TO HIGH SPD FAN 23 2965
HI 2958 TB101-6 +BV(ED) FROM FU1
2960 CA501-3 +BV(ED) TO WORK LIGHTS 24 2966
1 LGS2 (WORK)
2925 CA501-5 +BV(ED) TO DOME LIGHTS 25
2970 2975
306 CA501-6 +12V FROM PS2 26 1 LGS1 (DOME)
305 CA503-5 +12V TO RT DOME LIGHT
303 CA501-4 +12V FROM PS1 27
NO2 DSP (DISPLAY)
NOTES:
304 CA503-3 +12V TO RT WORK LIGHT
565 1 OPTIONAL
5934 CA304-10 L-COMM TO DISPLAY 28 5902
NO1
2 CHS3,CHB4,CHB6 & CHB7 ARE
2942 CA501-7 +BV(ED) TO LF SPOT LIGHT 29 2976 2972 PRESENT WITH TT MAST.
2944 CA503-7 +BV(ED) TO RT SPOT LIGHT 1 LGS3 (SPOT) 3 JUMPER REQUIRED IF TRUCK IS
30 NOT EQUIPPED WITH LOWER CUTOUT
1 SWITCH (LCS) OR OVERRIDE
SWITCH (ORS1) OPTIONS.
2951
BRS2 4 JUMPER REQUIRED FOR TL MAST.

5 JUMPER REQUIRED IF TRUCK IS NOT

(RIGHT) (LEFT) EQUIPED WITH WIRE GUIDANCE.
2926 2949
2
4 CHB7 2 CHB6 4

A B C 6363 - EO10789 131362 B Sh3

Crown 2000 PF11940-7 Rev. 8/03 Printed in U.S.A.

02 REV. 8/03
DIA–7530–041 DIA–7530–041
 DISPLAY
A B C

1 1

001 TB102-1 SERIAL + DISPLAY/STEER

002 TB102-2 SERIAL - DISPLAY/STEER

CA301
DISPLAY MODULE
1
2 CA303 COMMUNICATIONS
3 1 SERIAL +
2 SERIAL -
SERVICE
TERMINAL 6 703 3 5V
OR 7 511 4 L-COMM
PROGRAM 019 5 TRANSMIT
ANALYSIS 20 020 6 RECEIVE
CARTRIDGE 21 311 7 12V
PORT
22 8 BATTERY POSITIVE INPUT 0V=OPEN, 24V=CLOSED
2 23 9 BATTERY NEGATIVE INPUT 2
24 105 10 TERMINAL SENSE 0V=TRANSTERM
5 OR 12V=ALTERNATIVE
25
CA304 INPUTS/OUTPUTS
1
2938 TB102-3 +BV(K1B) FROM DIST PNL 2
546 TB102-4 L-COMM FROM PLATFORM 3
4
5
29106 TB101-20 +BV(ED) FROM RS NO 6 REVERSE SWITCH INPUT 0V=OPEN, 24V=CLOSED
29151 DMS1 N.O. (TB101) +BV FROM DMS1 7
8
9
5934 TB102-28 L-COMM FROM DPS NO1 10 DISPLAY SWITCH 1 (MODE) INPUT 5V=OPEN, 0V=CLOSED
5913 TB102-19 L-COMM FROM ORS1B NO 11 OVERRIDE SWITCH INPUT 5V=OPEN, 0V=CLOSED
5907 TB102-16 L-COMM FROM LCS1 NO 12 LOWER CUTOUT SWITCH INPUT 5V=OPEN, OV=CLOSED
5916 TB102-20 L-COMM FROM ZSS NO2 13 ZONE SELECT SWITCH 2 INPUT 5V=OPEN, 0V=CLOSED
29109 TB101-10 +BV FROM KYS START 14 KEY TEST INPUT 0V=OPEN, 24V=CLOSED

3 29108 TB101-17 +BV(K1B) FROM RAS1 NO 15 1ST SPD RAISE INPUT 0V=OPEN, 24V=CLOSED 3
29105 TB101-19 +BV(ED) FROM FS NO 16 FORWARD SWITCH INPUT 0V=OPEN, 24V=CLOSED
17
514 18 L-COMM
29110 TB102-3 +BV(K1B) FROM K1B 5920 19 STATUS ALARM OUTPUT 24V=OFF, 0V=ON
ALM1
5912 TB102-18 L-COMM FROM DPS NO2 20 DISPLAY SWITCH 2 (OPTION) INPUT 5V=OPEN, 0V=CLOSED
5910 TB102-17 L-COMM FROM GUS NO 21 GUIDANCE SWITCH INPUT 5V=MANUAL, 0V=AUTO
5917 TB102-21 L-COMM FROM ZSS NO8 22 ZONE SELECT SWITCH 1 INPUT 5V=OPEN, 0V=CLOSED
5909 TB102-12 L-COMM FROM ZSS NO7 23 ZONE SELECT SWITCH 3 INPUT 5V=OPEN, 0V=CLOSED
29107 TB101-14 +BV(K1B) FROM LOS1 NO 24 1ST SPD LOWER INPUT 0V=OPEN, 24V=CLOSED
004 25 CHANNEL B
CA302 003 26 CHANNEL A
BLU 1 27

ECR1 BLK 2 701 28 +5VL

STEERING ORG 3
ENCODER RED 4
YEL 5
6

4 4

A B C 6784 044892V

Crown 2000 PF11940-8 Printed in U.S.A.

DIA–7530–042 DIA–7530–042
 LIGHT and FAN
A B C

LGT2
503 WORK
301 LIGHT
LEFT

1 PS1 1
(DC-DC CONVERTER)
301
CA501 302 1 +12V OUT
503
559 TB101-8 P-COMM FROM PLATFORM 1 504 504 2
BATTERY
COMM
560 TB101-9 P-COMM FROM PLATFORM 2 505 3

2960 TB102-24 +BV(ED) FROM LGS2 NO 3 2990 2990 4 +BV INPUT

303 TB102-27 12V TO RT WORK LGT 4 302

2925 TB102-25 +BV(ED) FROM LGS1 NO 5 2931 PS2

(DC-DC CONVERTER)
306 TB102-26 +BV(ED) TO RT DOME LGT 6 310 310
309 1 +12V OUT
2942 TB102-29 +BV(ED) FROM LGS3 NO 7 2998
505 2
8 541 BATTERY
COMM
3
9
2931 4 +BV INPUT
2 2
LEFT
OVERHEAD
GUARD
HARNESS

LGT3
DOME BLK
LIGHT 542
LEFT
BLK LGT4
RED SPOTLIGHT
LEFT
TB502 1 2 3 4 5

LGT7
SPOTLIGHT
RIGHT

3 RIGHT 3
BLK
OVERHEAD
GUARD
HARNESS RES1 FAN FAN
RED SUPPRESSOR
CA503 SB30

562 TB101-9 P-COMM FROM PLATFORM 1 508 2920 1

561 TB101-8 P-COMM FROM PLATFORM 2 510 510 2

507
304 TB102-27 12V FROM PS1 3 307 3
2933
2962 TB102-23 +BV(ED) FROM FNS NO(HIGH) 4 2992 2992 4
2934
305 TB102-26 12V FROM PS2 5 308 308 5
BLK
2963 TB102-22 +BV(ED) FROM FNS NO(LOW) 6 2916

2944 TB102-29 +BV(ED) FROM LGS3 NO 7 2920

9
4 BLK 4
307 LGT5
LGT6 WORK
508 LIGHT
DOME
LIGHT 509 RIGHT
RIGHT

A B C 6784 044889V

Crown 2000 PF11940-9 Printed in U.S.A.

DIA–7530–043 DIA–7530–043
 4
3
2
1
29 299 29

1
29 95 C4 CA 79 C

1
10 A8 CO FRE
3 C A807807- 0 ND EZ

RCS1
RCS2

RGS2
RGS1

BRES2
A8 -11 12 + 8-5 ITI ER

CHS2
+

BRES1
CHS1
20 07 ON

LGT1

1
2
2 -7 +BVBV(K BV(K IN
G

RED
+B (K 1B

-
(STROBE)

+
BLK
V( 1B ) T 1B)
29 (SE
7 ED ) F O T 502

BLK
BLK

BLK

BLK
BLK

BLK

WHT
WHT
WHT

WHT
WHT
WHT
29 8 ( E P ) F RO K1 O F/
R C 2915

HN2
WHT P

6
71 SE O OM M T 1 &
RED/WHT

7
9
13

BLK
BLK

11
(S E WE K1 HS- K12 NL

1
2
3
4
5

WHT
WHT

5
6
2B 2

8
EE PO R

10
14
W P BLK

(TRAVEL ALARM)
SB21
52 PO ER AN
W E

DIA–7530–044
A
A

51 0 (S E PA L)

3
2
1
3
2
1
8
7
6
5
4
3
2
1

4
4
9

13
12

15
14
11
10
7 E R P N +B PO

CA201
W

13
51 (S E A EL V
E P
6 E O N )+ B BLK

CA215
ER

Crown 2000 PF11940-10 Rev. 8/04

CA214
CA216
(S P W EL B EF H
EE O E ) V O SR
+ WHT C
PO WE R P BV AFTRE
GRN S

CA213
14 C

FU2

FU5
FU3
W R P AN AF ER ED

FU4

FU6
H

FU1
29 ER A EL T E RED

STEER
SPARE
E

BRAKE
B5

TP5
10

CONTROL
1 PA NE ) L- R D

TRACTION
RED C

LIGHTS/FAN
TB N L) P CO ED 15 H
EL - M GRN

TP1 TP2
10 40
1 3 ) C M B4
T -4 P- OM
C M WHT H
O
HEIGHT SWITCHES

29 B4 +B
0 M BLK
TS
M

1 2 3 4 5 6
29 97 3-1 V(E 45

1 2 3 4 5 6 7 8 9
16

10 TB 0 D 00

TP7
T
8

0 40 -3 ) T
CA202
TB 3 .7 O RA
03 29 V T C

K1A
1 4 -5

K1

TP3
TP4
03 2 C 02 201 03- +B PO RAC TIO
3 A C 6 V T 1
BL M

K1B
03 CA 401A4 CA +B (ED1 T CO N
K A 1

CA212
4 4 -6 03 40 V( ) O N W T ST
03 C 01 L -2 2- E TO TR T
5 A4 -4 -C +B 1 + D) T A H B C 1
R T T 101 AB
C 01 L O V B T R C
A4 - -C M ( V O A ED B - 1
+ G T 10 1 + LE
01 5 L O M K1 TO TR C
-3 -C MM TO B) T A R B 1 B 1 1
O N T 10 -2 V
L- OM T S TO R C R B 1 + F 1
C M O PD T AC
O BL G T 10 -4 + BV RO
( M 1
M TO SP L RA B 1
M D IM C
TP8
W U T 10 -5 BV K1B K
H B 1 + T ) Y 1
1

TO SP LI IT
1 2 3 4 5 6 7 8 9

M R T/B 10 -6 BV O K TO S I
ED L 1- +B (K Y G
SP D L IT 1
D IM 2 /B K T 7 + V( 1B S PLA N
CA203
TP9
2

TP18
LI IT LK B BV ED ) F CO T
M 3
IT 2 TB 101 (E ) T RO M FO
D R
4 K8A B 1 -8 ) O M M

1 2 3 4 5 6 7 8 9 10
2 LK M 01- P- TO LG BR
W 9 C L T S
2 H TB1 AS P- O G S 1

K7A
C MM TS & N
R T T 01 T C
2 ED B - O O

CA211
G 1 1 AB M T & FAN

TP25
M O F
2 RN TB 01- 0 + LE L A
O T 10 11 BV 2 TO GT N

K4A
2 RG B 1- P F LG S

K4B
B 1 1 - R

5
TS &
2 LU TB 01- 2 + CO OM F
0 W 1 1 B M & AN
FR 13 2 H TB 01 3 + V F M KY FA

B
B

O G
1 2 3 4 5 6 7 8 9

BLK R T/B 10 -14 BV R TO S N

59 014M SRN + HTS2500
ED L 1- + ( O
1 E M H
2 2 -
ST K B

1 2 3 4 5 6
29

/B T 6 V D A O
EE CA204 WHT
TP12

59 5 C 92 CA TR CA
TP11
3

TP10

LK B +B (K ) F U R
R
4

23 A 7 ( 40 M 40
IN 3 T 10 V 1 U X N
59 C 406 CA 6-2OD 6-9 G B
B1 1- (K B) SE RA
1 1 F D
27 A4 -2 40 6 F A U 3 LK M 01- 7 + B) RO S ISE
C

03 REV. 8/04
06 8 6) A
- P U T O W A 1 B F M P

CA210
59 A 1 - +B L 3 H TB ST 8 + V( RO L AR
/M

TP24
32 40 8 P CO V T K3B
C
59 C 6-7 -C M (E TO A R T T 10 BV K1 M O E
3 A O M D N 3 ED B 1- A (K B) LO S1 TO
59 3 C 40 P-C M FR ) T ST UA G 1 1 B 1B FR S N P
3 A 6 O M OO R L K7B
3 RN TB 01 9 + LE ) F O 2/H O LA
59 8 C 40 -27 MM FR M K5 MO O T 10 -20 BV 3 TF
R M SL

K2
K4
3 RG B 1- + (E
26 A 6- L- F O S +, D
4 1 T B 1 2 B 2 O R C O
M A S R
59 CA 06 5 L CO ROM S R K6 M
3

3 LU TB 01- 1 + V( D) F 95 R S1 N
31 40 -24 -C MM M TR MO + W T 10 22 BV ED R 5 ( AS N O
3 H B1 1 L ( ) O C 2 O

TP23
TP22
C 6- L- OM T ST M D T - E A
1 2 3 4 5 6 7 8 9

TP6
A4 25 C M O R O
WHT
R /B 0 23 -C D FR M 4 N
O
17

06 L OM T ST M D ED L 1- L O ) O F 0
-6 -CO M O R OD HTS1200 /B K 24 -C MM TO M S N2) R
CA205 BLK O
TP14

TP13

L- M T ST M LK TB

DTS1
7

K3A
C M O R O M FR GT RS O EV
TP17
O T S M D 4 TB 101 M O S N C
M O T O O

TP21
M SR D B 10 -2 FR M 3,G O
IL
TO T MO 4 LK M 1- 5 + O HT TS +
R W T A 26 B M S 4
ST M D 4 H B1 ST + V( H 25
T
R OD R T T 02 C
E
BV K1 S 1
00
M
O
4 D B - A (K B)
TP16
TP15

D G T 10 1 S BL 1B TO 200
4 R B 2 E E

1 2 3 4 5 6 7 8 9 10 11 12 13
O N 1 - R )F T C
O
4 R TB 02- 2 S IAL 4 R HS
O - M
B G 1 3 E M 3

K2A

K3

K7
TP28
4 LU TB 02 +B RIA + D TH
W T 10 -4 V( L- ISP S-
4 H B 2 L- K D L
T 1 - 1 3
1 2 3 4 5 6 7 8 9
4

K8
R /B 0 5 CO B IS AY
ED L 2- L- M ) P /
TP19

/B K T 7 0 CO M TO LAY STE
6
5
4
3
2
1
1
2

8
7
6
5
4
3
2
1
3

9
8
7
4
3
2
1
4
5

10

CA209
LK B -3 M T D /S E
O
CA206

CA208
CA207

TB 102 .7V M T P ISP TE R

10 -8 PO O LA LA ER
2- +B T PL TF Y
5919

1 1 A O
BLK
BLK

0 55 298 C V
0 0
513

5943 01 09 1 C C
2984
2983
2982

2985
5921

W BL
5901
2901

P- (EDTO TFORM
59 59 29 59 29 50 29 29 29163 HT K 0 C CA A4 A4 OMM
U

NOTES:
C ) TR R
1 P2

A4 40 05 05-
P1

C
C

37 42 87 41 88 1 93 86 CA CA 05 5-1 -4 L 3 + NIC O T A M
C C C C C CA C C 41 417 - A M O C

1 Optional
ED

2 S SE -C BV M H
A4 A4 A4 A4 A4 41 A4 A4 5945 5944 7-2 S-1 S ER RI OM (K1 TION TO EA
06 14 14 14 14 4- 14 14 B ER ER IAL AL+ M T B) S
I - D O T H TE

7 1.25 TL Only.
-1 -8 -6 -5 -4 3 P -2 -1 RA A O

3 TL Mast Only.
IA L

2 Travel Alarms:
9 L + L + - + + K L
DIS IS S EA R
1
2
3

29160

-C BV -C BV CO BV BV E PL PLA TR STR TE S
O (K O (E M (K (E AY Y/ MO M
R
SV4
1

SV3
3
2

29161

M 1 M D M 1 D
29162

M B M ) T B )
/ST ST D OD
R R S
3
2
1

2901
5901
TDM

TO ) F TO TO O ) T TO
SB22

Lift Cutout Is Required.

LE RO R BR BR O B BR

8 Present On Guided Trucks

SB23

VE M ED K K M RK K
4 GRN
GRN
29160

L TH UC MO O M RE
2
3
1

To CA210-3, Insulate Wire 13,

SE S1 E D D O L
5918
2981

4 Height Determined On TT Mast

L 2 D EA
5918
2981

SE
SV2
SV1

LOWER

If Not Equipped With Wire Guidance.

Lead Of 5 To CA214-2 And Install
B) Forward (Forks Last)-Connect White
A) Reverse (Forks First)-Connect White

Lead Of 5 To CA214-3 (Pin 2 Open)

Lead Of 5 To CA214-2 (Pin 3 Open)

6 Install GRN Jumper Wire From CA216-6

SINGLE SPEED

To CA216-7 If A Single "NO OVERRIDE"

Jumper From Pins 2 And 3 As Shown.

5 Install GRN Jumper Wire From CA216-15

SV1

C) Travel (Either Direction)-Connect White

Printed in U.S.A.
DISTRIBUTION PANEL

DIA–7530–044
8882 131363 B
4
3
2
1
 TRACTION CONTROLLER
A B C

CA401 (PCAT) 1
4 1
1 MRC1
5 2
2
TRACTION CONTROLLER
6 3
035 CA212-10 L-COMM FROM DIST PNL 3 SPEED LIMIT 4 INPUT

1 033 CA212-8 L-COMM FROM DIST PNL 4 SPEED LIMIT 2 INPUT

1
<2V = FULL SPEED
034 CA212-9 L-COMM FROM DIST PNL 5 SPEED LIMIT 3 INPUT >2V = LIMITED SPEED

032 CA212-7 L-COMM FROM DIST PNL 6 SPEED LIMIT 1 INPUT

CA402 (PCBT) 1
4 1
201 CA212-5 +BV FROM FU2 1 BATTERY POSITIVE INPUT
0V=OFF, 24V=ON
5 2
2
6 3
2953 F 5928
3

FORWARD CONTACTOR OUTPUT

4
24V=OFF, 0V=ON
5929 REVERSE CONTACTOR OUTPUT
R 5
2955 CA204-3 +BV(K1B) FROM BRS1 24V=OFF, 0V=ON
BYPASS CONTACTOR OUTPUT
1A 5930 6 24V=OFF, 0V=ON

2999
TB403 (TB11)
COMMAND INPUT
101 CA212-2 0-3.7V FROM POT1 (ACCEL) 1 3.7V=OFF, 0V=FULL ON
KEY SWITCH INPUT
2 29101 CA212-1 +BV(ED) FROM FU5 4
0V=OPEN, 24V=CLOSED 2
START SWITCH INPUT
29102 CA212-6 +BV(K1B) FROM BRS1 2 0V=OPEN, 24V=CLOSED
FORWARD SWITCH INPUT
2997 CA212-3 +BV(ED) FROM FS NO 5 0V=OPEN, 24V=CLOSED
SEAT SWITCH INPUT
2996 3 0V=OPEN, 24V=CLOSED
REVERSE SWITCH INPUT
29100 CA212-4 +BV(ED) FROM RS NO 6 0V=OPEN, 24V=CLOSED

CA404 (PCYT)

554 CA406-2 T-COMM TO STR MOD 4 T-COMM OUTPUT 1

8 1
702 CA406-20 +5V TO STR MOD 5 5V OUT
9 2
6
10 3
7
11 4
016 TB606-9 BRUSHWEAR INPUT 8 BRUSH WEAR INPUT
3 12 5
3
015 TB606-7 OVER TEMP INPUT 9 OVERTEMP INPUT
13 6
705 TB606-2 +5V TO TMM 10 5V OUTPUT
14 7
11

12

026 CA406-10 (XMIT) FROM STR MOD 13 TRANSMIT

025 CA406-1 (RCV) TO STR MOD 14 RECEIVE

NOTE:
+

1 PIN ORIENTATION IS SHOWN AS VIEWED

FROM WIRE SIDE OF PLUG.
A1 A2 P T2 N

TRAC M1 FU13
MOTOR

4 4
+

F R

F R 1A

A B C 5500 - EO10100 131364 A

Crown 2000 PF11940-11 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–045 DIA–7530–045
 STEERING
A B C

STEERING MODULE
CA405
009 CA206-3 SERIAL+ DISPLAY/STEER 1 SERIAL+
010 CA206-4 SERIAL- DISPLAY/STEER 2 SERIAL-
2980 CA206-1 +BV(K1B) FROM K1B 3 BATTERY POSITIVE INPUT 24V=ON, 0V=OFF
551 CA206-2 L-COMM FROM DIST PNL 4 BATTERY NEGATIVE INPUT
5
1 CA406
1
025 CA404-14 (RCV) FROM TRAC 1 RECEIVE
554 CA404-4 T-COMM FROM TRAC 2 T-COMM INPUT
532 3 L-COMM OUTPUT
4
028 5 CHANNEL A INPUT
5931 CA210-13 L-COMM FROM RCS2 6 RAISE CUTOUT SWITCH 2 INPUT 5V=OPEN, 0V=CLOSED
5927 CA210-8 P-COMM TO P1- & P2- 7 LIFT CONTACTOR OUTPUT 24V=OFF, 0V=ON
2927 CA210-5 +BV(ED) FROM FU6 K5 5936 8 STEER ENABLE RELAY OUTPUT 24V=OFF, 0V=ON
013 CA210-3 AUTO/MANUAL TO GUID 9 AUTO/MANUIAL OUTPUT 24V=MAN, 0V=AUTO
026 CA404-13 (XMIT) TO TRAC 10 TRANSMIT
710 11 5V OUTPUT
12
13
029 14 CHANNEL B INPUT
5933 CA210-10 L-COMM FROM BRES1 & BRES2 15 BATTERY RESTRAINT INPUT 5V=OPEN, 0V=CLOSED
16
17
5923 CA210-7 P-COMM TO K4- 18 STEER ANGLE RELAY OUTPUT 24V=OFF, 0V=ON
5937 CA209-8 P-COMM TO K7, K8 19 GUIDANCE SPD RED RELAY 24V=NO REDUCE SPD
20 OV=REDUCE SPD
702 CA404-5 +5V FROM TRAC 5V INPUT
2 21 2
22
030 23 INDEX
5938 CA210-11 L-COMM FROM RGS1 & RGS2 24 RAIL GUIDE SWITCH INPUT 5V=OPEN, 0V=CLOSED
5926 CA210-12 L-COMM FROM RCS1 25 RAISE CUTOUT SWITCH 1 INPUT 5V=OPEN, 0V=CLOSED
26
5932 CA210-9 L-COMM FROM HTS180 27 180" SWITCH INPUT 5V=OPEN, 0V=CLOSED
5925 CA210-6 P-COMM TO K2- 28 BRAKE RELAY OUTPUT 24V=OFF, 0V=ON
TB407
028 1
ED-B K5A
532 2
+
029 3 FU10 STEER
ACK30 M2
MOTOR
710 4
030 K5B

CH A
BLU
L-COMM
BLK
ORG
CH B NOTE:
+5VL ECR2 1 OPTIONAL
RED
INDEX STEERING
YEL FEEDBACK
ENCODER
CONNECTOR MODULE

3 3
CA412
CA411

CA413

5
6
2
2
3
4

6
4

4
5
2
3

1
1

5
6

CA417 GUIDANCE MODULE

1 SERIAL +
1
2 SERIAL -
BLU 3 LOAD WHEEL SENSOR BAR +5V
YEL 4 LOAD WHEEL SENSOR BAR BATTERY NEGATIVE
ORG 5 LOAD WHEEL SENSOR BAR SELF TEST
BLK CA207-3 SERIAL +
WHT CA207-4 SERIAL - 6
BRN 7 STEER WHEEL SENSOR BAR COIL 4
LOAD WHEEL SENSOR BAR CA418
BLK 8 LOAD WHEEL SENSOR BAR COIL 6
COIL 5 1 GRN
COIL 6 2 GRN 9 LOAD WHEEL SENSOR BAR COIL 5
BLK
10
BATTERY NEGATIVE 3 YEL
4 11
LOAD WHEEL 12
+5V 5 BLU HARNESS
BLK 13 TACHOMETER CH A
SELF TEST 6 ORG
7 WHT 14 TACHOMETER CH B
COIL 7 RED
BLU 15 STEER WHEEL SENSOR BAR +5V
COIL 8 8 BRN CA416
SS1 16 STEER WHEEL SENSOR BAR BATTERY NEGATIVE
9 RED 1 YEL
TRACTION
TACHOMETER
2 RED 17 STEER WHEEL SENSOR BAR COIL 3
2918 FU7 (SEE POWER PANEL) YEL
519 NEG BUS (SEE POWER PANEL) GRN 3 BRN 18 LOAD WHEEL SENSOR BAR COIL 8
STEER WHEEL SENSOR BAR CA419 4 RED 19 LOAD WHEEL SENSOR BAR COIL 7
BLK
COIL 1 1 GRN 20 BATTERY POSITIVE INPUT
4 COIL 2 2 BLK 21 BATTERY NEGATIVE INPUT
4
BATTERY NEGATIVE 3 YEL RED 22 TACHOMETER +5V
4 BLK 23 TACHOMETER BATTERY NEGATIVE
STEER WHEEL
+5V 5 BLU
HARNESS
24
SELF TEST 6 ORG 25
COIL 3 7 RED ORG 26 STEER WHEEL SENSOR BAR SELF TEST
COIL 4 8 BRN GRN 27 STEER WHEEL SENSOR BAR COIL 1
9 BLK 28 STEER WHEEL SENSOR BAR COIL 2

A B C 6784 045916 A

Crown 2000 PF11940-12 Printed in U.S.A.

DIA–7530–046 DIA–7530–046
 BRAKE MODULE
A B C

1 1

CA414

5942 CA209-7 L-COMM FROM HTS2500 COM 8 TP1 LEVEL SELECT INPUT

7 TP2 REDUCE 1 INPUT (NOT USED)

2987 CA209-6 +BV(K1B) TO K3+ 6 SWITCH OUTPUT

5941 CA209-5 L-COMM FROM HTS1200 COM 5 TP3 REDUCE 2 INPUT

24V INPUT
2988 CA209-4 +BV(ED) FROM FILTER 4
0V=OFF, 24V=ON
501 CA209-3 P-COMM FROM DIST PNL 3 TP4 BATTERY NEGATIVE INPUT

2993 CA209-2 +BV(K1B) FROM K2A 2 TP8 SWITCH INPUT

2986 CA209-1 +BV(ED) FROM DTS NO 1 TP5 BRAKE RELEASE

2 0V=APPLIED, 24V=RELEASE 2

BRAKING FORCE
TRUCK HEIGHT
STEER 1201mm TO
0 TO 2501mm TO
ANGLE 1200mm 2500mm FULL HGT
< 10° FULL 2/3 1/3
> 10° FULL 2/3 1/3

BRAKE MODULE TEST POINTS:

TP1 +12V > HTS2500
TP2 0V
TP3 +12V > 10°
OR > 1200mm
3 3
TP4 BATTERY NEGATIVE
CA415
TP5 +24V TO RELEASE BRAKE
6
TP6 +24V 1/3 BRAKE RELEASED
TP7 +24V 2/3 BRAKE RELEASED 5

YEL 4
INNER COIL (1/3 BRAKING)
ELECTRIC BLU 3 TP6 1/3 BRAKE RELEASE
BRAKE
(BRK1) ORG 2
OUTER COIL (2/3 BRAKING)
WHT 1 TP7 2/3 BRAKE RELEASED

4 4

A B C 5500 - EO10468 131569 A

Crown 2000 PF11940-13 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–047 DIA–7530–047
 TRUCK MANAGEMENT MODULE TMM
A B C

1 1
TMM
(TRUCK MANAGEMENT MODULE)
705 PC404-10 +5V FROM TRAC TB601

5939 1 OVER TEMP 1 IN 0V=OVER TEMP, 5V=OK

1 705 2 5V INPUT 0V=OFF 5V=OK

5939 5940 3 OVER TEMP 2 IN 0V=OVER TEMP, 5V=OK

M1 525 5935 4 OVER TEMP 3 IN 0V=OVER TEMP, 5V=OK

TRAC
MOTOR 2956 2956 5 BRUSH WEAR 1 24V=BRUSH WEAR, 0V=OK

2957 2957 6 BRUSH WEAR 1 24V=BRUSH WEAR, 0V=OK

2 015 7 DATA OUT SEE TABLE

1
2968 8 BRUSH WEAR 2 24V=BRUSH WEAR, 0V=OK
5940
2 016 9 DATA OUT SEE TABLE 2
M3 528
PUMP 2959 10 BRUSH WEAR 2 24V=BRUSH WEAR, 0V=OK
MOTOR 1 2968
2969 11 BRUSH WEAR 3 24V=BRUSH WEAR, 0V=OK
2959
2967 12 BRUSH WEAR 3 24V=BRUSH WEAR, 0V=OK
2 1
13
5935
525 14
M4 527 527
PUMP 528 15 BATT NEG
MOTOR 2 2969 529

2967

2
015 PC404-9
OVER TEMP TO TRAC
016 PC404-8
BRUSH WEAR TO TRAC
3 529 BAT NEG FROM NEGATIVE BUS 3

CONDITION OUTPUT PIN VOLTAGE

M1 QVER TEMP TB601-7 0.70V

NOTE: M3 OVER TEMP TB601-7 1.60V
1 TEMPERATURE SENSOR M4 OVER TEMP TB601-7 2.40V
M1 BRUSH WEAR 1 TB601-9 0.70V
2 BRUSH WEAR SENSOR
M1 BRUSH WEAR 2 TB601-9 0.70V
M3 BRUSH WEAR 1 TB601-9 1.60V
M3 BRUSH WEAR 2 TB601-9 1.60V
M4 BRUSH WEAR 1 TB601-9 2.40V
M4 BRUSH WEAR 2 TB601-9 2.40V

4 4

A B C 6784 044888V

Crown 2000 PF11940-14 Printed in U.S.A.

DIA–7530–048 DIA–7530–048
 FREEZER CONDITION
A B C

1 R/W
29136 RES2
FREEZER/CORROSION 1 R/W
CA807 RGS1
DISTRIBUTION PANEL 29135
1 29137 1 R/W
29138 RES4
2 1 R/W
K12A 29141
BRES1
CA808 3 29142
FU11 1 R/W
24
515 BATT NEG FROM NEGATIVE BUS 1 4 WHT
RES5
1 521 BATT NEG FROM NEGATIVE BUS 2 5
BLK 1 R/W 1
25 29139 BRES2
WHT
29104 +BV(ED) FROM ED-A (R+ FRONT TERM) 3 6 1 R/W
K12B BLK
29140 RES3
29109 +BV(ED) FROM ED-A (R+ FRONT TERM) 4 7 1 R/W
FU12
RGS2
2979 CA215-1 +BV(K1B) FROM DIST PNL 5 8
26
9 WHT
THS-1 RES6
K11A 2 CHS1
10 BLK
BLK WHT
11
RES25
12 CHB5
RES7
K11 K12 CHS2

BLK WHT
NOTES: RES24
1 CHB4
DASHED BOXES CONTAIN OPTIONAL FEATURES.
2 THS-1 SHOWN AT AMBIENT OF 21° C (70° F)
CA215 5° C (40° F) = CLOSED
DISTRIBUTION PANEL
15° C (60° F) = OPEN
3 2994
3 THS-2 SHOWN AT AMBIENT OF 21° C (70° F)
4 2995 50° C (120° F) = CLOSED
60° C (140° F) = OPEN
5 29103 4 WIRED IN THIS MANNER ON TL MAST ONLY.
P-COMM 5 WIRED IN THIS MANNER ON TT ONLY.
2 CA205 7 8 CA204 7 8
6 WIRED IN THIS MANNER ON 1.0 SP ONLY. 2
27
RED
4
GRN
RES18
POWER UNIT HTS1200

TB101
PLATFORM
29123 29121 29119 29117 29115
3 WHT/BLK 25 29111
THS-2 3
3 RED/BLK 26 29112 RES20 RES14 RES13 RES12 RES11 RES10 RES9
DMS1 RS FS HNS RAS/ EDS GTS-R
LOS
29124 29122 29120 29118 29116
TB102
043588-007
29125
4 WHT/BLK 8 29129
29133
29127 RES16 RES26 RES28 RES29 RES27
9 BRS1 LOS3 RAS3 RAS4 LOS4
GRN BRS2 6 6 6
FREEZER 6
4 RED/BLK 29130
CONDITIONING 29126
10
SCHEMATIC 043588-006
29134
29128
ED-A 11 043588-007 043588-008
RED
FU11
FU12 1 R/W
K11A WHT 5 RES19
3 BLK
CHB6 3
K12B 1 R/W
2
BLK 29131
THS-1 K12A RES8
RES2 (GTS-L) WHT 1 R/W
(POWER (RGS1)
29132 5 RES21
UNIT) CHB7
RES9
(GTS-R) 1 R/W
+

RES3
(RGS2) RES10
(EDS) 1 R/W
5 RES15
RES11 CHS3
3 1 R/W
RES4 (RAS/LOS)
THS-2 (BRES1)
(PLAT- RES12
FORM) (HNS) RES8
RES5 RES13 GTS-L
(BRES2) (FS)
RES14
(RS)
RES6
(CHS3) RES15
(CHS1)

RES7 RES16 27
(BRS1,2) RES18
(CHS4)
HTS1200

RES25 RES26
(CHS5) (LOS3)
RES18 RES28
(HTS1200) (RAS3)
RES26 GTS3 OR
(CHS6) RES19 RES29 R3,L3
4 (CHS2) (RAS4) RES22 4
RES20 RES27
(DMS1) (LOS4)
RES21
(CHS7) GTS4 OR
R4,L4
RES22
RES23
(GTS3)
K11 K12 K13
RES23
(GTS4)
1.25 ONLY

A B C 5500 - EO10468 131570 A

Crown 2000 PF11940-15 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–049 DIA–7530–049
 POWER CABLES
A B C

LEFT REAR TERMINAL LEFT REAR TERMINAL

TO BATT + 001 RIGHT FRONT TERMINAL

TO BATT -
1 002
1

ACK30
FU10

ALS175
ALS175
2924

FU8

FU9
DIST PANEL
CA213

ABC15
ACK140

FU7
1 2 3 4 5 6

FU13
2918
2971
2941
2978
202

013
516 P1
517
520
+ - TRAC
MRC1
A1 A2 P T2 N MOTOR

010
A2 A1
003
LIFT LIFT
MOTOR 1 MOTOR 2
2 004 2
NEG

STEERING P2
006 MOTOR
D2 D1
1A R F
BUS

012

009

007
008

005 011

2918
2930
C 2935
K5
2911

NO
NC

2912

2941

1 2 3 4 21 20
3 CA407
STEERING
CA417
GUIDANCE
3
519
518

POWER LEAD ASSEMBLY OR HARNESS

CABLE # DESCRIPTION
NUMBER ALL TRUCKS WIRE GUIDE ONLY
001 043156-004 PC #2/0
002 043156-005 PC #2/0 202 117938
003 084571-227 PC #1 516 117938
004 084571-223 PC #1 517 117938
005 084571-228 PC #1 518 117938
006 084571-224 PC #1 519 126816
007 084571-225 PC #1 520 117938
008 084571-224 PC #1 2918 126816
009 084571-232 PC #1 2971 117938
010 084571-229 PC #1 2978 117938
011 084571-230 PC #1 2930 117938
012 084571-231 PC #1 2935 117938
013 084571-234 PC #1

NOTES: 2941 117938

4 1 THE GUIDANCE MODULE AND FU7 ARE PRESENT 4
ONLY ON WIRE GUIDED TRUCKS.
2911 090963-026
2 P2, LIFT MOTOR 2, FU9, AND CABLES 011 THRU 013 2912 090963-027
ARE PRESENT ONLY ON HIGH PERFORMANCE LIFT TRUCKS. 2924 090963-028

A B C 6784 045917 A

Crown 2000 PF11940-16 Printed in U.S.A.

DIA–7530–050 DIA–7530–050
 WIRE HARNESSES

Harnesses Components Connected By:

044981 DMS1 Two Handed Control, TB102

044982 Override Switch, TB102
117859 Lift/Lower One Speed Power Unit
117895 To Overhead Guard Left from TB101, TB102
117896 To Overhead Guard Right from TB101, TB102
117897 Switch Panel
117901 Display Module/Service Terminal
117908 Horn/Brake/Chain Switches (TT)
117927 Overhead Guard Left-Dome Light, Worklight, TB502, PS1, PS2
117928 Overhead Guard Right-SB30, Dome Light, Worklight, Fan
117931 Brake Module
117932 Lift/Lower Two Speed Power Unit
117938 Main Power Unit Harness
117944 Horn/Brake
118842 Strobe Light
118844 Truck Management Module-TB601
118845 Service Terminal
119274-001 Freezer/Condition Battery Restraint Switches 1 & 2 and Rail Guide
Switches 1 & 2 Heaters
119274-002 Freezer/Condition Two Handed Control Switch Heater
119275-001 Freezer/Condition Chain Slack Switches 3 & 4 Heaters
119276-001 Freezer/Condition Thermostat 2-TB101
119277 Freezer/Condition Battery Restraint Switch 2 & Rail Guidance Switch 2 Heater
119278 Freezer/Condition Battery Restraint Switch 1 & Rail Guidance Switch 1 Heater
119279 Freezer Condition Main
119280-001 Freezer/Condition Gate Switches 1 & 3 (1.0SP) Heaters
119281-001 Freezer/Condition Chain Break Switches 6 & 7 Heaters and Brake Switch Heater
119282-001 Freezer/Condition Control Pod & Gate Switches 2 &4 (1.0SP) Heaters,
Gate Switches 1 & 2 (1.25SP) Heaters
122569 Two Handed Control Switch (DMS1)
125157 Traction Panel TB403, F, R, 1A, CA401 (PCA, CA402 (PCB), TB403 (TB11)
To CA212
126816 Guidance Module CA417 To CA207, CA416, CA418, CA419
126969 Steering Module

Crown 2000 PF11940-17 Rev. 4/03 Printed in U.S.A.

01 REV. 4/03
DIA–7530–051 DIA–7530–051
 PLATFORM
4259

Two Handed
Control Switch
(DMS1) Control Panel 044982
122569
GTS1, GTS3
119280-001
GTS2, 044981
GTS4

TB101 TB102

119282-001
Travel Alarm
THS2
119276-001
Brake Switch
Assembly
(BRS, THS3) CHS3, CHS4
CHB6, CHB7

119275-001

119281-001

Crown 2000 PF11940-17 Printed in U.S.A.

DIA–7530–051-SUP-1 DIA–7530–051-SUP-1
 PLATFORM
4257

117928

CA503

CA501
117927
117896

117895 117901
DMS1
118845
119274-002
CA303
CA301

TB101 117897 119277 L.H.

TB102
117908 (TT) 119278 R.H.
117944 (TL)
Battery Retainer
BRES1, BRES2 119274-001
Resistors

Rail Guide
RGS1, RGS2
Resistors

119274-001

Crown 2000 PF11940-17 Printed in U.S.A.

DIA–7530–051-SUP-2 DIA–7530–051-SUP-2
 POWER UNIT
4258-01
118842

Strobe Light
SB21

117859 1 Speed Lower

Distribution Panel
117932 2 Speed Lift/Lower
!W
AR
Th
brais
ketruck
sw s or
NIN
Wa
vehrn
itc
Ste h is trave
eri in
do
es
ng the cotntr
G
l no
ha
olve
hapiclethe
pus ma
cau pen
tion that To
hing y no w
. and an
wh
to accor Po en
tow t wo sit
useiden
ing
extrt cou rk. ionTow
eme ld .

Driv
e

119279

Lift/Power
YE

125157
GRL FA
TP N ULT
PO
1 W
ER
TP
2

Panel
TP
3
TP
4
TP
8
TP
5
BR
P AK
RE/ N 11
E
M
V.– 75OD
98 ULE

TP
6
TP
7

117931

126816

118844

117938 Wire Guidance

A1
B+
A2
B-

126969
Traction Panel

Wire Guidance Module

Crown 2000 PF11940-17 Printed in U.S.A.

DIA–7530–051-SUP-3 DIA–7530–051-SUP-3
 C POWER UNIT
10519

Part of 19
Main Frame
18 B
15 B
12

17 A

16
14
Part of 12
13
Power Unit
13

20
A
11

21
11 10

21

2
7

Crown 2003 PF13575 Printed in U.S.A.

01.0–7532–001 01.0–7532–001
 C POWER UNIT

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 130656-004 Power Unit 1 11 060016-015 Screw 2

2 130440 R.H. Door 1 060005-008 Lockwasher 2
3 130439 L.H. Door 1 060021-009 Nut 2
4 115453 Latch Screw 2 12 117910 Prop Bar 1
5 * L.H. Skid (Shown) 1 060038-006 Cotter Pin 1
6 * Screw 13 130938 Retainer 2
* Screw 060014-059 Screw 2
* Flatwasher 060042-016 Nut 2
* Lockwasher 14 130900-001 Edge Trim 1
* Nut 15 130821 Wire Cover 1
7 117674 L.H. Hinge (Shown) 1 16 060031-012 Nut 2
117675 R.H.Hinge 1 17 060016-015 Screw 1
8 060017-027 Screw 4 18 060016-031 Screw 1
060030-026 Flatwasher 4 19 130544-001 Gray Top Cover 1
060005-009 Lockwasher 4 130544-003 Beige Top Cover 1
9 * 130209-001 L.H. Narrow Battery Cover 1 20 060016-015 Screw 2
* 130302-001 L.H. Wide Battery Cover (Shown)1 060021-073 Nut 2
* 130208-001 R.H. Narrow Battery Cover 1 21 060016-028 Screw 2
* 130437-001 R.H. Wide Battery Cover 1 060005-008 Lockwasher 2
10 118328 Guide 1 060021-009 Nut 2

Always Specify Model, Data & Serial Numbers

030501 5476/5783

Printed in U.S.A.

01.0–7532–002 01.0–7532–002
 C POWER UNIT

Index 5 Index 6

Model Model
R.H L.H. Screw Qty. Flatwasher Qty. Lockwasher Qty. Nut Qty.
1.25SP 1.0SP
Up To Up To
118506-001 118506-002 060020-031 4 060030-058 AR 060005-014 AR 060021-015 4 7010 mm 6860 mm
Lift Height Lift Height
7035 mm 6885 mm
060020-026
& Up To & Up To
120056-001 120057-001 (100 mm AR 060030-058 8 060005-014 8 060021-015 8
7925 mm 8230 mm
Long)
Lift Height Lift Height
7950 mm 8255 mm
060020-034
& Up To & Up To
120056-002 120057-002 (85 mm AR 060030-058 8 060005-014 8 060021-015 8
8385 mm 8685 mm
Long)
Lift Height Lift Height
060020-033
(70 mm AR 060030-058 8 060005-014 8 060021-015 8
Long)
8405 mm 8710 mm
& Up To & Up To
120056-003 120057-003 060020-015 4 060030-106 4 060005-014 4 060021-015 4
9300 mm 9600 mm
Lift Height Lift Height

Crown 2003 PF13575 Printed in U.S.A.

01.0–7532–001-SUP 01.0–7532–001-SUP
This page available for NOTES.
 C BATTERY/RETAINERS
10876

8 4

RK
FO ND
E

6 5

C
C
18 D
6
7 17

B
D
19
19

14 16
7
11

12 12 11
9 B
16

13 15
13
BRES2 15
2 BRES1 10
14
A
3

1
20

Crown 2003 PF13574 Printed in U.S.A.

01.2–7532–001 01.2–7532–001
 C BATTERY/RETAINERS

Index Part No. Part Name No. Req.

1 130552 Roller Assembly

Includes Index 2 8
130189 Roller 1
2 065007-017 Bearing Sleeve 2
3 130474 Shaft Roller 4
4 118041 Drip Panel R.H. 1
5 118043 Drip Panel L.H. 1
6 111594 Foam Tape 1
7 Retainer See Section 1.0 2
8 130578 Side Cover Sleeve 4
9 118045-002 Switch Mount R.H. 1
10 118045-001 Switch Mount L.H. 1
11 130808-001 Switch Lever L.H. 1
130808-002 Switch Lever R.H. 1
12 060031-005 Nut 2
13 077656 Switch BRES1, BRES2 2
075585 Switch Seal 2
14 092143 Fastening Plate 2
15 060012-008 Screw 4
060005-048 Lockwasher 4
16 060016-036 Screw 4
060005-008 Lockwasher 4
060030-017 Flatwasher 4
17 119218 Block 2
18 060016-004 Screw 2
060021-009 Nut 2
19 119219-001 Screw 2
20 * 041963 Battery 516 Amp Hour 1
* 041964 Battery 594 Amp Hour 1
* 041962 Battery 688 Amp Hour 1

Always Specify Model, Data & Serial Numbers

Battery Size 910 x 360 mm

030501 5477

Printed in U.S.A.

01.2–7532–002 01.2–7532–002
 C HYDRAULIC SYSTEM - MAST
10850

4
5 3 TL MAST

2
1
Part of
Power 6
Unit
15
3 7
14 8

15 9
From
Power Unit

4
5 3

2
1 12
Part of 11
Power 6
Unit 13 2
15

3 7 10
14
8
15 7 TT MAST
From
Power
Unit

Crown 2003 PF13595 Printed in U.S.A.

02.0–7530–104 02.0–7530–104
 C HYDRAULIC SYSTEM - MAST

Index Part No. Part Name No. Req.

1 131221 Tube 1
2 064030-008 Nut Bulkhead TL 1
064030-008 Nut Bulkhead TT 2
3 060021-011 Nut 2
060005-009 Lockwasher 2
060017-007 Screw 2
4 130674 Bracket 1
5 064034-005 Bulkhead Fitting 1
6 064257-100 Hose 1
7 064071-003 Tee TL 1
064071-003 Tee TT 2
8 064257-101 Hose 1
9 064090-003 Connector 1
10 * Next Page Hose 1
11 064034-005 Bulkhead Fitting 1
12 117561 Tube 1
13 064061-005 Elbow 1
14 061002-015 Clamp Harness 1
15 060015-006 Screw 1
060005-007 Lockwasher 1
060021-006 Nut 1

Always Specify Model, Data & Serial Numbers

030715 5710 - EO9837

Printed in U.S.A.

02.0–7530–105 02.0–7530–105
 C HYDRAULIC SYSTEM - MAST

Hose SP3011 & SP3021(1.25) & SP3012 & SP3022(1.0) TT Mast

1.25SP 1.0SP
Collapsed Height Lift Height Lift Height
Index 10 mm mm mm
064257-092 2325 4955 5715
064257-093 2415 5335 6095
064257-094 2720 6095 6860
064257-095 3025 7010 7770
064257-145 3175 7470 8230
064257-096 3330 7925 8685
064257-097 3635 8385 9145
064257-146 3785 8840 9600
064257-098 3940 9300

Crown 2003 PF13595 Printed in U.S.A.

02.0–7530–104-SUP 02.0–7530–104-SUP
This page available for NOTES.
 C HYDRAULIC SYSTEM - MAST
10848

WITH LIFTING FORK

1.0SP
10
TL Only

16

Part Of
4 Platform
Part of
Power Unit 16 5 3
18
F on 2
Manifold 1
TL MAST
6
Part of 1
Power Unit TT MAST
3 7
1 8
1 9

From Power
Unit
1.0SP
TT Only
22

17

21 Part Of
Platform
16
4
Part of 16
Power Unit 5 3 19
20
2 12
F on 1
Manifold 11
6 13 2
Part of 1
Power Unit
3 7 23
1 8
1 7
From
Power
Unit

Crown 2003 PF13618 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
02.0–7530–604 02.0–7530–604
 C HYDRAULIC SYSTEM - MAST

Index Part No. Part Name No. Req.

1 131221 Tube 1
2 064030-008 Nut Bulkhead TL 1
064030-008 Nut Bulkhead TT 2
3 060021-011 Nut 2
060005-009 Lockwasher 2
060017-007 Screw 2
4 130674 Bracket 1
5 064034-005 Bulkhead Fitting 1
6 064257-100 Hose 1
7 064071-003 Tee TL 1
064071-003 Tee TT 2
8 064257-101 Hose 1
9 064090-003 Connector 1
10 * Next Page Hose 1
11 064034-005 Bulkhead Fitting 1
12 117561 Tube 1
13 064061-005 Elbow 1
14 061002-015 Clamp Harness 1
15 060015-006 Screw 1
060005-007 Lockwasher 1
060021-006 Nut 1
16 064034-001 Bulkhead Fitting 1
064030-002 Nut Bulkhead 1
17 120077 Guide TT 1
18 118513 Bracket TL 1
060017-014 Screw 3
060005-009 Lockwasher 3
060021-011 Nut 3
19 119659 Guide Weld 1
20 060017-032 Screw 4
060005-009 Lockwasher 4
060021-011 Nut 4
061004-023 Adhesive Thread Locking AR
21 119663 Plate 1
22 * Next Page Hose 1
23 * Next Page Hose 1

Always Specify Model, Data & Serial Numbers

*See the following supplemental chart

030715 6507

Printed in U.S.A.
01 REV. 9/03
02.0–7530–605 02.0–7530–605
 C HYDRAULIC SYSTEM - MAST

Hose SP3012 & SP3022(1.0) TL Mast

Collapsed 1.0 SP
Height Lift Height
Index 10 mm mm
064255-107 2325 4215
064255-103 2415 4520
064255-109 2720 5130
064255-224 3025 5690
064255-316 3330 6200

Hose SP3011& SP3021(1.25) & SP3012 & SP3022(1.0) TT Mast

1.25SP 1.0SP
CollapsedHeight Lift Height Lift Height Model
Index 22 Index 23 mm mm mm
064257-092 2325 4955 1.0 & 1.25SP
064255-316 2325 5715 1.0SP Only
064257-093 2415 5335 1.0 & 1.25SP
064255-317 2415 6095 1.0SP Only
064257-094 2720 6095 1.0 & 1.25SP
064255-318 2720 6860 1.0SP Only
064257-095 3025 7010 1.0 & 1.25SP
064255-198 3025 7770 1.0SP Only
064257-145 3175 7470 1.0 & 1.25SP
064255-200 3175 8230 1.0SP Only
064257-096 3330 7925 1.0 & 1.25SP
064255-230 3330 8685 1.0SP Only
064257-097 3635 8385 1.0 & 1.25SP
064255-360 3635 9145 1.0SP Only
064257-146 3785 8840 1.0 & 1.25SP
064255-361 3785 9600 1.0SP Only
064257-098 3940 9300 1.25SP Only

Crown 2003 PF13618 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
02.0–7530–604-SUP 02.0–7530–604-SUP
This page available for NOTES.
This page available for NOTES.
 C MANIFOLD
5930-01
TWO SPEED LIFT
TP
ACC

P1 C
CV2 SV2
CV1
FC2
RV1 5 GPM

FC1
5 GPM MV1
CV3
SV1
P2 CV4

21

4
2 3

21

26
T

27
8
7
5 6 22
MV 23
24
C

9 SV 25
10 2 C
11 SV AC 21
1
2 16
1 FC 15
12 CV CV FC 14
2 4 1
CV 13
16 CV
3
15 21
14 RV 22 25
13 23
20 24
19
18
17
P1 16
15
14
P2
21 13

21

Crown 1996 PF10936-1 Rev. 11/04 Printed in U.S.A.

04 REV. 11/04
02.4–7330–052 02.4–7330–052
 C MANIFOLD

118943 MANIFOLD

Index Part No. Part Name No. Req.

1 117739 Valve Needle MV 1

118944 Kit Seal Includes 2, 3 & 4 1
106845-002 Disc Orifice 1
2 O-Ring 1
3 O-Ring 1
4 Back-Up Ring 1
5 107412 Valve Solenoid SV2 Includes
6, 7 & 8 1
104164-002 Coil 24 V 1
111790 Kit Seal Includes 6, 7 & 8 1
6 O-Ring 1
7 O-Ring 1
8 Back-Up Ring 1
9 Back-Up Ring 1
10 O-Ring 1
11 O-Ring 1
12 117304-001 Valve Solenoid SV1 Includes
9, 10 & 11 1
104164-008 Coil 20 V 1
118398 Kit Seal Includes 9, 10 & 11 1
13 117380 Valve Check CV1, 2, 3 & 4
Includes 14, 15 & 16 4
118398 Kit Seal Includes 14, 15 & 16 4
14 064019-045 O-Ring 4
15 064019-042 O-Ring 4
16 064074-020 Back-Up Ring 4
17 117913 Valve Relief RV Includes
18, 19 & 20 1
118398 Kit Seal Includes 18, 19 & 20 1
18 064019-045 O-Ring 1
19 064019-042 O-Ring 1
20 064074-020 Back-Up Ring 1
21 064091-006 Plug Internal w/O-Ring 6
22 Back-Up Ring 2
23 O-Ring 2
24 O-Ring 2
25 123704-001 Flow Regulator FC1 & FC2
Includes 22, 23 & 24 2
125169 Package Seal Includes
22, 23 & 24 1
26 117604 Block Manifold 1
27 122822 Module Time Delay TDM 1
060013-003 Screw 2
060005-004 Lockwasher 2

Always Specify Model, Data & Serial Numbers

960715 9664

Crown 1996 PF10936-2 Rev. 11/04 Printed in U.S.A.

04 REV. 11/04
02.4–7330–053 02.4–7330–053
 C DRIVE UNIT
8858-01

56 A 26
40
41
55 31
27
40
54
Traction Motor 48 39
See Section 03.1 30
53 42
38
44 29
52 37
43
51 28 35

50 45
27 34

63 43 33
5 26
44 32

49 36
42 24
48 22
47 21 25
Part of
Power Unit 59
46

18
69 17 23
A 62 64
60 21
61
68 66 20
70 19 4
65 58
62

67
10
16
2 57
15 3
14
13 7
12
11
9
8

6 Traction Tire -
See Section 03.2

Crown 2001 PF13147-1 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
03.0–7330–003 03.0–7330–003
 C DRIVE UNIT

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 129431 Housing Drive Unit 1 36 061008-004 Key Woodruff 1

2 060017-010 Screw 2 37 060044-005 Lockwasher 1
060005-009 Lockwasher 2 38 060043-005 Locknut 1
3 064091-005 Plug 1 39 083501 Gasket 1
4 128447-001 Cover 1 065005-002 Sealer Gasket AR
060016-031 Screw 7 40 086618 Cover 1
060005-008 Lockwasher 7 060016-030 Screw Tighten to 20 - 27 Nm
5 065081-065 Bearing 1 (15 - 20 ft. lbs.) 4
6 078885-001 Lug Bolt 8 061004-013 Adhesive Thread Locking 1
7 083500 Gasket 1 060005-037 Lockwasher 4
8 127974 Axle Includes Index 19 1 41 064020-004 Plug Vented Pipe 1
9 087412 Seal 1 42 083531 Spacer 2
065005-001 Gasket Sealer AR 43 060009-039 Ring Retaining 2
10 060015-053 Screw 5 44 065081-003 Bearing Ball 2
11 060000-005 Roll Pin 2 45 086016 Gear Idler 1
12 087461 Retainer Seal 1 46 086015 Shaft Idler 1
065005-001 Sealer Gasket AR 47 064019-061 O-Ring 1
13 087408 Gasket 1 48 064019-033 O-Ring 2
14 065024 Bearing Cone 1 49 085581 Retainer 1
15 065023 Bearing Cup 1 50 085586 Shaft Pinion 1
16 083513 Cam 1 51 065081-032 Bearing Ball 1
17 065018 Bearing Cup 1 52 085580 Retainer 1
18 065019 Bearing Cone 1 061004-004 Adhesive Thread Locking 1
19 128941 Hub Includes Index 8 1 53 085928-001 Shim 0.20 mm (.008 in.) AR
065005-003 Anti-Seize 1 085928-002 Shim 0.25 mm (.010 in.) AR
20 089248-001 Shim 0.13 mm (.005 in.) AR 085928-003 Shim 0.33 mm (.013 in.) AR
089248-002 Shim 0.18 mm (.007 in.) AR 54 085927 Spacer 1
089248-003 Shim 0.51 mm (.020 in.) AR 55 064138-003 Seal Oil 1
21 128297 Gear and Pinion Matched 1 56 060009-097 Ring Retaining 1
22 128725 Locknut 1 57 064020-003 Plug Pipe 1
23 078885-003 Bolt 7 061004-005 Adhesive Thread Locking 1
061004-004 Adhesive Thread Locking 1 58 128942 Nut Preload 1
24 110559 Screw Cap 2 59 131101 Locking Bolt 1
25 089239-001 Wire Lock 60 065014-001 Bearing Thrust 1
Cut to Length Required 1 61 061011-020 Pin Dowel 2
26 065052 Bearing Cone 2 62 065015-001 Race Bearing 2
27 065051 Bearing Cup 2 63 060018-005 Screw 4
28 083514 Spacer 1 060005-043 Lockwasher 4
29 083516-001 Shim 0.20 mm (.008 in.) AR 64 065013-004 Bearing Needle 1
083516-002 Shim 0.25 mm (.010 in.) AR 65 065063-003 Bearing Inner Race 1
083516-003 Shim 0.33 mm (.013 in.) AR 66 085582 Seal Felt 1
30 083517 Retainer Bearing 1 061001-015 Adhesive 1
31 060016-004 Screw 6 67 117793 Stud 1
060005-008 Lockwasher 6 68 060023-010 Bolt 4
32 083511 Flatwasher Special 1 061004-010 Adhesive Thread Locking AR
33 060044-006 Lockwasher 1 69 061011-004 Pin Dowel 2
34 060043-006 Locknut 1 70 064198-002 Plug Drain 1
35 087386 Gear 1st Reduction 1 061004-005 Adhesive Thread Locking AR

Always Specify Model, Data & Serial Numbers

010305 7444 - EO10977

Crown 2001 PF13147-2 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
03.0–7330–004 03.0–7330–004
 C DRIVE TIRE
10057-01

Hub
Tire (Size -
330 x 140 x 205 mm)
13 x 5.5 x 8 in.

Lug Bolt 1
4 5

7 8

3 2
0

6
0

Finger Tighten Lug Bolts Then

Torque to 135 to 150 Nm
(100 to 110 ft. lbs.) In Sequence As Shown

Crown 2002 PF13472-1 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
03.2–7332–001 03.2–7332–001
 C DRIVE TIRE

‡ TIRE *TIRE
HUB † LUG BOLT TREAD COMPOSITION/COLOR
ASSEMBLY (See Note)
087880-003 087391 078885-001 079266-030-01 Smooth Poly/Black
087880-009 087391 078885-001 079266-040-01 Smooth Poly/Non-Marking/Cream
087880-014 087391 078885-001 079266-030-02 Center Groove Poly/Black
087880-015 087391 078885-001 079266-030-03 22° Siped Poly/Black
087880-016 087391 078885-001 079266-030-04 Razor Siped Poly/Black

‡ Includes Tire And Hub.

† Quantity of 8 Lug Bolts Per Tire.
Choice of first dash number depends on drive tire application. Refer to chart below when ordering tire.

First Dash No. Application

-030 Medium cut/tear resistance, highest capacity of our softer compound tires, good ride
and traction.
-040 Very similiar to the -030 but with even higher capacity.

021231 7436

Crown 2002 PF13472-2 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
03.2–7332–002 03.2–7332–002
 C ELECTRICAL COMPONENTS - POWER UNIT
10881-01

Two Speed Lift

27 SB20
SS1
28 See
24 30
Section 02.4 LGT1
M3 & M4
27 2
25 19

29 SB21 5

T
C
MV
SV
2 C
AC

26 CV
RV
1
2
SV

CV
3
1 FC

CV
2
2

P2
FC
1

3
M1
RV
1

29
SV SV
4 3 P1

TDM 16
16
4
5
HN2
6
11
8 12
E 12 C
M2 1
23 17
10
21
G C
9 See
Section 02.4
F 27
14
T

15
C

D
C
C
A

E
17 B 27
18
F
One Speed Lift
G D
!W
Th
br AR
sw
St is NING
ak
W
ar itces
tru
caee
ve
ha n th
hic T
ow
h is
ck
pprin
ut or
do
leegpu
ion
en Po
Ttra
ow
in
m es
.th
an sit
thve
ay
atsh
Dr e
ion
l no
dive
aning
no co
. tntha
to actorwo
us rove
cid
e tork l
ex wi. when
en
tretng
co
meuld

13
17
A1
B+
A2
B-
A
7
22
20
15

B 20
22 M3
Y
T EGLR
TP 1 NP
25
TP2

A
OW

14
TP
P3 ER
TP 4
TP8
BR5
AK
TP E
MO

26
TP 6
7 DU
LE

Crown 2003 PF13576 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.0–7532–001 04.0–7532–001
C ELECTRICAL COMPONENTS - POWER UNIT

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 065004-037 Grommet 2 17 Traction Panel

2 * 112951-001 Strobe Light (See Section 04.9) (See Section 04.1) 1
LGT1 1 060017-077 Screw 6
* 101458 Flashing Light (See Section 04.9) 060005-054 Lockwasher 6
LGT1 1 060021-011 Nut 6
3 130724-001 Strobe Light Cover Black 18 Steering Feedback
Includes SB21 1 (See Section 04.8) 1
130724-002 Strobe Light Cover Beige 19 Brake (See Section 05.3) 1
Includes SB21 1 20 * Aisle Guide Wheel Switch
4 * 061011-003 Dowel Pin Two Speed Lift 5 (See Section 10.0) 2
5 130715-002 Flashing Light Support 1 060020-026 Screw 100 mm Long AR
060016-003 Screw 4 060020-034 Screw 85 mm Long AR
060005-008 Lockwasher 4 060020-033 Screw 70 mm Long AR
060030-017 Flatwasher 4 060030-058 Flatwasher 8
6 * 116253 Plate Clamp Two Speed Lift 1 060005-014 Lockwasher 8
7 102126-002 Grounding Strap 1 060021-015 Nut 8
060016-003 Screw 1 21 * Wire Guide Module
060005-008 Lockwasher 1 (See Section 04.3) 1
060030-294 Flatwasher 1 060016-018 Screw 2
8 * 060017-007 Screw 25 mm Long 060005-008 Lockwasher 2
Two Speed Lift 2 22 * Wire Guide Sensor
060005-009 Lockwasher 2 (See Section 04.3) 2
060030-026 Flatwasher 2 060016-003 Screw 2
9 043271-003 Connector 1 060005-002 Lockwasher 2
10 060015-062 Screw 2 23 Servo Motor M2
060005-006 Lockwasher 2 (See Section 06.2) 1
060021-006 Nut 2 060017-010 Screw 4
11 * 115565 Travel Alarm HN2 1 060005-009 Lockwasher 4
12 060015-054 Screw 2 24 * Sensor Bearing Assembly SS1
060005-007 Lockwasher 2 (See Section 05.3) 1
060030-092 Flatwasher 2
060021-006 Nut 2 *One Speed Lift
13 Distribution Panel 25 Pump Motor M3
(See Section 04.3) 1 (See Section 02.2) 1
14 * Lift/Power Panel 26 060017-027 Screw 20 mm Long 4
(See Section 04.3) 1 060005-009 Lockwasher 4
060017-077 Screw 3 060030-026 Flatwasher 4
060005-054 Lockwasher 3 27 Manifold Block
060021-011 Nut 3 (See Section 02.4) 1
15 Battery Retainer Switch 060017-006 Screw 2
(See Section 01.2) 2 060005-009 Lockwasher 2
060016-036 Screw 4
060005-008 Lockwasher 4
060030-017 Flatwasher 4
16 * Drive Motor M1
(See Section 03.1) 1
060018-005 Screw 4
060005-043 Lockwasher 4

Printed in U.S.A.
01 REV. 9/03
04.0–7532–002 04.0–7532–002
 C ELECTRICAL COMPONENTS - POWER UNIT

Index Part No. Part Name No. Req.

*Two Speed Lift

25 Pump Motor M3 & M4
(See Section 02.2) 2
26 060017-021 Screw 15 mm Long 3
060005-009 Lockwasher 3
060030-026 Flatwasher 3
27 Manifold Block
(See Section 02.4) 1
060017-006 Screw 2
060005-009 Lockwasher 2
28 * 086322 Suppressor SB20 1
060013-003 Screw 2
060005-004 Lockwasher 2
29 * 122822 Time Delay Module TDM 1
060013-003 Screw 2
060005-004 Lockwasher 2

30 * 118898 Strobe Light Cover 1

060014-015 Screw 2
060005-045 Lockwasher 2
060030-217 Flatwasher 2

Always Specify Model, Data & Serial Numbers

030501 6499

Printed in U.S.A.
01 REV. 9/03
04.0–7532–003 04.0–7532–003
This page available for NOTES.
 TRACTION PANEL
10276

42 25

41

8 9

Distribution Panel
See Section 04.3 6

12 38

10
SB22 11 7
1
!W
AR
NIN
G
TMM
A Module
9 13

B
2
C

Transistor 39
Traction Panel C
See Section 04.2 4
24 5
A
35 F&R
3 21
35 E
D E
22 B
23
23
28
29 1A 18 40
K5
17
27
F 19
20

A1
B+
26
A2
B-
33 D
30 31
37 14
16
34 Steering
Module 15
F

32 36
16

Crown 2002 PF13353 Printed in U.S.A.

04.1–7530–003 04.1–7530–003
 TRACTION PANEL

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 125155 Panel 1 23 060063-006 Screw 2

2 129688 Transistor Panel 060005-008 Lockwasher 2
See Section 4.2 1 24 060015-003 Screw 2
093983 Heat Sink Compound 1 060005-007 Lockwasher 2
3 060017-010 Screw 2 25 060005-008 Lockwasher 2
060030-026 Flatwasher 2 060021-009 Nut 2
060005-009 Lockwasher 2 26 060013-005 Screw 2
4 060030-026 Flatwasher 1 060005-004 Lockwasher 2
060005-009 Lockwasher 1 27 118428 Standoff 2
5 118435 Standoff 1 28 060005-007 Lockwasher 2
6 119751 Support Panel 1 29 118431 Cover 1
7 060016-036 Screw 2 30 060015-082 Screw 2
060005-008 Lockwasher 2 31 117900 Steering Module 1
8 119748 Plate 1 093983 Heat Sink Compound 1
9 060016-003 Screw 3 32 060015-016 Screw 4
060005-008 Lockwasher 3 060005-007 Lockwasher 4
10 118356 Terminal Block SB22 1 33 060016-004 Screw 3
11 060013-011 Screw 2 060005-008 Lockwasher 3
060005-004 Lockwasher 2 060030-265 Flatwasher 3
12 119474 Distribution Panel 34 060017-007 Screw 1
See Section 4.3 1 060005-009 Lockwasher 1
13 117946 Truck Management Module 060030-233 Flatwasher 1
TMM 1 35 125158 Bus Bar 1
14 078953-002 Standoff 2 060030-017 Flatwasher 1
15 118427 Bus Bar 1 36 125159 Bus Bar 1
16 060015-012 Screw 4 060030-017 Flatwasher 1
060005-007 Lockwasher 4 37 118430 Bus Bar 1
060030-012 Flatwasher 4 38 060017-077 Screw 6
17 110613-001 Contactor 1A 060005-054 Lockwasher 6
See Section 4.4 1 060021-011 Nut 6
18 118426 Contactor Mount 1 39 060013-020 Screw 2
19 060061-006 Screw M5 4 060005-004 Lockwasher 2
060030-217 Flatwasher 4 40 100326 Relay K5 1
060005-005 Lockwasher 4 41 119750 Clamp Plate 1
20 060015-003 Screw 2 42 119253 Clamp Base 1
060005-007 Lockwasher 2
21 111634 Contactor F/R Always Specify Model, Data & Serial Numbers
See Section 4.4 1
060065-004 Screw M4 4 090963-026 Cable Assembly Red/White #2911 1
22 125196 Bus Bar 1 090963-027 Cable Assembly Red/White #2912 1

020401 2908 - E07746

Printed in U.S.A.

04.1–7530–004 04.1–7530–004
 TRANSISTOR PANEL
5413-01

14
25
28 D
3 22

B 15
20

6 31
1 24
25 C
23
21 17
5
26
30
18
29
19 A
B
8
C
D 29 2
28 28 A 4
26 7

16 6
11
9
Part Of 23 25
Index 5 27

13

10 26

12
27 23

Part Of
Index 4
27
Crown 2002 PF13348 Rev. 9/02 Printed in U.S.A.
01 REV. 9/02
04.2–7330–003 04.2–7330–003
 TRANSISTOR PANEL

129688 TRANSISTOR PANEL ASSEMBLY

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 118960 Base 1 23 050010-020 Lockwasher 4

2 118962 Heat Sink 1 050009-018 Flatwasher 4
3 118963 Flexible Bus 3 103327 Nut M8 4
4 118964 Snubber Assembly 1 24 118980 Screw M5 3
5 118964 Snubber Assembly 1 050010-010 Lockwasher 3
6 118965 Double Terminal Post 2 050009-007 Flatwasher 3
7 118966 Bus Bar 1 077357 Insulating Sleeve 3
8 118967 Bus Bar 1 25 103025 Screw M5 4
9 118968 Bus Bar 1 26 118982 Bolt M6 8
10 118969 Bus Bar 1 050010-015 Lockwasher 8
11 118970 Flexible Bus 3 050009-012 Flatwasher 8
12 118970 Flexible Bus 3 27 118986 Bolt M6 6
13 118971 Capacitor 2 050010-015 Lockwasher 6
14 123672 Oscillator Card 1 050009-012 Flatwasher 6
15 118973 Capacitor Support Lower 1 28 118983 Bolt 4
16 129689 Transistor 1 118984 Lockwasher 4
17 118975 Insulation 1 118985 Flatwasher 4
18 118976 Diode Module 1 29 118987 Screw M4 2
19 118977 Diode Module 1 050010-006 Lockwasher 2
20 118978 Capacitor Support 2 30 050006-035 Screw M8 1
21 118979 Shunt Wire/Current Assembly 1 050010-020 Lockwasher 1
118961 Current Shunt 1 050009-018 Flatwasher 1
22 118981 Screw M5 1 31 118989 Screw M5 1
050010-010 Lockwasher 1 050010-010 Lockwasher 1
050009-007 Flatwasher 1 050009-007 Flatwasher 1

Always Specify Model, Data & Serial Numbers

020401 3892 - EO7303

Printed in U.S.A.
01 REV. 9/02
04.2–7330–004 04.2–7330–004
This page available for NOTES.
 DISTRIBUTION PANEL
10274

CA201

4
11 CA202

CA203
CA216
CA204

CA205
CA215

12 13 7
FU1 CA214 CA206
FU2
5 FU3
FU4 DTS1 CA207
FU5
FU6 14
K1 K7
CA213 CA208
K2
2 14
CA212
K8 CA209
CA211
3
K3
CA210 K4

10 4 6
!W
Th
AR
1
NI
brais
k truc
NG
sw es o
it
Ste ch is traves
kd
r o
el no
W eri
vear
hahincl the g
n in th cotnha
ca pp e th pu ma
e T trove
ut ioen at sh
n. an an y ow l wh
d to in
acg or no P en
us cideto t w osit
e exntwin o
trecogul
rk. ionTow
me d .

Driv
e

Crown 1995 PF10615 Rev. 4/02 Printed in U.S.A.

01 REV. 4/02
04.3–7530–001 04.3–7530–001
 DISTRIBUTION PANEL

*119474 DISTRIBUTION PANEL ASSEMBLY

(Includes Index 1, 4 thru 8 & 13)

Index Part No. Part Name No. Req.

1 Distribution Panel Includes

Index 2, 3, 12 & 14 1
2 062337-003 Relay K1 & K3 2
062338-001 Relay Socket 2
3 062339 Spring 2
4 060012-064 Screw #6 4
060005-048 Lockwasher 4
060021-003 Nut 4
5 094362-002 Fuse 15A FU1, FU2, FU3, FU4,
FU5 & FU6 6
6 ** 118548 Plate 1
7 060012-016 Screw #6 4
060005-048 Lockwasher 4
8†† 869126 Warning Tow Switch 1
9 † 120087 Distribution Panel Cover 1
10 060013-020 Screw #8 4
11 104401-015 Spacer 4
12 103687-007 Switch DTS1 1
13 103688 Frame Switch 1
14 062496-004 Relay K2, K4, K7 & K8 4
062142-002 Relay Socket 4

Always Specify Model, Data & Serial Numbers

** Plate Does Not Come With Warning Label. Warning

Label (Index 8) Must Be Ordered Separately.

† Cover must be kept in place to keep K2 relay seated

in socket.

†† Choice of dash number depends on language.

Dash Number Language

-001 German
-002 French
-003 Spanish
-004 Dutch
-005 Italian
-006 English

950417 2889 - E07746

Printed in U.S.A.
01 REV. 4/02
04.3–7530–002 04.3–7530–002
 C CONTACTOR
5674

2
MODEL FUNCTION
5
W P 3
WB P 4
WR P

PE 3500 1A

PC 3500 1A
6
SP 3000 1A

SP 3200 1A
8 7
TR 3500 1A

RR 3000 FW

RR 3500 FW

RD 3000 FW

RD 3500 FW 9

11

10
NOTE: On EV100 SCR motor control systems, the
contactors controlled by the control card (eg. forward,
reverse, 1A, FW), regardless of battery voltage, require 24
volt coils. Refer to the applicable contactor panel page
(section 04.1) for the correct contactor part number and
function.

110613-001 CONTACTOR ASSEMBLY (24V)

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 060059-001 Nut 2 9 114435 Moving Contact Assembly 1

2 060005-031 Lockwasher 2 10 117160 Coil 24V 1
3 060059-004 Half Nut 2 11 123601 Bushing 1
4 Spring Washer 2
5 107351 Screw 2 Always Specify Model, Data & Serial Numbers
6 114436 Top Cover 1
7 114437 Return Spring 1 120091 Contact Tip Kit Includes Index 1, 2,
8 114434 Fixed Contact Includes 3, 4, 8, 9 & 11 1
Index 1 thru 4 2

920210 7199 - EO10973

Crown 1992 PF9317 Rev. 1/04 Printed in U.S.A.

09 REV. 1/04
04.4–04.2–020 04.4–04.2–020
 CONTACTOR ASSEMBLY
10271
FORWARD/REVERSE
Model Function
2
PC 06.6 F/R 18 4 3
PC 6630 F/R
19 17
PE 06.5 F/R
PR 06.7 F/R 21 26 1
PR 6730 F/R 20
23
PR 6730 Int'l F/R 2
26 6
SP 7330 F/R 5
22
SP 7332 F/R 7
13 9 4
SP 7530 Int'l F/R
11
8
25 14 10
24 15
12
34 6
29

30 16
18
27
24 19 17
31
Assembled View
25 21
20 26
32 30 28 23

33 22 26
34

111634 F/R CONTACTOR ASSEMBLY (TRANS.- 24 VOLT, 100 AMP.)

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 114741 Magnetic Base Plate 1 22 060030-095 Flatwasher 2

2 060065-004 Screw M4 4 23 060042-016 Locknut #10 2
3 112268 Coil 2 24 104451 Clamp 2
4 112270 Frame 2 25 104443 Bus Clamp 4
5 104440 Spring 2 26 104452 Movable Tip 4
6 104450 Armature Assembly 27 112922 Stationary Tip 1
(Includes Index 7 Thru 12) 2 28 112921 Stationary Tip 1
7 Plunger 2 29 112920 Stationary Tip 1
8 Washer 2 30 060063-004 Screw M8 2
9 Washer Guide 2 060005-008 Lockwasher 2
10 060005-005 Lockwasher 2 060030-017 Flatwasher 2
11 060021-005 Nut 2 31 104444 Cover 2
12 Stud 2 32 060005-004 Lockwasher 8
13 104456 Bus Base 2 33 115589 Screw #8 8
14 104445 Stationary Tip 1 34 060063-007 Screw M8 2
15 104449 Stationary Tip 1 060005-008 Lockwasher 2
16 104448 Stationary Tip 1 060030-017 Flatwasher 2
17 104461 Plunger Bushing 2
18 104442 Movable Tip Carrier 2 Always Specify Model, Data & Serial Numbers
19 104441 Spring Guide Washer 4
113988 Contactor Tip Kit (Includes Index 14,
20 104439 Spring 2
15, 16, 18, 21, 26, 27, 28 and 29) 1
21 104453 Upper Insulation Bus 2
910325 3971 - EO8243

Crown 1991 PF9019 Rev. 9/02 Printed in U.S.A.

06 REV. 9/02
04.4–06.5–250 04.4–06.5–250
This page available for NOTES.
 C CONTACTOR
5675

1
MODEL FUNCTION
4
PE 3500 A, B

PC 3500 A, B

TR 3500 A, B

SP 3000 P1, P2
SP 3200 P1, P2
SP 3400 P1, P2
8
3
RR 3000 1A, P1
RR 3500 1A, P1

1 5
RS 3000 1A, P1
RS 3500 1A, P1

RD 3000 1A
RD 3500 1A

*RR/RD 5000 P2
*RR/RD 5000S P2
*RR/RD 5200 P2
*RR/RD 5200S P2 2
*RR/RD 5200(AC) P2
*RR/RD 5200S(AC) P2
9
*Regardless of truck battery voltage, the Access
1, 2, 3 system powers contactors with 24 volts.

6
NOTE: On EV100 SCR motor control systems, the
contactors controlled by the control card (eg. forward,
reverse, 1A, FW), regardless of battery voltage, require 24
volt coils. Refer to the applicable contactor panel page
(section 04.1) for the correct contactor part number and
function.

Crown 1993 PF9905-1 Rev. 12/04 Printed in U.S.A.

13 REV. 12/04
04.4–6535–050 04.4–6535–050
 C CONTACTOR

Index Part No. Part Name No. Req.

0 110613-003 24V Contactor 1

1 117157 Fixed Contact 2
2 117158 Moving Contact 1
3 114436 Top Cover 1
4 107351 Screw 2
5 117159 Return Spring 1
6 117160 Coil 1
7 118935 Cap End 1
8 117161 Dust Shield 2
9 123601 Bushing 1

Always Specify Model, Data & Serial Numbers

117162 Kit Contact Includes Index 1, 2 & 9 1

931201 9887

Crown 1993 PF9905-2 Rev. 12/04 Printed in U.S.A.

13 REV. 12/04
04.4–6535–051 04.4–6535–051
This page available for NOTES.
 C CONTROL MODULE - FRONT
3019

30
POT1 42
A 27 29
26 40
19
Part Of
Platform
22
20 24
25
18 28

21 23 16
40
17
43
17
31
KYS
40
18

1
B
6 5
5 15
4 4 7

7 13 2
3 10
14
12
FS
2 11 37
36

9 31
8
32

33 32 38
35 32
32 RS 39
41 37

36
34
38
B
39

Crown 1995 PF10531-1 Rev. 8/04 Printed in U.S.A.

01 REV. 8/04
04.6–7330–003 04.6–7330–003
 C CONTROL MODULE - FRONT

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 118391-001 Control Module 1 28 089549 Insulator 1

2 060038-005 Cotter Pin 2 29 060014-001 Screw #10 2
3 102458 Bar 1 30 125209 Potentiometer POT1 1
4 060030-190 Flatwasher AR 31 108066 Key Switch KYS Includes
5 089510 Bushing 2 Switch, 2 Keys & Ring 1
6 060030-163 Flatwasher 1 107151-002 Key 2
7 092224 Split Bushing 2 062623 Ignition Toggle Switch 1
8 102466 Spacer 1 120079-001 Insert 1
9 089509 Stop 1 32 060011-021 Screw #4 4
10 088611-002 Collar 2 060005-049 Lockwasher 4
11 108531 Torsion Spring 1 060021-023 Nut 4
12 089514 Plate 1 33 089336 Bracket 1
13 089548 Spacer 1 34 060031-020 Speed Nut 1
14 089356 Cam 1 35 089298-001 Rod 1
15 060030-226 Flatwasher 1 36 089342 Spacer 2
16 118620-001 Hand Grip 1 37 118901 Switch RS, FS 2
17 060000-108 Roll Pin 2 060064-003 Screw M3 4
18 060014-001 Screw #10 2 060005-036 Lockwasher 4
060005-005 Lockwasher 2 38 060011-010 Screw #4 2
060021-024 Nut 2 061004-014 Adhesive Thread Locking 1
19 089532 Bracket 1 39 090787 Lever 2
20 060021-024 Nut 2 40 060017-010 Screw 3
21 060005-005 Lockwasher 2 060005-009 Lockwasher 3
22 060030-044 Flatwasher 1 41 060014-006 Screw #10 2
23 080275 Pinion 1 060014-005 Screw #10 1
24 116329 Extension 1 060005-005 Lockwasher 3
25 062612 Blank Switch w/o Wire Guidance 1 42 060021-011 Nut 1
062611 Switch Panel w/Wire Guidance 1 43 060031-024 Speed Nut 1
118621 Wire Guide Decal 1
26 076649-002 Insulator 1 Always Specify Model, Data & Serial Numbers
27 089529 Plate 1

950417 8832

Crown 1995 PF10531-2 Rev. 8/04 Printed in U.S.A.

01 REV. 8/04
04.6–7330–004 04.6–7330–004
 C CONTROL CABLE - TL MAST
11111

Part Of Platform
Cable
4
Cable
1
Cable
Cable
3
2

TB102
TB101

3
4
2
1

Cable 2
Cable 1
9
Cable 3
8 Cable 4

Part Of
Bracket

5
5

Cable 1

Cable 2

Cable 4
Cable 3
Distribution
Panel

Crown 1995 PF10653 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–001 04.8–7530–001
 C CONTROL CABLE - TL MAST

Index Part No. Part Name No. Req.

1 * Control Cable #1 1
2 * Control Cable #2 1
3 * Control Cable #3 1
4 * Control Cable #4 1
5 119821-002 Bracket Lower 1
060017-006 Screw 4
060005-009 Lockwasher 4
060031-024 Nut Speed 4
6 118467-001 Connector Box 90° 4
7 078613 Spring Extension 4
8 105449 Grip Cable 4
9 061003-004 Tie Cable 8

Always Specify Model, Data & Serial Numbers

*See The Following Supplemental List

062007-015 Terminal 32
062592-007 Connector Plug Weidmuller 9 4

950612 6495

Printed in U.S.A.
01 REV. 9/03
04.8–7530–002 04.8–7530–002
 C CONTROL CABLE - TL MAST

Index 1, 2, 3 & 4: 119203-010 CABLE (8 Conductor) - 1.0TL

Collapsed Height Lift Height Length Required Order Number
Index No. mm mm m
1, 2 & 3 2325 4215 5. 5 119203-010
4 2325 4215 5. 2 119203-010
1, 2 & 3 2415 4520 5. 8 119203-010
4 2415 4520 5. 5 119203-010
1, 2 & 3 2720 5130 6.4 119203-010
4 2720 5130 6.1 119203-010
1, 2 & 3 3025 5690 7.0 119203-010
4 3025 5690 6. 7 119203-010
1, 2 & 3 3330 6200 7.6 119203-010
4 3330 6200 7.3 119203-010
Index 1, 2, 3 & 4: 119203-010 CABLE (8 Conductor) - 1.25TL
Collapsed Height Lift Height Length Required Order Number
Index No. mm mm m
1, 2 & 3 2325 3455 5. 5 119203-010
4 2325 3455 5. 2 119203-010
1, 2 & 3 2415 3760 5. 8 119203-010
4 2415 3760 5. 5 119203-010
1, 2 & 3 2720 4370 6.4 119203-010
4 2720 4370 6.1 119203-010
1, 2 & 3 3025 4930 7.0 119203-010
4 3025 4930 6. 7 119203-010
1, 2 & 3 3330 5435 7.6 119203-010
4 3330 5435 7.3 119203-010

When ordering Control Cable Index 1, 2, 3 & 4 (119203-010) specify the number of meters required for your specific
truck as noted in the chart. The cable can also be purchased in 76m rolls (part no. 119203-002) or 152m rolls (part
no. 119203-003). Cut the cable to the length required for your truck.

If cable failure has been caused by routine wear, etc. it is recommended that all control cables be replaced. If cable
failure has been caused by cutting, tearing, or other than normal wear, a single cable can be replaced. Check the
remaining cables condition and if questionable, replace all control cables.

Crown 1995 PF10653 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–001-SUP 04.8–7530–001-SUP
This page available for NOTES.
 C CONTROL CABLE - TT MAST
10845

Part of Platform

Cable 3

Cable 4 TB102
TB101
Cable 2
Cable 1

4
3 Cable 1
1 Cable 2
2 Cable 3
Cable 4

8
7
140 mm Cable 4

Cable 3

Part Of Cable 5
Cable 1
Bracket Index 5
Cable 1

Cable 2

Cable 2
Cable 4
Cable 3
Distribution
Panel

Crown 2003 PF13555 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–027 04.8–7530–027
 C CONTROL CABLE - TT MAST

Index Part No. Part Name No. Req.

1 * Next Page Control Cable # 1 1

2 * Next Page Control Cable # 2 1
3 * Next Page Control Cable # 3 1
4 * Next Page Control Cable # 4 1
5 119821-002 Bracket Lower 1
060017-006 Screw 2
060005-009 Lockwasher 2
060031-024 Nut Speed 2
6 118467-001 Connector Box 90° 4
7 078613 Spring Extension 4
8 085430 Grip Cable 4
9 061003-004 Tie Cable 8

Always Specify Model, Data & Serial Numbers

062007-015 Terminal 32
062592-007 Connector Plug Weidmuller 9 4

*See The Following Supplemental Form

030501 6494

Printed in U.S.A.
01 REV. 9/03
04.8–7530–028 04.8–7530–028
 C CONTROL CABLE - TT MAST

Index 1, 2, 3, & 4: 119203-010 CABLE (8 Conductor) - 1.0TT

Index No. Collapsed Height Lift Height LENGTH REQUIRED ORDER NUMBER
mm mm m
1, 2 & 3 2325 5715 8.1 119203-010
4 2325 5715 7.5 119203-010
1, 2 & 3 2415 6095 8.5 119203-010
4 2415 6095 7.6 119203-010
1, 2 & 3 2720 6860 9.5 119203-010
4 2720 6860 8.5 119203-010
1, 2 & 3 3025 7770 10.5 119203-010
4 3025 7770 9.5 119203-010
1, 2 & 3 3175 8230 11 119203-010
4 3175 8230 10 119203-010
1, 2 & 3 3330 8685 11.5 119203-010
4 3330 8685 10.5 119203-010
1, 2 & 3 3635 9145 12.5 119203-010
4 3635 9145 11.5 119203-010
1, 2 & 3 3785 9600 13 119203-010
4 3785 9600 12 119203-010

Index 1, 2, 3, & 4: 119203-010 CABLE (8 Conductor) - 1.25TT

Index No. Collapsed Height Lift Height LENGTH REQUIRED ORDER NUMBER
mm mm m
1, 2 & 3 2325 4955 8.1 119203-010
4 2325 4955 7.5 119203-010
1, 2 & 3 2415 5335 8.5 119203-010
4 2415 5335 7.6 119203-010
1, 2 & 3 2720 6095 9.5 119203-010
4 2720 6095 8.5 119203-010
1, 2 & 3 3025 7010 10.5 119203-010
4 3025 7010 9.5 119203-010
1, 2 & 3 3175 7470 11 119203-010
4 3175 7470 10 119203-010
1, 2 & 3 3330 7925 11.5 119203-010
4 3330 7925 10.5 119203-010
1, 2 & 3 3635 8385 12.5 119203-010
4 3635 8385 11.5 119203-010
1, 2 & 3 3785 8840 13 119203-010
4 3785 8840 12 119203-010
1, 2 & 3 3940 9300 13.5 119203-010
4 3940 9300 12.5 119203-010

When ordering Control Cable Index 1, 2, 3 & 4 (119203-010) specify the number of meters required for your specific truck as
noted in the chart. The cable can also be purchased in 75 m rolls (part no. 119203-002) or 150 m rolls (part no. 119203-003).
Cut the cable to the length required for your truck.

If cable failure has been caused by routine wear, etc. it is recommended that all control cables be replaced. If cable failure
has been caused by cutting, tearing, or other than normal wear, a single cable can be replaced. Check the remaining cables
condition and if questionable, replace all control cables.

Crown 2003 PF13555 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–027-SUP 04.8–7530–027-SUP
This page available for NOTES.
 LIMIT SWITCHES
10860-01

TL MAST

RK
FO ND
E

A PL
AT
F OR
M

RIGHT D
SIDE
F E
I C

G J L

1.0 Only
H
K

LEFT B
SIDE

Location *Switch Description No. Req.

Assembly

A 073624 High Speed Raise Cutout Switch HSRCS 1

B 079133 Lifting Fork Raise Cutout LMS1 1.0SP 1
C 118178-008 Lower Cutout Switch LCS1 1
D 122405-001 Chain Break Switch CHB4, CHS2 1
E 122405-002 Chain Break Switch CHB5, CHS1 1
F 126870-001 4500 mm Height Switch HTS4500
Wire Guide - Collapsed Height 2415 mm and higher 1.0SP,
Collapsed Height of 3025 mm and higher 1.25SP 1
G 126870-001 2500 mm Height Switch HTS2500 1
H 126870-003 1200 mm Height Switch HTS1200 1.25SP 1
I 126870-003 1200 mm Height Switch HTS1200 1.0SP 1
J 082615 Raise Cutout Switch RCS2 1
K 082615 Raise Cutout Switch RCS1 1
L 118178-007 High Speed Lower Cutout Switch HSLCS 1

Always Specify Model, Data & Serial Numbers

* Except Chain Switches, See the Following Page for Parts Breakdown of Switch Assembly.
For Parts Breakdown of Chain Switches, See "Lift Chain" (Section 07.6)

Crown 2003 PF13568-1 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–058 04.8–7530–058
 LIMIT SWITCHES

1200 mm Height Switch HTS1200 Std.

Collapsed 1.25SP TL Switch 1.0SP TL Switch
Height Mounting Location Part Number Mounting Location Part Number
2325 mm Main Frame 126870-003 Platform 126870-003
2415 mm Main Frame 126870-003 Platform 126870-003
2720 mm Main Frame 126870-003 Platform 126870-003
3025 mm Main Frame 126870-003 Platform 126870-003
3330 mm Main Frame 126870-003 Platform 126870-003
2500 mm Height Switch HTS2500 Std
Collapsed 1.25SP TL Switch 1.0SP TL Switch
Height Mounting Location Part Number. Mounting Location Part Number
2325 mm Main Frame 126870-001 Main Frame 126870-001
2415 mm Main Frame 126870-001 Main Frame 126870-001
2720 mm Main Frame 126870-001 Main Frame 126870-001
3025 mm Main Frame 126870-001 Main Frame 126870-001
3330 mm Main Frame 126870-001 Main Frame 126870-001
4500 mm Height Switch HTS4500 Wire Guide Only
Collapsed 1.25SP TL Switch 1.0SP TL Switch
Height Mounting Location Part Number Mounting Location Part Number
2325 mm
2415 mm Main Frame 126870-001
2720 mm Main Frame 126870-001
3025 mm Main Frame 126870-001 Main Frame 126870-001
3330 mm Main Frame 126870-001 Main Frame 126870-001

Crown 2003 PF13568-2 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–058-SUP 04.8–7530–058-SUP
 LIMIT SWITCHES
10861

TT MAST
RK
FO ND
E

PLATFORM
B

C F
G K
RIGHT
SIDE E†

D H L
M
† 3025 mm Coll. Ht. 1.25SP
All 1.0SP
E

I
1.0 Only

J
LEFT
SIDE

Location * Switch Description No. Req.

Assembly
A 073624 High Speed Raise Cutout Switch HSRCS 1
B 122405-002 Chain Break/Slack Switches CHB4, CHS2 1
C 122405-001 Chain Break/Slack Switches CHB5, CHS1 1
D 126870-001 4500 mm Height Switch HTS4500 Up To & Including Collapsed Height 3330 mm (1.25SP) 1
126870-001 4500 mm Height Switch HTS4500 Up To & Including Collapsed Height 2720 mm (1.0SP) 1
126870-006 4500 mm Height Switch HTS4500 Collapsed Height 3635 mm & Above (1.25SP) 1
126870-006 4500 mm Height Switch HTS4500 Collapsed Height 3025 mm & Above (1.0SP) 1
E 126870-006 2500 mm Height Switch HTS2500 Collapsed Height Up To & Including 2720 mm - 1.25SP 1
† 126870-001 2500 mm Height Switch HTS2500 Collapsed Height 3025 mm & Above - 1.25SP & All 1.0SP 1
118178-008 Lower Cutout Switch LSC1 (Platform) Except on Collapsed Height 3020 mm - 1.25SP,
2325mm, 2415mm, 2720mm - 1.0SP 1
F 126870-003 1200 mm Height Switch HTS1200 All 1.25SP 1
G 126870-003 1200 mm Height Switch HTS1200 All 1.0SP 1
H 082615 Raise Cutout Switch RCS2 1
I 082615 Raise Cutout Switch RCS1 1
J 079133 Lifting Fork Raise Cutout LMS1 1.0SP 1
K 118178-007 High Speed Lower Cutout Switch HSLCS 1
L 122404 Chain Break/Slack Switches CHB7, CHS4 1
M 122404 Chain Break/Slack Switches CHB6, CHS3 1
Always Specify Model, Data & Serial Numbers
* Except Chain Switches, See the Following Page for Parts Breakdown of Switch Assembly.
For Parts Breakdown of Chain Switches, See "Lift Chain" (Section 07.6)
Crown 2003 PF13568-3 Rev. 9/03 Printed in U.S.A.
01 REV. 9/03
04.8–7530–059 04.8–7530–059
 LIMIT SWITCHES

1200 mm Height Switch HTS1200 Std.

Collapsed 1.25SP TT Switch 1.0SP TT Switch
Height Mounting Location Part Number Mounting Location Part Number
2325 mm Platform 126870-003 Platform 126870-003
2415 mm Platform 126870-003 Platform 126870-003
2720 mm Platform 126870-003 Platform 126870-003
3025 mm Platform 126870-003 Platform 126870-003
3175 mm Platform 126870-003 Platform 126870-003
3330 mm Platform 126870-003 Platform 126870-003
3635 mm Platform 126870-003 Platform 126870-003
3785 mm Platform 126870-003 Platform 126870-003
3940 mm Platform 126870-003
2500 mm Height Switch HTS2500 Std
Collapsed 1.25SP TT Switch 1.0SP TT Switch
Height Mounting Location Part Number. Mounting Location Part Number
2325 mm Main Frame 126870-006 Platform 126870-001
2415 mm Main Frame 126870-006 Platform 126870-001
2720 mm Main Frame 126870-006 Platform 126870-001
3025 mm Platform 126870-001 Platform 126870-001
3175 mm Platform 126870-001 Platform 126870-001
3330 mm Platform 126870-001 Platform 126870-001
3635 mm Platform 126870-001 Platform 126870-001
3785 mm Platform 126870-001 Platform 126870-001
3940 mm Platform 126870-001
4500 mm Height Switch HTS4500 Wire Guide Only
Collapsed 1.25SP TT Switch 1.0SP TT Switch
Height Mounting Location Part Number Mounting Location Part Number
2325 mm Main Frame 126870-001 Main Frame 126870-001
2415 mm Main Frame 126870-001 Main Frame 126870-001
2720 mm Main Frame 126870-001 Main Frame 126870-001
3025 mm Main Frame 126870-001 Main Frame 126870-006
3175 mm Main Frame 126870-001 Main Frame 126870-006
3330 mm Main Frame 126870-001 Main Frame 126870-006
3635 mm Main Frame 126870-006 Main Frame 126870-006
3785 mm Main Frame 126870-006 Main Frame 126870-006
3940 mm Main Frame 126870-006

Crown2003 PF13568-4 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–059-SUP 04.8–7530–059-SUP
 LIMIT SWITCHES
10862

HSLCS
LH Switch HSRCS
2 RH Switch
Assembly
Assembly

16

11 1 17 22

21

4
3
8 5 20
10 9
18
18
15 19
7
12
13
14 12

HTS1200
HTS2500 HTS1200
HTS4500 HTS2500
LH Switch RH Switch
2
Assembly Assembly 2

5
23
24

26 3
26
25 25
3 23 24 5
14
6
6
7 12
12 7
13 14 13
12 12

Crown 2003 PF13568-5 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–060 04.8–7530–060
 LIMIT SWITCHES

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 See Chart Box 1 15 118198 Cover Switch 1

2 060015-003 Screw 2 16 060015-003 Screw 2
060005-007 Lockwasher 2 060005-007 Lockwasher 2
060030-012 Flatwasher 2 060030-012 Flatwasher 2
3 073805-001 Bushing Strain Relief 1 17 083193 Insulator 1
4 117553-002 Insulator 1 18 062007-015 Terminal 2
5 See Chart Switch 2 19 087374-003 Lead 4 Conductor 3
6 062007-043 Terminal 4 20 073624 Switch 1
7 079495-023 Lead 2 Conductor 21 083192 Insulator 1
See Chart AR 22 060012-022 Screw 2
086572-001 Wire White Bulk (mm) 90 060030-045 Flatwasher 2
8 118209-002 Insulator 1 061004-019 Adhesive Thread Locking 1
9 060012-022 Screw 2 23 060011-024 Screw 2
060030-045 Flatwasher 2 24 060013-002 Screw 1
061004-019 Adhesive Thread Locking 1 060030-045 Flatwasher 1
10 082607 Actuator 1 25 122149 Insulator 1
11 060013-002 Screw 2 26 122148 Actuator 1
060021-004 Nut 2
061004-019 Adhesive Thread Locking 1 Always Specify Model, Data & Serial Numbers
12 060030-116 Flatwasher 2
13 082608-001 Roller 1 * 079495-023 & 087374-003 are Bulk Lead.
14 082609 Pin 1 The Quantity Ordered Equals the Length in Meters.

Switch Index 1 Index 5 * Index 7

Orientation
Assembly Switch Box Switch Lead Qty. (m)
126870-001 129279-001 062683 L.H. 2.7
126870-003 129279-003 062683 R.H. 1.8
126870-006 129279-003 062683 R.H. 6.7
118178-007 118208-001 082605 L.H. 2.3
118178-008 118208-001 062601 L.H. 1.8

030501 6493

Crown 2003 PF13568-6 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
04.8–7530–061 04.8–7530–061
This page available for NOTES.
This page available for NOTES.
 BRAKE
10561-01

20
18
21
9 22

23
11
A 19
12
B

Used on Trucks w/o Wire Guidance 10

17
9
24
B

Used on Trucks w/ Wire Guidance

5
4 7
B

13

A 14
3

2
15 16

Crown 2002 PF13398 Rev. 7/03 Printed in U.S.A.

01 REV. 7/03
05.3–7332–001 05.3–7332–001
 BRAKE

121771 BRAKE ASSEMBLY

Includes Index 3, 4, 6, 7, 14 & 15

Index Part No. Part Name No. Req.

1 Drive Motor See Section 3.1 1

2 118167 Adjuster 1
3 126953 Magnet & Coil Body 1
4 119042 Compression Spring 9
5 060016-058 Screw 3
061004-026 Thread Locking Adhesive 1
6 119043 Outer Armature 1
7 119044 Inner Armature 1
8 119677 Compression Spring 1
9 060000-098 Roll Pin 1
10 * 129921 Encoder Mounting Plate 1
11 * 060030-082 Flatwasher .5 mm (.016 in.)
Thick AR
* 060030-067 Flatwasher 1.5 mm (.063 in.)
Thick AR
12 * 118166-002 Nut 1
13 118166-001 Nut 1
14 119045 Brake Rotor 1
15 119046 Brake Pad Assembly Includes
6 Brake Pads 1
16 112152 Brake Pad 6
112153 Rivet 12
17 * 129919 Bracket Anti-Rotate 1
* 060014-060 Screw 2
* 060005-005 Lockwasher 2
18 * 128912 Sensor Retainer 1
19 * 130871 Sensor Bearing 1
20 * 060014-094 Screw 2
21 * 061085-001 Snap-In Clip 1
22 * 128888 Gasket 1
23 * 128898 Washer 1
24 * 129920 Adaptor Nut 1

Always Specify Model, Data & Serial Numbers

021231 6117

Printed in U.S.A.
01 REV. 7/03
05.3–7332–002 05.3–7332–002
 C STEERING GEARBOX
7472-01

17

16
A
2
15

18
7

3
35
34
B

A 18 19
14

20
38
13 21
22 23

29
Steering
Gearbox 12

24

1 11 25 37
B
26
10

9
Part of
Power Unit

to
8 Power
28 Unit
27
4
33 32
5
6 31 30
36

Crown 1996 PF10971-1 Rev. 2/05 Printed in U.S.A.

04 REV. 2/05
06.0–7330–102 06.0–7330–102
 C STEERING GEARBOX

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 084603 Stud 1 21 061009-020 Key Square 1

2 * Motor Electric See Section 06.2 1 22 117780 Gear 1st Reduction 1
* Motor 48V See Section 06.2 1 23 061011-001 Pin Dowel 2
* Motor 72V See Section 06.2 1 24 060030-178 Flatwasher 1
3 102969 Gasket 1 25 060030-224 Flatwasher 1
4 093061 Gear Idler 1 26 065081-060 Bearing Ball 1
5 065010-005 Bearing Ball w/Snap Ring 1 27 117704 Machining Gearbox 1
6 060009-095 Ring Retaining 1 28 064138-012 Seal Oil 1
7 060015-054 Screw 1/4" 4 29 065081-032 Bearing Ball 1
061004-006 Adhesive Thread Locking 1 30 060009-037 Ring Retaining 1
8 064020-002 Plug Pipe 1 31 060009-044 Ring Retaining 1
061004-005 Adhesive Thread Locking 1 32 118497 Pinion-Shaft Output 1
9 060009-002 Ring Retaining 1 33 061009-021 Key Square 1
10 065081-012 Bearing Ball 1 34 117782 Gear 2nd Reduction 1
11 060009-118 Ring Retaining 1 35 060030-178 Flatwasher 1.5 mm (.062 in.) 1
12 118500 Shaft Assembly 1 060030-179 Flatwasher .3 mm (.010 in.) 1
13 061009-019 Key Square 1 060030-180 Flatwasher .12 mm (.005 in.) 1
14 118502 Gasket 1 060030-181 Flatwasher .07 mm (.003 in.) 1
15 130490 Cover Gearbox Machining 1 060030-279 Flatwasher .8 mm (.031 in.) 1
16 060016-019 Screw 5/16" 6 36 060009-036 Ring Retaining 1
060005-008 Lockwasher 6 37 060017-010 Screw 3/8" 4
17 064020-004 Plug Pipe 1 060030-049 Flatwasher 4
061004-005 Adhesive Thread Locking 1 060005-009 Lockwasher 4
18 065081-044 Bearing Ball 2 38 060009-152 Ring Retaining 1
19 060030-178 Flatwasher 1.5 mm (.062 in.) AR
060030-179 Flatwasher .3 mm (.010 in.) AR Always Specify Model, Data & Serial Numbers
060030-180 Flatwasher .12 mm (.005 in.) AR
060030-181 Flatwasher .07 mm (.003 in.) AR 065005-002 Gasket Sealer 1
20 117781 Pinion-Shaft 2nd Reduction 1

*
To select part number, refer to truck data Important
Information
number. The data number consists of Maintenance
letters and numbers that represent truck see section
ITD
features. Refer to section ITD.

960508 9173

Crown 1996 PF10971-2 Rev. 2/05 Printed in U.S.A.

04 REV. 2/05
06.0–7330–103 06.0–7330–103
 C STEERING COMMAND
11613

ECR1 4
1 5
7

SB11
8 12
13
2 ALM1
6 14
3

9
17

9
11
15
10
16 23

14
Part of Platform 18

19

20

21

25 22

24

Crown 2004 PF13866-1 Printed in U.S.A.

06.0–7332–001 06.0–7332–001
 C STEERING COMMAND

Index Part No. Part Name No. Req.

1 130210-001 Encoder Assembly ECR1

Includes Connector & Terminal 1
129911 Encoder ECR1 1
062535-002 Connector 1
062536-003 Terminal 5
2 060011-005 Screw 2
060005-036 Lockwasher 2
3 117919 Cleat Motor Mount 2
4 060009-005 Retaining Ring 1
5 060009-068 Retaining Ring 1
6 117921 Retainer 1
7 117920 Spring 1
8 118352 Tapered Pin 1
9 065081-038 Bearing 2
10 131696 Housing Mount 1
11 060017-007 Screw 3
060005-009 Lockwasher 3
12 118356 Termination Block SB11 1
13 060013-008 Screw 2
060005-004 Lockwasher 2
14 128229 Electronic Signal ALM1 1
15 060012-043 Set Screw 1
16 118351 Shaft 1
17 060016-058 Screw 1
060005-008 Lockwasher 1
18 118354 Poly Stop 1
19 118355 Compression Spring 1
20 064091-001 Plug Includes O-Ring 1
21 118300 Wheel 1
22 060000-002 Roll Pin 1
23 060046-013 Spring Washer 1
24 118917 Steering Knob Assembly 1
25 060016-019 Screw 1
060005-008 Lockwasher 1

Always Specify Model, Data & Serial Numbers

8743 - EO13119

Crown 2004 PF13866-2 Printed in U.S.A.

06.0–7332–002 06.0–7332–002
This page available for NOTES.
 C MAST - TL
3743
4

25 5 1
3
RK 2
FO ND
E
6 7
28
3

6 6
2
27
31
26
12
14 8

13

15 14
31
32

16
11
17 29
18
30
12 9

10

19
10
12 9

21 24

PART OF
POWER PART OF MAIN
UNIT FRAME
21 22

23
21

24

Crown 1995 PF10621 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.1–7530–001 07.1–7530–001
 C MAST - TL

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 118197-002 Pulley 4 18 060020-019 Screw 4

2 060030-192 Flatwasher 1.25SP 1 060005-014 Lockwasher 4
060009-011 Ring Retaining 1.0SP 1 19 Switch Limit See Section 4.8
060009-043 Ring Retaining 1.25SP 1 20 † 044863- Main Frame 1
3 117556-002 Pulley Chain Assembly Includes 21 060023-004 Screw 6
Index 4 2 060005-023 Lockwasher 6
4 117557-002 Pulley Chain 2 060021-049 Nut 4
065081-045 Bearing 2 061004-019 Adhesive Thread Locking .5cc 1
060009-062 Ring Retaining 6 22 Load Wheel See Section 7.4 4
5 060017-094 Screw 1 23 Aisle Guide Wheel See
060005-009 Lockwasher 1 Section 10.0 2
061004-019 Adhesive Thread Locking .5cc 1 24 117558 Guard 1
6 060015-061 Screw 2 060017-014 Screw 2
060042-006 Nut Self Locking 2 060005-009 Lockwasher 2
7 117562-003 Shaft 1 060021-011 Nut 2
8 * Mast 2nd Stage 1 25 103418-023 Spacer 2
9 103284-001 Roller Column 2 26 117562-007 Shaft 1.0SP 1
10 060030-231 Flatwasher .75mm (.030 in.) 27 119655-001 Pulley 1.0SP 1
Thick AR 28 060017-035 Screw 1.0SP 1
11 Cylinder Mast See Section 8.1 2 060005-009 Lockwasher 1.0SP 1
12 119821-001 Bracket Lower 1 061004-019 Adhesive Thread Locking 1.0SP 1
119821-002 Bracket Upper 1 29 119654 Bracket 1
060017-006 Screw 4 30 061022-004 Clamp 1
060005-009 Lockwasher 4 31 119669 Guide 1
060031-024 Nut Speed 2 060017-006 Screw 2
13 074668-001 Roller Column 2 060005-009 Lockwasher 2
14 060030-085 Flatwasher .8mm (.031 in.) 060031-024 Nut Speed 1
Thick AR 32 119671-001 Cover 1
15 Chain Lift See Section 7.6 3 060017-007 Screw 3/8" 2
Switch Chain See Section 7.6 060005-009 Lockwasher 2
16 080069 Block Stop 2
17 092747-001 Stop Poly 2 Always Specify Model, Dat & Serial Numbers
107563-001 Bracket 2
074481-001 Shim 1.6mm (.063 in.) Thick AR * See the following supplemental list
060015-016 Screw 2
061004-026 Adhesive Thread Locking 1 † Part Number Incomplete (Reference Only).
When Ordering Contact Factory.

950612 6490

Printed in U.S.A.
01 REV. 9/03
07.1–7530–002 07.1–7530–002
 C MAST - TL

INDEX 8 2nd STAGE MAST 1.25TL

COLLAPSED HEIGHT STANDARD MAST
mm in.
2325 91.5 044845-412
2415 95 044845-413
2720 107 044845-414
3020 119 044845-415
3330 131 044845-416
INDEX 8 2nd STAGE MAST 1.0TL
2325 91.5 044845-012
2415 95 044845-013
2720 107 044845-014
3020 119 044845-015
3330 131 044845-016

Crown 1995 PF10621 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.1–7530–001-SUP 07.1–7530–001-SUP
This page available for NOTES.
 C MAST - TT
10837
16

7 6
11
RK 44 12 1
FO ND
E 15
13
7 6
25 14
24 18
B 15
17

13 18
7 45
6 13 18 2
20 19
6 24 24
21 3
4 7
B

24
30
4

31 3
30 26 5
47
4
6 7
9
46 10
4
24 22 7
RCS2 6
8
29 23 9
A 24
36

24 37
33 23 38

39
32 22
27 25
Part Of 34
Power Unit 28 24
A 40
35
32 41 43

42
Part Of Main
32
Frame

34

Crown 2003 PF13545 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.2–7530–003 07.2–7530–003
 C MAST - TT

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 * Next Page Mast 3rd Stage 1 27 117564 Guide 1

2 Yoke Assembly See Section 7.5 1 28 Cylinder Mast See Section 8.1 2
3 117559 Clamp 1 29 Switch Limit See Section 4.8
060005-009 Lockwasher 2 30 080069 Block Stop 2
060021-012 Nut 2 060020-019 Screw 4
4 Chain Lift See Section 7.6 2 060005-014 Lockwasher 4
Anchor Chain See Section 7.6 31 092747-001 Stop Poly 2
Switch Chain See Section 7.6 107563-001 Bracket 2
5 Cylinder Free Lift See Section 8.3 1 074481-001 Shim 1.6mm Thick AR
6 074668-001 Roller Column 6 060015-016 Screw 2
7 060030-085 Flatwasher .8mm Thick AR 061004-026 Adhesive Thread Locking .5cc 1
8 119679 Plate Pulley Assembly 32 060023-004 Screw 6
Includes Index 10 1 060005-023 Lockwasher 6
119642 Plate Pulley 1 060021-049 Nut 4
9 060017-032 Screw 4 061004-019 Adhesive Thread Locking .5cc 1
060005-009 Lockwasher 4 33 124019 Bumper Mast 2
060021-011 Nut 4 060030-266 Flatwasher 1.6mm Thick AR
10 117574-001 Pulley 8 060030-277 Flatwasher .8mm Thick AR
060030-026 Flatwasher 16 060017-065 Screw 2
060009-002 Ring Retaining 8 061004-026 Adhesive Thread Locking .5cc 1
11 103418-023 Spacer 2 34 117558 Guard 1
12 118197-002 Pulley 4 060017-014 Screw 2
13 060030-192 Flatwasher 2 060005-009 Lockwasher 2
060009-011 Ring Retaining 2 060021-011 Nut 2
14 117562-003 Shaft 1 35 119035 Tube Spring 2
15 117556-002 Pulley Chain Assembly 060019-019 Screw 4
Includes Index 16 2 060005-012 Lockwasher 4
060009-043 Ring Retaining 3 36 118952 Block 2
16 117557-002 Pulley Chain 2 060015-018 Screw 2
065081-045 Bearing 2 061004-026 Adhesive Thread Locking .5cc 1
060009-062 Ring Retaining 6 37 119032 Ram Spring 2
17 060017-035 Screw 1 060000-028 Pin Roll 2
060005-009 Lockwasher 1 38 060009-101 Ring Retaining 2
061004-019 Adhesive Thread Locking .5cc 1 39 119034 Rod 2
18 060015-061 Screw 2 40 119031 Spring 2
060042-006 Nut Self Locking 2 41 † 046152- Main Frame 1
19 117562-001 Shaft 1.25SP 1 42 Aisle Guide Wheel See
117562-006 Shaft 1.0SP 1 Section 10.0 2
20 117563 Pulley Hose 1 43 Load Wheel See Section 7.4 4
21 * Next Page Mast 2nd Stage 1 44 060017-094 Screw 1
22 103284-001 Roller Column 2 060005-009 Lockwasher 1
23 060030-231 Flatwasher .75mm Thick AR 45 119655-001 Pulley Hose 1
24 060017-006 Screw 1.25SP 8 46 119654 Bracket 1
060017-007 Screw 1.0SP 8 47 061022-004 Clamp 1
060005-009 Lockwasher 8
060031-024 Nut Speed 8 Always Specify Model, Data & Serial Numbers
25 119821-001 Bracket Lower 1
119821-002 Bracket Upper 1 † Part Number Incomplete (Reference Only).
26 118366 Guide 1.25SP 1 When Ordering Contact Factory.
119656 Guide 1.0SP 1
* See the following supplemental list.
119658-001 Cover Guide 1.0SP 1

030501 6491

Printed in U.S.A.
01 REV. 9/03
07.2–7530–004 07.2–7530–004
 C MAST - TT

Index 1 3rd Stage Mast 1.0TT Index 21 2nd Stage Mast 1.0TT
Collapsed Lift Standard Collapsed Lift Standard
Height Height Mast Height Height Mast
mm mm Part Number mm mm Part Number
2325 5715 044849-002 2325 5715 044845-002
2415 6095 044849-003 2415 6095 044845-003
2720 6860 044849-004 2720 6860 044845-004
3025 7770 044849-005 3025 7770 044845-005
3175 8230 044849-001 3175 8230 044845-001
3330 8685 044849-006 3330 8685 044845-006
3635 9145 044849-007 3635 9145 044845-007
3785 9600 044849-009 3785 9600 044845-009

Index 1 3rd Stage Mast 1.25TT Index 21 2nd Stage Mast 1.25TT
Collapsed Lift Standard Collapsed Lift Standard
Height Height Mast Height Height Mast
mm mm Part Number mm mm Part Number
2325 4955 044849-012 2325 4955 044845-002
2415 5335 044849-013 2415 5335 044845-003
2720 6095 044849-014 2720 6095 044845-004
3025 7010 044849-015 3025 7010 044845-005
3175 7470 044849-011 3175 7470 044845-001
3330 7925 044849-016 3330 7925 044845-006
3635 8385 044849-017 3635 8385 044845-007
3785 8840 044849-019 3785 8840 044845-009
3940 9300 044849-018 3940 9300 044845-008

Crown 2003 PF13545 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.2–7530–003-SUP 07.2–7530–003-SUP
This page available for NOTES.
 C LOAD WHEEL
10846-01
1
3
2
Wheel Size 2 3
150 x 70 mm 6
5
4
5

Trucks Equipped With

Aisle Guide Wheels

75 x 100 mm Outrigger - Used on

• All SP3011/21 (1.25) & SP3012/22 (1.0) TL,
• SP3011/21 (1.25) & SP3012/22 (1.0) TT With
Wheel Size
Collapsed Heights of 2325, 2415 & 2720 mm.
150 x 110 mm
3
2
1
Wheel Size
3 150 x 70 mm 2
2 3
1

2
3
5

4
5

6
6

100 x 200 mm Outrigger - Used on

100 x 100 mm Outrigger - Used on • SP3021H (1.25) TT Trucks With
• SP3021H (1.25) & SP3022H (1.0) TT Trucks With Collapsed Collapsed Height Of 3940 mm.
Heights Of 3025, 3175, 3330, 3635 & 3785 mm.

Crown 2003 PF13558 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.4–7530–001 07.4–7530–001
C LOAD WHEEL

Index Part No. Part Name †No. Req.

1 * Next Page Load Wheel Assembly

Includes Index 2 1
2 065081-008 Bearing 2
3 060030-057 Flatwasher 2
4 074659-001 Axle 3785 mm or Less
Collapsed Height 9600 mm
or Less Lift Height 1
105840 Axle For Trucks Equipped
With Aisle Guide Wheels and
3785 mm or Less
Collapsed Height 9600 mm
or Less Lift Height 1
074659-004 Axle 3940 mm Collapsed Height
9300 mm Lift Height 1
129855 Axle For Trucks Equipped With
Aisle Guide Wheels and
3940 mm Collapsed Height
9300 mm Lift Height 1
5 076048-001 Fitting Lubrication 1
6 060000-051 Pin Roll 1
060000-062 Pin Roll For Trucks Equipped
With Aisle Guide Wheels 1

Always Specify Model, Data & Serial Numbers

† Quantities Listed are for One Load Wheel Assembly

Printed in U.S.A.
01 REV. 9/03
07.4–7530–002 07.4–7530–002
 C LOAD WHEEL
Choice of load wheel depends on collapsed /lift height and application. Refer to charts below to determine load wheel
part number.

Index 1 Load Wheel Size 150 x 70 mm

SP3011/21 (1.25) & SP3021/22 (1.0) TL Mast

Lift Height Lift Height ‡ 091595- 082021-

Collapsed Height
1.25 1.0 Load Wheel Assembly Load Wheel

mm mm mm
2325 3455 4215 Any Dash Number Any Dash Number
2415 3760 4520 Any Dash Number Any Dash Number
2720 4370 5130 Any Dash Number Any Dash Number
3025 4930 5690 Any Dash Number Any Dash Number
3330 5435 6200 Any Dash Number Any Dash Number
Index 1 Load Wheel Size 150 x 70 mm
SP3011/21 (1.25) & SP3021/22 (1.0) TT Mast
Lift Height Lift Height ‡ 091595- 082021-
Collapsed Height
1.25 1.0 Load Wheel Assembly Load Wheel
mm mm mm
2325 4955 5715 Any Dash Number Any Dash Number
2415 5335 6095 Any Dash Number Any Dash Number
2720 6095 6860 Any Dash Number Any Dash Number
3025 7010 7770 -035 or -040 -035 or -040
3175 7470 8230 -035 or -040 -035 or -040
3330 7925 8685 -035 or -040 -035 or -040
3635 8385 9145 -035 or -040 -035 or -040
3785 8840 9600 -035 or -040 -035 or -040
Index 1 Load Wheel Size 150 x 110 mm
SP3021H (1.25) TT Mast
Lift Height ‡ 129873- 082020-
Collapsed Height
1.25 Load Wheel Assembly Load Wheel
mm mm
3940 9300 -035 or -040 -035 or -040

‡ Load Wheel Assembly Includes Bearings (Index 2).

Dash No. Application

010 85A durometer — Better cut and tear resistance, good for heavy loads and long runs. Excellent for docking,
rough floors, floor debris and traction.
025 90A durometer — Excellent performance for high capacity transport operations, easy riding. Good for
freezer, traction, resistant to flat spotting, best cut and tear resistance.
035 95A durometer — Excellent performance for high capacity transport operations, good cut and tear
resistance. Resistance to flat spotting and best for freezer use.
040 95A durometer — Excellent cut and tear resistance and high capacity transport operations. Use where
nothing else works.

030501 6485

Printed in U.S.A.
01 REV. 9/03
07.4–7530–003 07.4–7530–003
This page available for NOTES.
 C YOKE - TT
11666

2 - CHAIN MAST

15
16
4
3
2

14 2
5
13
12 3

11 8
6
7

6
9

10

9
Part Of
Lift Cylinder

Crown 2004 PF13873-1 Printed in U.S.A.

07.5–7530–050 07.5–7530–050
 C YOKE - TT

*123180-003 YOKE 2 - CHAIN MAST INCLUDES INDEX 1 thru 5, 7 thru 11 & 13 thru 16

Index Part No. Part Name No. Req.

1 128927-001 Pulley 4
2 060030-020 Flatwasher 2
3 060009-011 Retaining Ring 2
061004-026 Thread Locking Adhesive 1
4 123188 Yoke 1
5 123183-001 Shaft 1
6 060015-061 Screw 1
060042-006 Self-Locking Nut 1
7 123182-001 Shaft 1
8 060009-018 Retaining Ring 2
9 060030-057 Flatwasher 2
10 117575-004 Chain Pulley Assembly
Includes Bearings 1
117576-004 Chain Pulley 1
065081-027 Bearing 2
11 119655-001 Pulley 1
12 060030-022 Flatwasher 1
13 060030-135 Flatwasher 1
14 060009-005 Ring Retaining 1
15 060016-005 Screw 1
060005-008 Lockwasher 1
16 119651-003 Guide 1

Always Specify Model, Data & Serial Numbers

040820 8861 (IRE)

Crown 2004 PF13873-2 Printed in U.S.A.

07.5–7530–051 07.5–7530–051
 C LIFT CHAIN - TL MAST
10836
3

8 2

9
11 10
13
12
4
3
1

14
1

CHS2
CHB4
6 PA
PL RT
AT OF
FO
R 2
7 M
7 CHS1
5 CHB5 1

RK
FO ND
E

Crown 2003 PF13544 Printed in U.S.A.

07.6–7530–005 07.6–7530–005
 C LIFT CHAIN - TL MAST

Index Part No. Part Name No. Req.

1 060000-055 Pin Roll 6

2 042906 Pin 3
3 * Chain 2
4 060009-043 Ring Retaining 2
5 122405-002 Switch Mast Chain L.H.
CHS1, CHB5 1
062657 Switch 2
6 122405-001 Switch Mast Chain R.H.
CHS2, CHB4 1
062657 Switch 2
7 060015-003 Screw 4
060030-012 Flatwasher 4
060005-007 Lockwasher 4
8 117554-003 Anchor Chain 2
9 065007-030 Bearing Sleeve 2
10 117552 Spring Compression 2
11 118194-001 Plate 2
12 060021-028 Nut 4
13 060038-003 Pin Cotter 2
14 084985 Pin 1

Always Specify Model, Data & Serial Numbers

* See the following supplemental list.

030501 5221

Printed in U.S.A.

07.6–7530–006 07.6–7530–006
 C LIFT CHAIN - TL MAST

Index 3 Chain (Mast) 1.25TL

Collapsed Height Lift Height Length Required Part Number Order Quantity
mm mm mm Links Per Truck
2325 3455 2115 11 1 042907-024 2
2415 3760 2270 11 9 042907-002 2
2720 4370 2570 135 042907-003 2
3025 4930 2880 151 042907-025 2
3330 5435 318 0 16 7 042907-035 2
Index 3 Chain (Mast) 1.0TL
Collapsed Height Lift Height Length Required Part Number Order Quantity
mm mm mm Links Per Truck
2325 4215 2115 111 042907-024 2
2415 4520 2270 119 042907-002 2
2720 5130 2570 135 042907-003 2
3025 5690 2880 151 042907-025 2
3330 6200 3180 16 7 042907-035 2

Crown 2003 PF13544 Printed in U.S.A.

07.6–7530–005-SUP 07.6–7530–005-SUP
This page available for NOTES.
 C LIFT CHAIN - TT MAST
10833
14

A
13 2 3
1 B
12 12
3

7
2
8 9

10 12
11

3
P
PLART
AT O
A FO F
RM

2
B
12
CHS2 3
CHB4 13
5
13
10
6 2
6 CHS1
4 11
CHB5 12

10

11
10

12 2
14
1
14
12
RK
FO ND
E

Crown 2003 PF13542 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.6–7530–054 07.6–7530–054
 C LIFT CHAIN - TT MAST

Index Part No. Part Name No. Req.

1 084985 Pin 2
2 042906 Pin 6
3 * Chain 2
4 122405-002 Switch Mast Chain L.H.
CHS1, CHB5 1
062657 Switch 2
5 122405-001 Switch Mast Chain R.H.
CHS2, CHB4 1
062657 Switch 2
6 060015-003 Screw 4
060030-012 Flatwasher 4
060005-007 Lockwasher 4
7 065007-030 Bearing Sleeve 2
8 118194-001 Plate 2
9 117552 Spring Compression 2
10 060021-028 Nut 8
11 060038-003 Pin Cotter 4
12 060000-055 Roll Pin 12
13 117554-003 Anchor Chain 4
14 * Chain 2

Always Specify Model, Data & Serial Numbers

030501 6483

Printed in U.S.A.
01 REV. 9/03
07.6–7530–055 07.6–7530–055
 C LIFT CHAIN - TT MAST

Index 3 Chain (Free Lift) 1.0TT

Collapsed Height Lift Height Length Required Part Number Order Quantity
mm mm mm Links Per Truck
2325 5715 1240 65 042907-020 2
2415 6095 1315 69 042907-021 2
2720 6860 1470 77 042907-022 2
3025 7770 1620 85 042907-023 2
3175 8230 1695 89 042907-032 2
3330 8685 1770 93 042907-027 2
3635 9145 1925 101 042907-028 2
3785 9600 2000 105 042907-033 2
Index 3 Chain (Free Lift) 1.25TT
Collapsed Height Lift Height Length Required Part Number Order Quantity
mm mm mm Links Per Truck
2325 4955 1240 65 042907-020 2
2415 5335 1315 69 042907-021 2
2720 6095 1470 77 042907-022 2
3025 7010 1620 85 042907-023 2
3175 7470 1695 89 042907-032 2
3330 7925 1770 93 042907-027 2
3635 8385 1925 101 042907-028 2
3785 8840 2000 105 042907-033 2
3940 9300 2075 109 042907-034 2
Index 3 Chain (Mast) 1.0TT
Collapsed Height Lift Height Length Required Part Number Order Quantity
mm mm mm Links Per Truck
2325 5715 2115 111 042907-024 2
2415 6095 2270 119 042907-002 2
2720 6860 2570 135 042907-003 2
3025 7770 2880 151 042907-025 2
3175 8230 3030 159 042907-035 2
3330 8685 3180 167 042907-026 2
3635 9145 3485 183 042907-036 2
3785 9600 3640 191 042907-037 2
Index 3 Chain (Mast) 1.25TT
Collapsed Height Lift Height Length Required Part Number Order Quantity
mm mm mm Links Per Truck
2325 4955 2115 111 042907-024 2
2415 5335 2270 119 042907-002 2
2720 6095 2570 135 042907-003 2
3025 7010 2880 151 042907-025 2
3175 7470 3030 159 042907-035 2
3330 7925 3180 167 042907-026 2
3635 8385 3485 183 042907-036 2
3785 8840 3640 191 042907-037 2
3940 9300 3790 199 042907-038 2

Crown 2003 PF13542 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
07.6–7530–054-SUP 07.6–7530–054-SUP
This page available for NOTES.
 C MAST CYLINDER
3558

2 11
12

11
10 13
10 1

9
12 9

8
8
13

14

15

3 16
21

17
4
14 3
15
5 18
4
6 5 19
7

16 7

17 6
20
21 7
18

Crown 2003 PF13547 Printed in U.S.A.

08.1–7530–003 08.1–7530–003
 C MAST CYLINDER

*118568 CYLINDER ASSEMBLY

Index Part No. Part Name No. Req.

1 * Cylinder 1
2 * Ram 1
3 120981 Spring TL Only 1
4 117537-001 Piston TL Only 1
5 060009-151 Ring Retaining TL Only 1
6 073975-003 Bushing 1
7 060009-043 Ring Retaining 2
8 081161-017 Collar 1
9 064132-039 Packing Rod 1
10 117544 Cap 1
11 064135-002 Ring Wiper 1
12 074240 Seal 1
13 060015-078 Screw 1
14 118571 Poppet 1
15 118572 Spring Compression 1
16 064019-090 O-Ring 1
17 118573 Cap 1
18 060015-016 Screw 4
061004-026 Adhesive Thread Locking 1
19 079933 Button Rest 1
20 060017-036 Screw 2
060005-009 Lockwasher 2
21 064019-082 O-Ring 1

Always Specify Model, Data & Serial Numbers

118893 Kit Seal Includes Index 9, 11 thru 13,

16 & 21 1
091240-005 Sleeve Packing 1

Quantities Listed Are For One Cylinder

* See Supplemental List

030501 5265

Printed in U.S.A.

08.1–7530–004 08.1–7530–004
 C MAST CYLINDER
Mast Cylinder
Cylinder Assembly 1.25SP 1.0SP
Part Number Collapsed Height Lift Height Lift Height Mast Type
mm mm mm
118568-022 2325 4955 5715 TT
118568-023 2415 5335 6095 TT
118568-024 2720 6095 6860 TT
118568-025 3025 7010 7770 TT
118658-021 3175 7470 8230 TT
118568-026 3330 7925 8685 TT
118568-027 3635 8385 9145 TT
118568-029 3785 8840 9600 TT
118568-028 3940 9300 TT
118568-032 2325 3455 4215 TL
118568-033 2415 3760 4520 TL
118568-034 2720 4370 5130 TL
118568-035 3025 4930 5690 TL
118568-036 3330 5435 6200 TL
Index 1 Cylinder 1.25SP 1.0SP
Part Number Collapsed Height Lift Height Lift Height Mast Type
mm mm mm
118569-002 2325 4955 5715 TT
118569-003 2415 5335 6095 TT
118569-004 2720 6095 6860 TT
118569-005 3025 7010 7770 TT
118569-001 3175 7470 8230 TT
118569-006 3330 7925 8685 TT
118569-007 3635 8385 9145 TT
118569-009 3785 8840 9600 TT
118569-008 3940 9300 TT
118569-012 2325 3455 4215 TL
118569-013 2415 3760 4520 TL
118569-014 2720 4370 5130 TL
118569-015 3025 4930 5690 TL
118569-016 3330 5435 6200 TL
Index 2 Ram 1.25SP 1.0SP
Part Number Collapsed Height Lift Height Lift Height Mast Type
mm mm mm
117536-002 2325 4955 5715 TT
117536-003 2415 5335 6095 TT
117536-004 2720 6095 6860 TT
117536-005 3025 7010 7770 TT
117536-001 3175 7470 8230 TT
117536-006 3330 7925 8685 TT
117536-007 3635 8385 9145 TT
117536-009 3785 8840 9600 TT
117536-008 3940 9300 TT
117536-012 2325 3455 4215 TL
117536-013 2415 3760 4520 TL
117536-014 2720 4370 5130 TL
117536-015 3025 4930 5690 TL
117536-016 3330 5435 6200 TL
Crown 2003 PF13547 Printed in U.S.A.

08.1–7530–003-SUP 08.1–7530–003-SUP
This page available for NOTES.
 C FREE LIFT CYLINDER - TT
3022

11
10 7
14
9 6
12 15
8 7
13
16
2 12
1 21
11
17
13
1
10
18
3
19
4 9

14 15
3
7 8
6
5
4 20
16
7 5

21 17
18

Crown 2003 PF13548 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
08.3–7530–003 08.3–7530–003
 C FREE LIFT CYLINDER - TT

*118574 CYLINDER ASSEMBLY

Index Part No. Part Name No. Req.

1 * Cylinder 1
2 * Ram 1
3 087025 Spring 1
4 127489-001 Piston 1
5 060009-100 Ring Retaining 1
6 084882-001 Bushing 1
7 060009-096 Ring Retaining 2
8 081161-011 Collar 1
9 064132-018 Packing Rod 1
10 100516 Cap 1
11 064135-010 Ring Wiper 1
12 074240 Seal 1
13 060015-078 Screw 1
14 118577 Poppet 1
15 118578 Spring Compression 1
16 064019-090 O-Ring 1
17 118579 Cap 1
18 060015-016 Screw 4
061004-026 Adhesive Thread Locking 1
19 079933 Button Rest 1
20 060017-036 Screw 2
060005-009 Lockwasher 2
061004-026 Adhesive Thread Locking 1
21 064019-082 O-Ring 1

Always Specify Model, Data & Serial Numbers

118914 Kit Seal Includes Index 9, 11 thru 13,

16 & 21 1
091240-009 Sleeve Packing 1

Quantities Listed Are For One Cylinder

* See Supplemental List

030501 6481

Printed in U.S.A.
01 REV. 9/03
08.3–7530–004 08.3–7530–004
 C FREE LIFT CYLINDER - TT

Free Lift Cylinder

Assembly 1.25SP 1.0SP
Part Number Collapsed Height Lift Height Lift Height
mm mm mm
118574-402 2325 4955 5715
118574-403 241 5 5335 6095
118574-404 2720 6095 6860
118574-405 302 5 7010 7770
118574-401 3175 7470 8230
118574-406 3330 7925 8685
118574-407 363 5 8385 9145
118574-409 3785 8840 9600
118574-408 3940 9300
Index 1 Cylinder 1.25SP 1.0SP
Part Number Collapsed Height Lift Height Lift Height
mm mm mm
119591-002 2325 4955 5715
119591-003 241 5 5335 6095
119591-004 2720 6095 6860
119591-005 302 5 7010 7770
119591-001 3175 7470 8230
119591-006 3330 7925 8685
119591-007 363 5 8385 9145
119591-009 3785 8840 9600
119591-008 3940 9300
Index 2 Ram 1.25SP 1.0SP
Part Number Collapsed Height Lift Height Lift Height
mm mm mm
117546-002 2325 4955 5715
117546-003 241 5 5335 6095
117546-004 2720 6095 6860
117546-005 302 5 7010 7770
117546-001 3175 7470 8230
117546-006 3330 7925 8685
117546-007 363 5 8385 9145
117546-009 3785 8840 9600
117546-008 3940 9300

Crown 2003 PF13548 Rev. 9/03 Printed in U.S.A.

01 REV. 9/03
08.3–7530–003-SUP 08.3–7530–003-SUP
 C FORK
12358

Part Of
Platform
1
2
5
3
6
4

Crown 1994 PF10253-1 Rev. 1/05 Printed in U.S.A.

01 REV. 1/05
09.0–7330–250 09.0–7330–250
 C FORK

Index Part No. Part Name No. Req.

1 083404 Shim 1.5 mm (.060 in.) Thick AR

2 083403 Spacer 6 mm (.25 in.) Thick 4
3 083402 Mounting Bar 2
4 060000-042
Roll Pin 2
5 060015-054
Screw 1/4"
30 mm (1.25 in.) Length AR
060015-067 Screw 1/4"
45 mm (1.75 in.) Length AR
061004-019 Thread Locking Adhesive 1
6 105775 Fork Rod 2
7 060009-019 Retaining Ring 4
8 * Fork 2

Always Specify Model, Data & Serial Numbers

Quantities listed are for both forks.

Index 8 - Fork
Length
Part Number
mm (in.)
079369-002 2135 (84)
102476-001 760 (30)
102476-002 915 (36)
102476-010 990 (39)
102476-003 1065 (42)
102476-009 1145 (45)
102476-004 1220 (48)
102476-005 1370 (54)
102476-006 1525 (60)
102476-007 1830 (72)
102476-008 2135 (84)
125366 2135 (84)

941223 10101

Crown 1994 PF10253-2 Rev. 1/05 Printed in U.S.A.

01 REV. 1/05
09.0–7330–251 09.0–7330–251
 C PLATFORM - OPERATOR SIDE
10829

1
25

B
7

21
22 20

9 21
C
23 23
23 B 2 17
3
29
5
27 C K10 15 16
28 TB102
27
16
A 26 15
27 TB101
16 4
9 6 24
DB1 K9
14
24 10
13 A

8
12

11

18
19

Crown 2003 PF13541 Printed in U.S.A.

09.0–7530–003 09.0–7530–003
 C PLATFORM - OPERATOR SIDE

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 Platform Contact Factory 1 16 060013-010 Screw 4

2 069124 Label Display Module 1 060005-004 Lockwasher 4
** 869139 Label Warning Module 1 060021-004 Nut 4
3 060031-024 Nut Speed 1 17 079565-008 Strip Marking 2
4 † 088083-001 Relay K9 1 18 Fork See Section 09.0 2
† 086803 Insulator 1 19 Gate See Section 09.0 2
† 060013-010 Screw 2 20 * 117867-014-0S EU Standard Steering
† 060005-004 Lockwasher 2 Display Module 1
† 060021-004 Nut 2 117867-016-0S EU Rear Steering Display
5 088083-001 Relay K10 1 Module 1
086803 Insulator 1 21 060014-004 Screw 4
060013-010 Screw 2 060042-016 Nut Self Locking 4
060005-004 Lockwasher 2 22 118363 Plate Mounting Display 2
060021-004 Nut 2 23 060016-081 Screw 2
6 120720 Block Diode Override DB1 1 060005-008 Lockwasher 2
060013-003 Screw 2 060030-017 Flatwasher 2
060005-004 Lockwasher 2 060031-012 Nut Speed 2
060021-004 Nut 2 24 065004-038 Grommet 2
7 Control Module 25 Panel Switch
See Section 04.6 1 See Section 04.8 1
8 118833-002 Console Without Pallet Grab 1 26 061002-018 Clamp Harness 3
118833-003 Console With Pallet Grab 1 27 060015-006 Screw 3
9 118832-001 Screw Painted Head 6 060005-007 Lockwasher 3
060031-011 Nut Speed 4 060021-006 Nut 3
10 Steering Command 28 062525-002 Connector Service Terminal 1
See Section 06.0 1 29 104401-018 Spacer 2
11 079528 Extinguisher Fire 1 061004-026 Adhesive Thread Locking 1
060014-021 Screw 3
060005-005 Lockwasher 3 Always Specify Model, Data & Serial Numbers
060021-024 Nut 3
12 ‡ 104436 Bumper 2 061003-004 Tie Cable 140 mm Length 14
† 104436 Bumper 4
061007-002 Cement Liter 1 ** Choice of dash number depends on language.
13 ‡ 101212 Mat Rubber 1065 mm Platform 1
‡ 101213-001 Mat Rubber 1220 mm Platform 1 Dash Number Language
‡ 101213-002 Mat Rubber 1370 mm Platform 1 -001 German
‡ 101213-003 Mat Rubber 1525 mm Platform 1 -002 French
‡ 101213-004 Mat Rubber 1625 mm Platform 1 -003 Spanish
† 042771 Mat Rubber 1065 mm Platform 1 -004 Dutch
† 042881-001 Mat Rubber 1220 mm Platform 1 -005 Italian
† 042881-002 Mat Rubber 1370 mm Platform 1 -006 English
† 042881-003 Mat Rubber 1525 mm Platform 1
† 042881-004 Mat Rubber 1625 mm Platform 1 † 1.25SP Only
14 130817 Pedal Cover 1.25SP Trucks ‡ 1.0SP Only
Without Pallet Grab 1
060124-001 Fastener 2
15 079564-012 Block Terminal 2
105605-101 Label TB101 1
105605-102 Label TB102 1

030501 5179

Printed in U.S.A.

09.0–7530–004 09.0–7530–004
 GATE
3258
7
54 in. (1370 mm)
60 in. (1525 mm) 6 6 2
64 in. (1625 mm) GTS1
PLATFORMS ONLY GTS3

15 1
2 10
14
16 13 1 23
10 3
9 19

12 19
17
2 18 22
11 4

1
5
10 10 8
7
13
6 1
3 21
6
20
GTS1 19
GTS3 13
2
2
19
1
10 18
9 3 20
19
13
1

19
12

17
18

11
4
8

1 42 & 48 in.
13 5 (1065 & 1220 mm)
10 PLATFORM ONLY
3
19 20

1 2
19
18
20
Crown 1995 PF-10676 Rev. 9/95 Printed in U.S.A.
01 REV. 9/95
09.0–7530–150 09.0–7530–150
 GATE

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 103601-001 Bearing Nylon 4 13 108279-002 Collar 1065mm (42 in.),

2 060000-051 Pin Roll 1065mm (42 in.), 1220mm (48 in.) 2
1220mm (48 in.) 2 108279-002 Collar 1370mm (54 in.),
060000-051 Pin Roll 1370mm (54 in.), 1525mm (60 in.), 1625mm
1525mm (60 in.), (64 in.) Platform 3
1625mm (64 in.) 4 14 102442 Bumper Recess 1370mm
3 118416 Gate 2 (54 in.), 1525mm (60 in.),
4 060016-072 Screw 5/16" 2 1625mm (64 in.) Platform 1
060005-008 Lockwasher 2 15 060030-059 Flatwasher 1
060030-017 Flatwasher 2 16 060014-022 Screw #10 1
5 074909 Spring 1 060005-005 Lockwasher 1
6 060012-035 Screw #6 2 061004-019 Adhesive Thread Locking 1
060005-003 Lockwasher 2 17 107005-002 Handle Includes Bearing 1
060030-045 Flatwasher 2 065038-015 Bearing Oilite 1
060021-003 Nut 2 18 118364 Shaft 2
7 073624 Switch GTS1, GTS2, GTS3, 19 060017-099 Screw 3/8" 4
GTS4 (1.0SP) 4 060046-021 Washer Spring 4
073624 Switch GST1, GTS2 (1.25SP) 2 061004-019 Adhesive Thread Locking 1
117553-001 Insulator 1 20 060030-075 Flatwasher 2
8 106994-003 Gate Lower 1 21 117986-001 Cover RH 1370mm (54 in.),
9 118360 Shaft Gate 1065mm (42 in.), 1525mm (60 in.) Platform 1
1220mm (48 in.) Platform 1 117987-001 Cover LH Not Shown 1
118368-001 Shaft 1370mm (54 in.), 117986-002 Cover RH 1625mm (64 in.)
1525mm (60 in.) Platform 1 Platform 1
118368-002 Shaft 1625mm (64 in.) Platform 1 117987-002 Cover LH 1
10 060030-202 Shim 1mm (.04 in.) thick AR 22 118832-001 Screw Painted Head 1/4" 2
11 108281 Shaft 1065mm (42 in.), 23 100752-001 Collar 1370mm (54 in.),
1220mm (48 in.) 1 1525mm (60 in.), 1625mm
108326 Shaft 1370mm (54 in.), 1525mm (64 in.) Platform 1
(60 in.), 1625mm (64 in.)
Platform 1 Except for gate switches (index 7), quantities listed
12 105376 Bumper Gate 1065mm (42 in.), are for one gate assembly only.
1220mm (48 in.) Platform 1
087805 Bumper 1370mm (54 in.), Always Specify Model & Serial Number
1525mm (60 in.),
1625mm (64 in.) Platform 1
061001-004 Adhesive 1

950612 4817 - 41859

Printed in U.S.A.
01 REV. 9/95
09.0–7530–151 09.0–7530–151
 C 3 BAR GATE
11665

2
3

2
GTS1
GTS3

5
7 6
4
10
20 11
8
4
12
15
5
12 14
4 16
9
17
19
6 11
7 18
4 10

5 12
Part Of Truck
Platform 13
4
14
6
7
11 12 13
4 10

12
1065 & 1220 mm 13
(42 & 48 in.)
Platform Only 13 14
12

Crown 2004 PF13872-1 Printed in U.S.A.

09.0–7530–200 09.0–7530–200
 C 3 BAR GATE

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 118360 Shaft 1 10 118416 Gate 3

2 117553-001 Insulator 1 11 060017-099 Screw 6
060012-035 Screw #6 2 061004-019 Adhesive Thread Locking 1
060005-003 Lockwasher 2 12 060046-021 Spring Washer 6
060030-045 Flatwasher 2 13 060030-075 Flatwasher 4
060021-003 Nut 2 14 118364 Shaft 3
3 * 073624 Switch GTS1, GTS2, GTS3, 15 065038-015 Bearing 1
GTS4 (1.0SP) 4 16 107005-002 Handle Includes Index 15 1
* 073624 Switch GST1, GTS2 (1.25SP) 2 17 060016-072 Screw 2
4 103601-001 Nylon Bearing 6 060005-008 Lockwasher 2
5 060000-051 Roll Pin 3 060030-017 Flatwasher 2
6 108279-002 Collar 3 18 132800 Lower Gate 1
7 060030-202 Shim 1 mm (.04 in.) Thick AR 19 046213-001 Shaft 1
8 105376 Bumper 1 20 108281 Shaft 1
061001-019 Adhesive 1
9 079791 Spring 1 Always Specify Model, Data & Serial Numbers

Except for gate switches (index 3), quantities listed

are for one gate assembly only.

040820 8834 (IRE)

Crown 2004 PF13872-2 Printed in U.S.A.

09.0–7530–201 09.0–7530–201
This page available for NOTES.
 C AISLE GUIDE WHEELS
10557

1
2

RK
FO ND
5 E
3

Part of 1
6 7
Power Unit

1
8
15
13
9
17 14

10 8

11
16
12

11

10
13
13
18
18

19
19
20
20
21
Part of 21
Main Frame 20
22
20
19 22
Part of Main Frame 19
w/ Tip Mounted Aisle Guides

Crown 2003 PF13538 Printed in U.S.A.

10.0–7530–003 10.0–7530–003
 C AISLE GUIDE WHEELS

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 060020-026 Screw 100 mm Long AR 9 117982 Pin Shear 4

060020-034 Screw 85 mm Long AR 10 060030-068 Flatwasher AR
060020-033 Screw 70 mm Long AR 11 065081-021 Bearing 4
060030-058 Flatwasher 8 12 092538 Wheel Assembly Includes
060005-014 Lockwasher 8 Index 11 2
060021-015 Nut 8 081645-020 Wheel 50 x 100 mm 2
2 060020-015 Screw 4 13 076048-001 Lubrication Fitting 4
060005-014 Lockwasher 4 14 117979 Axle 2
060030-106 Flatwasher 4 15 † Yoke 2
3 060017-014 Screw 4 16 094537 Spring Extension 4
060005-054 Lockwasher 4 17 084022-002 Stop Poly 2
117980 Block Mount 2 18 105838 Axle 50 x 65 mm Wheel 2
4 087373 Switch RGS1 & RGS2 2 105839 Axle 50 x 100 mm Wheel 2
060012-022 Screw 4 19 060030-104 Flatwasher 50 x 65 mm Wheel 4
060005-048 Lockwasher 4 060030-050 Flatwasher 50 x 100 mm Wheel 4
5 117992-001 Spacer 6.5 mm Thick AR 20 073894 Bearing 50 x 65 mm Wheel 4
117992-002 Spacer 25 mm Thick AR 073893 Seal 50 x 65 mm Wheel 4
117992-003 Spacer 1.5 mm Thick AR 065081-021 Bearing 50 x 100 mm Wheel 4
6 117991-001 Spacer 6.5 mm Thick AR 21 082442 Wheel Assembly 50 x 65 mm
117991-002 Spacer 25 mm Thick AR Includes Bearing And Seal 2
117991-003 Spacer 1.5 mm Thick AR 082443-020 Wheel 50 x 65 mm 2
7 † Bracket Aisle Guide R.H. Shown 1 092538 Wheel Assembly 50 x 100 mm
† Bracket Aisle Guide L.H. 1 Includes Bearing 2
8 117983 Block Skid 2 081645-020 Wheel 50 x 100 mm 2
060017-027 Screw 4 22 060000-030 Pin Roll 2
060005-054 Lockwasher 4
Always Specify Model, Data & Serial Numbers

†See The Following Supplemental List

030501 5159

Printed in U.S.A.

10.0–7530–004 10.0–7530–004
 C AISLE GUIDE WHEELS

Width Across Index 7 Width Across Index 7

Index 15 Index 15
Guide Wheels Bracket Aisle Guide Guide Wheels Bracket Aisle Guide
Yoke Yoke
mm L.H. R.H. mm L.H. R.H.
1156 044912-001 044920-001 044921-001 1486 044912-005 044920-005 044921-005
1162 044912-001 044920-001 044921-001 1492 044912-005 044920-005 044921-005
1168 044912-001 044920-001 044921-001 1499 044912-005 044920-005 044921-005
1175 044912-001 044920-001 044921-001 1505 044912-005 044920-005 044921-005
1181 044912-001 044920-001 044921-001 1511 044912-006 044920-006 044921-006
1187 044912-001 044920-001 044921-001 1518 044912-006 044920-006 044921-006
1194 044912-001 044920-001 044921-001 1524 044912-006 044920-006 044921-006
1200 044912-001 044920-001 044921-001 1530 044912-006 044920-006 044921-006
1207 044912-002 044920-002 044921-002 1537 044912-006 044920-006 044921-006
1213 044912-002 044920-002 044921-002 1543 044912-006 044920-006 044921-006
1219 044912-002 044920-002 044921-002 1549 044912-006 044920-006 044921-006
1226 044912-002 044920-002 044921-002 1556 044912-006 044920-006 044921-006
1232 044912-002 044920-002 044921-002 1562 044912-006 044920-006 044921-006
1238 044912-002 044920-002 044921-002 1568 044912-006 044920-006 044921-006
1245 044912-002 044920-002 044921-002 1575 044912-006 044920-006 044921-006
1251 044912-002 044920-002 044921-002 1581 044912-006 044920-006 044921-006
1257 044912-002 044920-002 044921-002 1588 044912-007 044920-007 044921-007
1264 044912-002 044920-002 044921-002 1594 044912-007 044920-007 044921-007
1270 044912-002 044920-002 044921-002 1600 044912-007 044920-007 044921-007
1276 044912-002 044920-002 044921-002 1607 044912-007 044920-007 044921-007
1283 044912-003 044920-003 044921-003 1613 044912-007 044920-007 044921-007
1289 044912-003 044920-003 044921-003 1619 044912-007 044920-007 044921-007
1295 044912-003 044920-003 044921-003 1626 044912-007 044920-007 044921-007
1302 044912-003 044920-003 044921-003 1632 044912-007 044920-007 044921-007
1308 044912-003 044920-003 044921-003 1638 044912-007 044920-007 044921-007
1314 044912-003 044920-003 044921-003 1645 044912-007 044920-007 044921-007
1321 044912-003 044920-003 044921-003 1651 044912-007 044920-007 044921-007
1327 044912-003 044920-003 044921-003 1657 044912-007 044920-007 044921-007
1334 044912-003 044920-003 044921-003 1664 044912-008 044920-008 044921-008
1340 044912-003 044920-003 044921-003 1670 044912-008 044920-008 044921-008
1346 044912-003 044920-003 044921-003 1676 044912-008 044920-008 044921-008
1353 044912-003 044920-003 044921-003 1683 044912-008 044920-008 044921-008
1359 044912-004 044920-004 044921-004 1689 044912-008 044920-008 044921-008
1365 044912-004 044920-004 044921-004 1695 044912-008 044920-008 044921-008
1372 044912-004 044920-004 044921-004 1702 044912-008 044920-008 044921-008
1378 044912-004 044920-004 044921-004 1708 044912-008 044920-008 044921-008
1384 044912-004 044920-004 044921-004 1715 044912-008 044920-008 044921-008
1391 044912-004 044920-004 044921-004 1721 044912-008 044920-008 044921-008
1397 044912-004 044920-004 044921-004 1727 044912-008 044920-008 044921-008
1403 044912-004 044920-004 044921-004 1734 044912-008 044920-008 044921-008
1410 044912-004 044920-004 044921-004 1740 044912-009 044920-009 044921-009
1416 044912-004 044920-004 044921-004 1746 044912-009 044920-009 044921-009
1422 044912-004 044920-004 044921-004 1753 044912-009 044920-009 044921-009
1429 044912-004 044920-004 044921-004 1759 044912-009 044920-009 044921-009
1435 044912-005 044920-005 044921-005 1765 044912-009 044920-009 044921-009
1441 044912-005 044920-005 044921-005 1772 044912-009 044920-009 044921-009
1448 044912-005 044920-005 044921-005 1778 044912-009 044920-009 044921-009
1454 044912-005 044920-005 044921-005 1784 044912-009 044920-009 044921-009
1461 044912-005 044920-005 044921-005 1791 044912-009 044920-009 044921-009
1467 044912-005 044920-005 044921-005 1797 044912-009 044920-009 044921-009
1473 044912-005 044920-005 044921-005 1803 044912-009 044920-009 044921-009
1480 044912-005 044920-005 044921-005 1810 044912-009 044920-009 044921-009

Crown 2003 PF13538 Printed in U.S.A.

10.0–7530–003-SUP 10.0–7530–003-SUP
This page available for NOTES.
 C LOW PROFILE AISLE GUIDE WHEELS
4150-01
1
2

3 RK
5 FO ND
E

4
B
1
C
6 C
PART OF POWER UNIT 7

B 1

17
15
A
14

8
16 9
A
12
9
19
13 10
11
18
PART OF MAIN FRAME

19
20
21

22 20
19

Crown 2003 PF13539 Printed in U.S.A.

10.0–7530–052 10.0–7530–052
 C LOW PROFILE AISLE GUIDE WHEELS

Index Part No. Part Name No. Req. Index Part No. Part Name No. Req.

1 060020-026 Screw 100 mm Long AR 8 060030-068 Flatwasher AR

060020-034 Screw 85 mm Long AR 9 055002-002 Bearing 4
060020-033 Screw 70 mm Long AR 10 060005-023 Lockwasher 1
060030-058 Flatwasher 8 11 060021-040 Nut 1
060005-014 Lockwasher 8 061004-019 Adhesive Thread Locking 1
060021-015 Nut 8 12 045122 Wheel Assembly Includes
2 060020-015 Screw 4 Index 9 2
060005-014 Lockwasher 4 045121 Wheel 50 x 100 mm 2
060030-106 Flatwasher 4 13 076048-001 Fitting Lubrication 2
3 060017-014 Screw 4 14 044553 Fitting Lubrication 2
060005-054 Lockwasher 4 15 † Yoke 2
117980 Block Mount 2 16 094537 Spring Extension 4
4 087373 Switch RGS1 & RGS2 2 17 084022-002 Stop Poly 2
060012-022 Screw 4 18 105838 Axle 50 x 65 mm Wheel 2
060005-048 Lockwasher 4 19 060030-104 Flatwasher 50 x 65 mm Wheel 4
5 045099-001 Spacer 6.5 mm Thick AR 20 073894 Bearing 50 x 65 mm Wheel 4
045099-002 Spacer 25 mm Thick AR 073893 Seal 50 x 65 mm Wheel 4
045099-003 Spacer 1.5 mm Thick AR 21 082442 Wheel Assembly 50 x 65 mm
6 045100-001 Spacer 6.5 mm Thick AR Includes Bearing And Seal 2
045100-002 Spacer 25 mm Thick AR 082443-020 Wheel 50 x 65 mm 2
045100-003 Spacer 1.5 mm Thick AR 22 060000-030 Pin Roll 2
7 † Bracket Aisle Guide R.H. Shown 1
† Bracket Aisle Guide L.H. 1 Always Specify Model, Data & Serial Numbers

†See The Following Supplemental List

030105 5160

Printed in U.S.A.

10.0–7530–053 10.0–7530–053
 C LOW PROFILE AISLE GUIDE WHEELS

Width Across Index 7 Width Across Index 7

Index 15 Index 15
Guide Wheels Bracket Aisle Guide Guide Wheels Bracket Aisle Guide
Yoke Yoke
mm L.H. R.H. mm L.H. R.H.
1156 045026-001 045029-001 045030-001 1486 045026-005 045029-005 045030-005
1162 045026-001 045029-001 045030-001 1492 045026-005 045029-005 045030-005
1168 045026-001 045029-001 045030-001 1499 045026-005 045029-005 045030-005
1175 045026-001 045029-001 045030-001 1505 045026-005 045029-005 045030-005
1181 045026-001 045029-001 045030-001 1511 045026-006 045029-006 045030-006
1187 045026-001 045029-001 045030-001 1518 045026-006 045029-006 045030-006
1194 045026-001 045029-001 045030-001 1524 045026-006 045029-006 045030-006
1200 045026-001 045029-001 045030-001 1530 045026-006 045029-006 045030-006
1207 045026-002 045029-002 045030-002 1537 045026-006 045029-006 045030-006
1213 045026-002 045029-002 045030-002 1543 045026-006 045029-006 045030-006
1219 045026-002 045029-002 045030-002 1549 045026-006 045029-006 045030-006
1226 045026-002 045029-002 045030-002 1556 045026-006 045029-006 045030-006
1232 045026-002 045029-002 045030-002 1562 045026-006 045029-006 045030-006
1238 045026-002 045029-002 045030-002 1568 045026-006 045029-006 045030-006
1245 045026-002 045029-002 045030-002 1575 045026-006 045029-006 045030-006
1251 045026-002 045029-002 045030-002 1581 045026-006 045029-006 045030-006
1257 045026-002 045029-002 045030-002 1588 045026-007 045029-007 045030-007
1264 045026-002 045029-002 045030-002 1594 045026-007 045029-007 045030-007
1270 045026-002 045029-002 045030-002 1600 045026-007 045029-007 045030-007
1276 045026-002 045029-002 045030-002 1607 045026-007 045029-007 045030-007
1283 045026-003 045029-003 045030-003 1613 045026-007 045029-007 045030-007
1289 045026-003 045029-003 045030-003 1619 045026-007 045029-007 045030-007
1295 045026-003 045029-003 045030-003 1626 045026-007 045029-007 045030-007
1302 045026-003 045029-003 045030-003 1632 045026-007 045029-007 045030-007
1308 045026-003 045029-003 045030-003 1638 045026-007 045029-007 045030-007
1314 045026-003 045029-003 045030-003 1645 045026-007 045029-007 045030-007
1321 045026-003 045029-003 045030-003 1651 045026-007 045029-007 045030-007
1327 045026-003 045029-003 045030-003 1657 045026-007 045029-007 045030-007
1334 045026-003 045029-003 045030-003 1664 045026-008 045029-008 045030-008
1340 045026-003 045029-003 045030-003 1670 045026-008 045029-008 045030-008
1346 045026-003 045029-003 045030-003 1676 045026-008 045029-008 045030-008
1353 045026-003 045029-003 045030-003 1683 045026-008 045029-008 045030-008
1359 045026-004 045029-004 045030-004 1689 045026-008 045029-008 045030-008
1365 045026-004 045029-004 045030-004 1695 045026-008 045029-008 045030-008
1372 045026-004 045029-004 045030-004 1702 045026-008 045029-008 045030-008
1378 045026-004 045029-004 045030-004 1708 045026-008 045029-008 045030-008
1384 045026-004 045029-004 045030-004 1715 045026-008 045029-008 045030-008
1391 045026-004 045029-004 045030-004 1721 045026-008 045029-008 045030-008
1397 045026-004 045029-004 045030-004 1727 045026-008 045029-008 045030-008
1403 045026-004 045029-004 045030-004 1734 045026-008 045029-008 045030-008
1410 045026-004 045029-004 045030-004 1740 045026-009 045029-009 045030-009
1416 045026-004 045029-004 045030-004 1746 045026-009 045029-009 045030-009
1422 045026-004 045029-004 045030-004 1753 045026-009 045029-009 045030-009
1429 045026-004 045029-004 045030-004 1759 045026-009 045029-009 045030-009
1435 045026-005 045029-005 045030-005 1765 045026-009 045029-009 045030-009
1441 045026-005 045029-005 045030-005 1772 045026-009 045029-009 045030-009
1448 045026-005 045029-005 045030-005 1778 045026-009 045029-009 045030-009
1454 045026-005 045029-005 045030-005 1784 045026-009 045029-009 045030-009
1461 045026-005 045029-005 045030-005 1791 045026-009 045029-009 045030-009
1467 045026-005 045029-005 045030-005 1797 045026-009 045029-009 045030-009
1473 045026-005 045029-005 045030-005 1803 045026-009 045029-009 045030-009
1480 045026-005 045029-005 045030-005 1810 045026-009 045029-009 045030-009

Crown 2003 PF13539 Printed in U.S.A.

10.0–7530–052-SUP 10.0–7530–052-SUP
This page available for NOTES.
This page available for NOTES.
 SERVICE SPECIFICATIONS

MODEL SP 3011-1.25 SP 3021-1.25 SP 3021H-1.25

Capacity†† 1250 kg

Load Center 600 mm

Voltage 24V

Operator Type Stand-up Rider Stockpicker

Tire Type Load/Drive: Poly/Poly

Wheels Load/Drive: 4/1x

Head Length ** TL/TT: 1895/1920 mm

Forks
Standard L x W x T: 1070 x 100 x 50 mm
Optional Lengths: 760, 915, 990, 1145, 1220, 1370, 1525, 1830, 2135mm

Wheel Base TL/TT: 1410/1385 mm

Turning Radius TL/TT: 1750/1730 mm

Travel Speeds Steered Wheel ≤ 10° Steered Wheel ≥ 10°

Lift Height Travel Speed m/s Brake Force Travel Speed m/s Brake Force
MM Empty Loaded (Percentage) Empty Loaded (Percentage)

0 - 1200 9.0 7.9 100 9.0 7.9 100

1200 - 2500 4.0 3.3 67 2.5 1.9 67

2500 - 4500 2.5 1.9 33 2.5 1.9 33

4500 - Max. 2.5 1.9 33 2.5 1.9 33

Guided

0 - 1200 †9.7/10.5 †8.5/9.2 100

1200 - 2500 7.0 5.9 67

2500 - 4500 4.0 3.3 33

4500 - Max. 2.5 1.9 33

** From power unit to platform edge.

† 2.6KW/3.0KW Motor
†† 1250 kg at 6200 mm, 1000 kg at 7010 mm, 750 kg at 8385 mm and 550 kg at 9300 mm lift height.

030501 5825

Crown 2003 PF13602-1 Printed in U.S.A.

11.0–7530–004 11.0–7530–004
 SERVICE SPECIFICATIONS

Lifting Speed SP 3011-1.25 SP 3021-1.25

m/s m/s
Empty Loaded Empty Loaded

TL: 0.23 0.14 0.23 0.14 Low

0.41 0.23 High

TT: 0.20 0.13 0.20 0.13 Low

0.36 0.22 High

Lowering Speed
TL: 0.20 0.19 0.20 0.19 Low
0.41 0.38 High

TT: 0.20 0.19 0.20 0.19 Low

0.41 0.38 High

Battery
Min./Max., Amp. Hour: 500/800

Min./Max., Weight: 690/860 kg

Battery Size:
920 x 357 x 787mm

MODELS All 1.25 TL Trucks

Lift Height mm 3455 3760 4370 4930 5435

Free Lift mm 75 115 115 115 115

Collapsed Height mm 2325 2415 2720 3020 3330

Extended Height mm 5705 6010 6615 7175 7685

Straddle Width mm 1070

Operator Compartment
Width mm 1070 1220 1370

Aisle Guide Wheel

Range mm 1155 To 1660
(In 6.5 mm increments)

Truck Weight SP3011

Without Battery kg 2405 2430 2490 2625 2680

Truck Weight SP3021

Without Battery kg 2430 2455 2515 2650 2705

Crown 2003 PF13602-2 Printed in U.S.A.

11.0–7530–005 11.0–7530–005
 SERVICE SPECIFICATIONS

MODELS SP 3011/3021 1.25 TT SP 3021-H 1.25 TT

Lift Height †† mm 4955 5335 6095 7010 7470 7925 8385 8840 9300

Free Lift mm 75 165 470 775 925 1080 1385 1535 1690

Collapsed Height mm 2325 2415 2720 3025 3175 3330 3635 3785 3940

Extended Height mm 7225 7610 8370 9285 9740 10,200 10,655 11,112 11,570

Straddle Width Std. mm 1070 1070 1070 1220 1370 1370 1420 1525 1525

Operator
Compartment mm 1070 1070 1070 1220 1370 1370 1370 1525 1525
Width Std.

Aisle Guide Wheel

Range mm 1155-1660 1240 To 1390 To 1390 To 1440 To 1545 To 1545 To
(In 6.5mm increments) 1810 1960 1960 2015 2115 2115

Truck Weight SP 3011

Without Battery kg 2665 2705 2790 N/A N/A N/A N/A N/A N/A

Truck Weight SP 3021

Without Battery kg 2690 2730 2815 3045 3130 3170 3260 3325 3520

MODELS (TL/TT) SP 3011 SP 3021 SP 3021H

Traction Motor
(60 Min. Rating) kW 2.6 Std./3.0 Opt. 3.0 Std.

Motors, Controls
Drive Type: Series
Diameter: 170 mm Std./190 mm Opt. 190 mm Std.
Control: Transistor

Lift Type: Series

Diameter: 140 mm
Control : Contactor

Hydraulic Pump(s)
Lift Type: Gear
Flow (Nominal
@ 2000RPM): 19 Litres/ Min.
Pressure (Max.): 27.6 MPa

Relief Valve 15.44-15.62 MPa TL

Pressure 18.00-18.17 MPa TT

Drive Unit Type: Helical & Spiral-Bevel Gear

Lubrication: Integral Oil Pump
Reduction Ratio: 17.1:1 Double Gear Reduction

Steering Electronic Power Steering

††1250 kg at 6200 mm, 1000 kg at 7010 mm, 750 kg at 8385 mm, 550 kg at 9300 mm Lift Height
Crown 2003 PF13602-3 Printed in U.S.A.

11.0–7530–006 11.0–7530–006
This page available for NOTES.
 C SERVICE SPECIFICATIONS

MODEL SP 3012-1.0 SP 3022-1.0 SP 3022H-1.0

Capacity†† 1000 kg

Load Center 600 mm

Voltage 24V

Operator Type Stand-up Rider Stockpicker

Tire Type Load/Drive: Poly/Poly

Wheels Load/Drive: 4/1x

Head Length ** TL/TT: 2120/2145 mm

Forks
Standard L x W x T: 1070 x 100 x 40 mm
Optional Lengths: 760, 915, 990, 1145, 1220 mm

Wheel Base TL/TT: 1410/1385 mm

Turning Radius TL/TT: 1750/1730 mm

Travel Speeds Steered Wheel ≤ 10° Steered Wheel ≥ 10°

Lift Height Travel Speed m/s Brake Force Travel Speed m/s Brake Force
mm Empty Loaded (Percentage) Empty Loaded (Percentage)

0 - 1200 9.0 7.9 100 9.0 7.9 100

1200 - 2500 4.0 3.3 67 2.5 1.9 67

2500 - 4500 2.5 1.9 33 2.5 1.9 33

4500 - Max. 2.5 1.9 33 2.5 1.9 33

Guided

0 - 1200 †9.7/10.5 †8.5/9.2 100

1200 - 2500 7.0 5.9 67

2500 - 4500 4.0 3.3 33

4500 - Max. 2.5 1.9 33

** From power unit to fork face.

† 2.6KW/3.0KW Motor
†† 1000 kg at 6095 mm, 800 kg at 6860 mm, 500 kg at 8685 mm and 350 kg at 9600 mm lift height.

030501 5831

Crown 2003 PF13603-1 Printed in U.S.A.

11.0–7530–053 11.0–7530–053
 C SERVICE SPECIFICATIONS

Lifting Speed SP 3012-1.0 SP 3022-1.0

m/s m/s
Empty Loaded Empty Loaded

TL: 0.23 0.14 0.23 0.14 Low

0.41 0.23 High

TT: 0.20 0.13 0.20 0.13 Low

0.36 0.22 High

Lowering Speed
TL: 0.20 0.19 0.20 0.19 Low
0.41 0.38 High

TT: 0.20 0.19 0.20 0.19 Low

0.41 0.38 High

Battery
Min./Max., Amp. Hour: 500/800

Min./Max., Weight: 690/860 kg

Battery Size:
920 x 357 x 787mm

MODELS All 1.0 TL Trucks

Lift Height mm 4215 4520 5130 5690 6200

Free Lift mm 835 875 875 875 875

Collapsed Height mm 2325 2415 2720 3025 3330

Extended Height mm 5700 6010 6615 7175 7685

Straddle Width mm 1070

Operator Compartment
Width mm 1070 Std. 1220 1370 Opt.

Aisle Guide Wheel

Range mm 1155 To 1660
(In 6.5 mm increments)

Truck Weight SP3012

Without Battery kg 2580 2605 2665 2800 2855

Truck Weight SP3022

Without Battery kg 2605 2630 2690 2825 2880

Crown 2003 PF13603-2 Printed in U.S.A.

11.0–7530–054 11.0–7530–054
 C SERVICE SPECIFICATIONS

MODELS SP 3012/3022 1.0 TT SP 3022-H 1.0 TT

Lift Height†† mm 5715 6095 6860 7770 8230 8685 9145 9600

Free Lift mm 835 925 1230 1535 1685 1840 2145 2295

Collapsed Height mm 2325 2415 2720 3025 3175 3330 3635 3785

Extended Height mm 7225 7610 8370 9285 9740 10,200 10,655 11,112

Straddle Width Std. mm 1070 1070 1220 1370 1370 1420 1525 1525

Operator
Compartment mm 1070 1070 1220 1370 1370 1370 1525 1525
Width Std.

Aisle Guide Wheel

Range mm 1155-1660 1240 To 1390 To 1390 To 1440 To 1545 To
(In 6.5 mm increments) 1810 1960 1960 2015 2115

Truck Weight SP 3011

Without Battery kg 2840 2880 2965 N/A N/A N/A N/A N/A

Truck Weight SP 3021

Without Battery kg 2865 2905 2990 3220 3305 3345 3435 3500

MODELS (TL/TT) SP 3012 SP 3022 SP 3022H

Traction Motor
(60 Min. Rating) kW 2.6 Std./3.0 Opt. 3.0 Std.

Motors, Controls
Drive Type: Series
Diameter: 170 mm Std./190 mm Opt. 190 mm Std.
Control: Transistor

Lift Type: Series

Diameter: 140 mm
Control : Contactor

Hydraulic Pump(s)
Lift Type: Gear
Flow (Nominal
@ 2000RPM): 19 Litres/Min.
Pressure (Max.): 27.6 MPa

Relief Valve 15.44-15.62 MPa TL

Pressure 18.00-18.17 MPa TT

Drive Unit Type: Helical & Spiral-Bevel Gear

Lubrication: Integral Oil Pump
Reduction Ratio: 17.1:1 Double Gear Reduction

Steering Electronic Power Steering

††1000 kg at 6095 mm, 800 kg at 6860 mm, 500 kg at 8685 mm, & 350 kg at 9600 mm Lift Height
Crown 2003 PF13603-3 Printed in U.S.A.

11.0–7530–055 11.0–7530–055
 SP 3000 Customer

PF10601-0GB-0C

REV. B
mfg 111705