ELECTRICAL SYSTEM

Event Codes

Event Codes
Access Module Listing:
Access 1: Display Control Module (DCM)
Access 3™: Traction Control Module (TCM)

CAUTION

Due to capacitance voltage present in the traction mo-

tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
1. Move truck to a secure non traffic maintenance area
with a level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller
for 15 or more seconds.

Fig. 1 (17394-01)

1 Access 1 - Display Control Module (DCM) (Shown) Access

3™ - Traction Control Module (TCM)
2 Battery Discharge Indicator
3 Display Screen
4 Battery Retainer Switch Indicator
5 Enter or Return Key - used to navigate in and out of menus
and accept inputs
6 Navigation Keys - up, down, left and right arrows; used to
scroll through menus
7 Operator Improper Sequence Error Indicator
8 Service Required Indicator
* NOTE: These three indicators are viewable during initial
key-on, self test and indicator functioning.

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ELECTRICAL SYSTEM
Event Code 110

Event Code 110

Unable to Establish Communication with
Access 3™ at Power Up
Lack of CAN communication between Access 3™ and
Access 1. Check CAN line connections between
Access 1 and Access 3™. Check for a non-responsive
Access 3™.
Step 1: Turn the truck OFF. Disconnect the battery.
Fig. 2 (14988)
Check CAN HI and CAN LO terminals to make
sure they are fully inserted into the connectors
on Access 1 and Access 3™. CAN HI = Event Code 111
Access 3™ CA201-23 & Access 1 CA401-8.
Access 3™ does not enter Setup Mode properly
CAN LO = Access 3™ CA201-15 & Access 1
Step 1: Turn the truck OFF. Turn the truck back ON.
CA401-9.
Step 2: Check the resistance between the CAN HI and • If:Event continues.
CAN LO terminals. Disconnect Access 3™ – Then follow troubleshooting steps for Event Code
110.
CA201. Use a DVOM to check the resistance
between pins 15 and 23 on the wire harness
connector. Make sure Access 1 CA401 is still Event Code 162
connected and fully seated. Resistance should
be 60 ± 1 ohm. Load Sense Issue
Access 1 input CA401-13 receives a signal of 0.125 V
• If: Resistance is 60 ± 1 ohm.
or less (25 counts or less in Service Level 2 Analyzer
– Then disconnect Access 1 CA401 and check the Menu A2.11).
resistance between pins 8 and 9 on the wire har-
Step 1: Turn truck OFF. Disconnect Access 1 CA401
ness connector. Resistance, with both CA201
and CA401 disconnected, should be 120 ± & PT1 connector CA615. Visually inspect con-
1 ohm. nectors CA401 and CA615 to verify all con-
• If: Resistance is not 120 ± 1 ohm. tacts are correctly seated.
– Then replace the main wire harness.
• If: Resistance is 120 ± 1 ohm and event continues.
– Then replace Access 1.
Step 3: Connect CA201 and CA401. Connect the bat-
tery. Turn the truck ON. Monitor the event
code.
• If:Event code continues.
– Then use a DVOM to verify Access 3™ has
power. Check for +BV at Access 3™ PC201-1.
• If:Voltage is less than +BV.
– Then find and repair the open circuit.
• If:Voltage is +BV.
– Then replace Access 3™. Configure new
Access 3™ controller in Utilities Menu U2.

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 ELECTRICAL SYSTEM
Event Code 300

– Then replace Access 1.

Correct PT1 Counts

(View in A2.11)

Load on Forks Counts

kg lb ± 50
0 0 150
455 1000 200
910 2000 250
1360 3000 300
1815 4000 350
2270 5000 400
2720 6000 450
3175 7000 500
3630 8000 550
Fig. 3 (14989-01)
• If:Contact is not flush with the front of the connec-
tor.
– Then reseat the contact. Event Code 300
Use a DVOM to check for continuity between CA401-5 Internal Access 3™ Issue
and CA615-1 on the wire harness. Check for continuity Access 3™ has an internal issue. The Access 3™
between CA401-14 and CA615-2 on the wire harness. software does not recognize a bit that is set on a 50 Hz
Finally, check for continuity between CA401-13 and loop. This software monitor ensures it will never lock up
CA615-4 the on wire harness. or enter an infinite loop. The likely causes are corrupt
• If:Any measured resistance is more than 3 ohm. software or an internal hardware issue.
– Then replace the wire harness. Step 1: Update Access 3™ with the latest version of
• If:No measured resistance is more than 3 ohm. software. Turn the truck OFF and back ON.
– Then proceed to Step 2. Verify truck operation.
Step 2: Connect Access 1 CA401, but leave CA615 • If:Event continues.
disconnected. Turn the truck ON. Connect a – Then proceed to Step 2.
DVOM to CA615-1 of the wire harness con- Step 2: Replace Access 3™. Configure new
nector and Access 3™ B+ to check the volt- Access 3™ in Utilities Menu U2.
age.
• If:Voltage is 10 V (± 1.0 V).
– Then proceed to Step 3.
Event Code 301
• If:Voltage is 0.0 V (± 0.3 V). Access 1 periodic SDO timeout
– Then replace Access 1. Event Code 301 occurs when Access 3™ and
Step 3: Check voltage at CA615-2 of the PT1 wire har- Access 5 cannot communicate with Access 1.
ness connector and Access 3™ B-. Incorrect wiring in the CAN circuit or a defective
Access 1 causes this code.
• If:Voltage is 10 V (± 1.0 V).
– Then replace PT1. Verify operation.
• If:Voltage is not 10 V (± 1.0 V).

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Event Code 312

Step 1: Turn the truck OFF. Make sure CAN HI and

CAN LO terminals are fully connected to the
back of Access 1 and Access 3™. CAN HI = Event Code 312
CA201-23 on Access 3™ and CA401-8 on AC over current
Access 1. CAN LO = CA201-15 on
Higher than normal current is sensed at Access 3™
Access 3™ and CA401-9 on Access 1. terminals U, V or W. Possible causes are shorted
Step 2: Measure resistance between CAN HI and power cables or M1 windings or an ENC1 issue.
CAN LO terminals. Disconnect CA201 on
Access 3™ and measure the resistance be- CAUTION
tween pins 15 and 23 on the harness connec- Due to capacitance voltage present in the traction mo-
tor (battery disconnected). Make sure CA401 tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
on Access 1 is fully connected. The correct re-
ciated power cables, discharge the capacitors.
sistance is 59–61 Ω. 1. Move truck to a secure non traffic maintenance area
• If:Resistance is not 59–61 Ω. with a level floor.
– Then disconnect the Access 1 harness connec- 2. Lockout/Tagout truck as described in Battery - Lock-
tor (CA401) and measure the resistance between out/Tagout in this section.
pins 8 and 9 on the harness connector (CA401). 3. Place a minimum 100 ohm, 10 watt resistor between
The correct resistance with CA201 and CA401 the positive and negative terminals of the controller for
disconnected is 119–121 Ω. 15 or more seconds.
• If:Resistance is not 119–121 Ω.
– Then replace the main wire harness. Step 1: Turn the truck OFF. Disconnect the battery.
• If:Resistance is 119–121 Ω. Discharge the Access 3™ capacitors. Discon-
– Then replace Access 1. nect each of the three-phase power cables
Step 3: Connect the connectors and the battery. Turn from Access 3™ and M1. One at a time, use a
the truck ON and check if the event continues. DVOM to check the resistance between the
power cable and frame.
• If:Event continues.
• If:Cables are shorted.
– Then make sure Access 3™ has power. Check
for +BV at CA201-1. – Then repair or replace as necessary.
• If:No +BV. • If:Cables are OK.
– Then find the open circuit. – Then proceed to Step 2.
• If:+BV. Step 2: Check the wire harness to ENC1 and the
– Then replace Access 3™. ENC1 connector (CA405) for opens or shorts.
• If:Harness or connector has shorts or breaks.
– Then repair or replace the harness as necessary.
Access 3™ Access 1
CA401 • If:Wire harness and connector are OK.
CA201
+BV (AK) 1 3 +BV (AK) – Then proceed to Step 3.
004
Step 3: Check the encoder (ENC1) operation.
CAN LO 15 005 8 CAN HI
120
002 9 CAN LO Ohm • If:The ENC1 is not working correctly.
CAN HI 23 006
R1 – Then replace the encoder.
121 • If:ENC1 is ok.
OHM
BUTT SPLICE
– Then proceed to step 4.
Fig. 4 (21213-03) Step 4: With the power cables disconnected from M1,
check the resistance of each M1 terminal to
truck frame.
• If:Any terminals are shorted (not open).

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– Then replace M1.
• If:M1 windings do not show a connection to the
frame.
– Then the issue could be intermittent or higher re-
sistance than the meter can detect.
Step 5: Use a DVOM to check Access 3™ terminal re-
sistance to the truck frame. Keep the power
cables disconnected from Access 3™. Check
the resistance of each phase terminal to the
truck frame.
• If:Any of the terminals are shorted.
– Then replace Access 3™.
• If:Access 3™ terminals are OK.
– Then replace M1.
Fig. 5 (14991)
Event Code 313
Current Sensor Offset Calibration Issue
Access 3™ has an internal issue. The AC current
measurement is out of the expected range while
Access 3™ is at rest.
CAUTION
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
1. Move truck to a secure non traffic maintenance area
with a level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller for
15 or more seconds.
Crown 2007 PF15787-5 Rev. 8/11
ELECTRICAL SYSTEM
Event Code 313
Step 1: Turn the truck OFF. Disconnect the battery.
Discharge the Access 3™ capacitors. Con-
nect the battery. Turn the truck ON.
• If:Event code continues.
– Then proceed to Step 2.
Step 2: Clear the events in the Access 1 history. Turn
the truck OFF, then back ON.
• If:Event code continues.
– Then proceed to Step 3.
Step 3: Turn the truck OFF and replace Access 3™.
Configure new Access 3™ in Utilities Menu
U2.
• If:Event code continues.
– Then replace Access 1.
Event Code 318
DC Bus High - Hardware Detected (high battery
voltage at Access 3™)
DC voltage to Access 3™ (between + and BNEG
terminals) is 50 V or more.
Step 1: Turn the truck OFF. Disconnect the battery.
Use a DVOM to check the battery voltage at
the battery terminals.
• If:The voltage is more than 28 V.
– Then make sure the battery is in good condition,
proper voltage for battery (24 V or 12 cells) and
charger is in good working order.
• If:The battery is less than 28 V.
– Then proceed to Step 2.
Step 2: Check if the line contactor (L) has opened dur-
ing a regen brake with the battery at full
charge.
• If:Battery has recently come off of the charger.
– Then the battery can temporarily go over the limit
with a harsh regen brake.
• If:Battery just came off charger and performed a re-
gen brake.
– Then battery is fully charged to maximum and will
drop in voltage within a few minutes with normal
use.
• If:Battery has not been charged recently.
– Then proceed to Step 3.
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Event Code 320
Step 3: Determine if the line contactor (L) is in good
working order with good tips and a good return
spring.
• If:The line contactor (L) tips or spring are bad.
– Then replace or repair the line contactor (L).
• If:The line contactor (L) is functioning properly.
– Then check the wiring going to the line contactor
(L) coil.
• If:Wire terminals are loose or wire is damaged.
– Then repair or replace the harness as necessary.
• If:Harness is OK.
– Then proceed to Step 4.
Step 4: Check the power connections of the line con-
tactor (L) and Access 3™. Make sure the ter-
minals are tightened to the proper torque
specification and the threads are in good con-
dition.
• If:The connections are loose or corroded.
– Then tighten or replace the terminals as neces-
sary.
• If:Connections are OK.
– Then proceed to Step 5.
Step 5: Turn the truck ON. Use a DVOM to measure
the voltage of FU1 in the circuit. Measure from
the +BV side of FU1 to the Access 3™ BNEG
terminal. Then measure from the + side of FU1
to the Access 3™ BNEG terminal.
• If:There is a difference in voltage of 0.5 V or more.
– Then replace FU1.
• If:Voltage is +BV on both sides of FU1.
– Then proceed to Step 6.
Step 6: Turn the truck OFF. Discharge the Access 3™
capacitors. Check the Access 3™ battery ter-
minal connections.
• If:Connections are loose or corroded.
– Then tighten or replace the terminals.
• If:Connections are tight and in good condition.
– Then proceed to Step 7.
Step 7: Remove TR1 from the line contactor (L). Allow
TR1 to cool to room temperature. Use a
DVOM to check the resistance of TR1.
• If:Resistance is not 39.5 ohm.
– Then replace TR1.
• If:Resistance is 39.5 ohm.
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– Then proceed to Step 8.
Step 8: Inspect the line contactor terminal threads for
excess wear. Replace the contactor if neces-
sary. Install TR1 and the power cables back on
the line contactor (L). Torque the line contactor
(L) bolts to the specified torque. Do not over
tighten. Turn the truck on and monitor the
event code.
• If:Event code continues.
– Then check the battery condition under load.
• If:The battery condition is deteriorated.
– Then repair or replace the battery.
• If:The battery is OK.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 6 (14992-01)
Event Code 320
Access 3™ Low Supply Voltage (15 V)
The internally regulated voltage in Access 3™ dropped
below a percentage of the regulated supply voltage.
CAUTION
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.1. Move
truck to a secure non traffic maintenance area with a
level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller for
15 or more seconds.
Step 1: Turn the truck OFF. Disconnect the battery.
Discharge the Access 3™ capacitors. Use a
DVOM to check the battery voltage at the bat-
tery.
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 ELECTRICAL SYSTEM
Event Code 321

• If:The the voltage is more than17 V.

– Then proceed to Step 2.
• If:The voltage is less than 17 V.
– Then recharge or replace battery.
• If:Event code continues.
– Then check the condition of the battery or make
adjustments to the Battery Empty setting in Per-
formance Menu P4. Fig. 7 (14992-01)
Step 2: Check the condition of the battery terminals on
each end of the battery connector.
• If:The connections are loose or corroded.
Event Code 321
– Then tighten or replace the terminals. Supply (5 V) Low or High Voltage
• If:The connections are OK. The internally regulated voltage in Access 3™ dropped
– Then proceed to Step 3. below a percentage of the regulated supply voltage.
Step 3: Check the power connections of the line con- Follow troubleshooting steps for Event Code 320.
tactor (L) and Access 3™ (+BV, + and BNEG
terminals). Make sure the terminals are tight-
ened to the proper torque specification and the
threads are in good condition.
• If:The connections are loose or corroded.
– Then tighten or replace the terminals as needed.
• If:Connections are OK.
– Then proceed to Step 4. Fig. 8 (14992-01)
Step 4: Remove FU1. Check the condition of FU1.
• If:FU1 show any damage to the element, viewing
glass or terminals. Event Code 322
– Then replace FU1. Heatsink Temperature High
• If:No damage is visible. The Access 3™ heatsink temperature is above 115 °C
– Then install FU1 and proceed to Step 5. (239 °F).
Step 5: Turn the truck ON. Use a DVOM to measure Step 1: Check the heatsink temperature in Access 1
the voltage of FU1 in the circuit. Measure from Analyzer Menu A2.12.
the +BV side of FU1 to the Access 3™ BNEG • If:Temperature is 115 °C (239 °F) or more.
terminal. Then measure from the + side of FU1 – Then Access 3™ is overheated. Proceed to Step
to the Access 3™ BNEG terminal. 2.
• If:There is a difference in voltage of 0.5 V or more. • If:Temperature is less than 115 °C (239 °F).
– Then replace FU1. – Then skip to Step 6.
• If:Voltage is +BV on both sides of FU1. • If:Access 3™ temperature is less than 115 °C
– Then replace Access 3™. Configure new (239 °F), but was allowed to cool before performing
Access 3™ in Utilities Menu U2. service.
– Then proceed to Step 2.

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Event Code 322
CAUTION
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
1. Move truck to a secure non traffic maintenance area
with a level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller for
15 or more seconds.
Step 2: Turn the truck OFF. Disconnect the battery.
Discharge the Access 3™ capacitors (with the
battery disconnected, discharge the capaci-
tors by placing a 100 ohm, two watt resistor
across the Access 3™ BNEG and + terminals
for a minimum of 15 seconds). Check for
loose, corroded or damaged terminal connec-
tions on Access 3™. Check +BV, + and BNEG
terminals. Check U, V and W power cable ter-
minals. Also check FU1 terminals.
• If:Connections are loose.
– Then tighten to a torque of 15 Nm (11 ± 1.5 ft lb).
• If:Connection terminals are bad.
– Then replace cables as necessary.
• If:Terminals are OK.
– Then proceed to Step 3.
Step 3: Check the U, V and W M1 power cables for ex-
cess wear. Check +BV and BNEG power ca-
bles for excess wear.
• If:The any cable(s) shows signs of excess wear.
– Then replace the cable(s) as necessary.
• If:The power cables are OK.
– Then proceed to Step 4.
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Fig. 9 (14993-01)
Step 4: Check the Access 3™ mounting bolts located
in each of the four corners of Access 3™.
Proper torque for the bolts is 24.5 Nm (18 ±
5.0 ft lb) or reference section on fastener
torque for an M8 8.8 bolt).
• If:The bolts are loose.
– Then completely unbolt controller from power
unit wall. Blow or wipe clean Access 3™ and the
mounting wall surfaces. Mount Access 3™ onto
the power unit wall and torque to above specifica-
tions.
• If:Mounting is correct.
– Then proceed to Step 5.
Step 5: Determine if the truck is under a heavy-duty
cycle or high ambient temperatures.
• If:The truck is overheating due to these conditions
and performance is degraded.
– Then allow the truck to cool down.
• If:The truck is not overheating due to the above
conditions.
– Then proceed to Step 6.
Step 6: Does this fault occur when Access 3™ is at
room temperature (after the truck has been
OFF for some time)?
• If:No.
– Then proceed to Step 7.
• If:Yes.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Step 7: Use Analyzer Menu A3.6 to check for exces-
sive current in M1 due to a mechanical condi-
tion of the drive motor, drive unit or brakes.
Refer to Control of Hazardous Energy in the
Service and Parts Manual to lift and block the
truck frame so the drive tire is off the ground.
Crown 2007 PF15787-8 Rev. 8/11

Apply full throttle in walkie speed mode (not
high speed).
• If:Analyzer Menu A3.6 motor current is more than
65 amps.
– Then the issue is due to a mechanical condition
in the drive motor, drive unit, brakes, etc. Repair
as necessary.
• If:Analyzer Menu A3.6 motor current is less than 65
amps.
– Then replace Access 3™. Configure
Access 3™ in Utilities Menu U2.
Event Code 323
DC Bus Low - Software Detected (low battery volt-
age at Access 3™)
Event Code 323 occurs when Access 3™ software
finds that the DC Supply voltage at + and B- terminals
is less than12 V.
Step 1: Measure the voltage at the battery terminals
with the battery disconnected.
• If:Voltage < 17 V.
– Then charge or replace the battery.
• If:Voltage > 17 V.
– Then continue to Step 2.
Step 2: Check the condition of the battery terminals.
• If:Connections are bad.
– Then repair or replace the terminals as neces-
sary.
• If:Connections are good.
– Then continue to Step 3.
Step 3: Check the condition of the connections at the
line contactor (L), B+, +, and B- terminals on
Access 3™. Make sure Access 3™ terminals
are torqued to 13–17 Nm (9.6–12.5 ft lb) and
the threads are in good condition. Make sure
the control wiring to the line contactor is in
good condition.
• If:A defect is found.
– Then repair or replace as necessary.
• If:Conditions are good.
– Then continue to Step 4.
Step 4: Connect the battery, turn the truck ON, and
measure the voltage at Access 3™ pin
CA201-1.
Crown 2007 PF15787-9 Rev. 12/13
ELECTRICAL SYSTEM
Event Code 323
• If:Voltage < 17 V.
– Then continue to Step 5.
• If:Voltage > 17 V.
– Then continue to Step 6.
Step 5: Turn the truck OFF and disconnect the battery.
Remove FU2 from the fuse holder and check
for continuity.
• If:FU2 is open.
new – Then replace FU2.
• If:FU2 is good.
– Then continue to Step 6.
Step 6: Measure for voltage loss of FU1. Connect the
battery and turn the truck ON. Measure the DC
voltage between Access 3™ terminals B+ and
B- and record the results. Measure the DC
voltage between Access 3™ terminals + and
B- and record the results. Calculate the volt-
age difference between the 2 measurements.
• If:FU1 voltage loss is 0.5 V or more.
– Then replace FU1.
• If:FU1 voltage loss is 0.5 V or less.
– Then turn the truck OFF and disconnect the bat-
tery. Remove and examine FU1 for damage to
the fuse element, viewing glass, or terminals.
Make sure FU1 has continuity.
• If:FU1 is open or the fuse element, viewing glass,
or terminals are damaged.
– Then replace FU1.
• If:FU1 is good.
– Then replace FU1 with a known good fuse.
• If:FU1 is good.
– Then replace FU1 with a known good fuse.
• If:Event continues.
– Then replace Access 3™ (configure Access 3™
replacement in Utilities menu U2).
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Event Code 324

• If:Analyzer Menu A3.6 motor current is more than

65 amps.
– Then the issue is due to a mechanical condition
Access 3™
in the drive motor, drive unit, brakes, etc. Repair
CA201-1
KEY INPUT as necessary.
39.5 Ohm
FU2 TR1 + L CA201-2
LINE CONTATOR DRIVER
• If:Analyzer Menu A3.6 motor current is less than 65
-T+
+BV +
BNEG
amps.
FU1
L
M2 PUMP
– Then proceed to Step 3.
POLARITY P FIELD M2
DIODE

+
24V CR1 CAUTION
Due to capacitance voltage present in the traction mo-
Fig. 10 (28531) tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
Event Code 324 1. Move truck to a secure non traffic maintenance area
with a level floor.
DC Bus High - Software Detected (high battery volt- 2. Lockout/Tagout truck as described in Battery - Lock-
age at Access 3™). out/Tagout in this section.
Access 3™ software detects the DC Supply voltage, 3. Place a minimum 100 ohm, 10 watt resistor between
as measured at + and BNEG terminals, is 50 V or the positive and negative terminals of the controller for
more.Follow the trouble shooting steps for Event code 15 or more seconds.
118.

Step 3: Turn the truck OFF. Disconnect the battery.

Event Code 328
Traction Motor (M1) Temperature High
M1 temperature is more than 190 °C (374 °F). TS1,
embedded in the M1 windings, provides an analog
input to Access 3™. View M1 temperature in Analyzer
Menu A2.10.
Step 1: Check M1 temperature in Access 1 Analyzer
Menu A2.10.
• If:Temperature is 190 °C (374 °F) or more.
– Then M1 is overheated. Proceed to Step 2.
• If:Temperature is less than 190 °C (374 °F).
– Then skip to Step 8.
• If:Temperature is less than 190 °C (374 °F) but was
allowed to cool before performing service.
– Then proceed to Step 2.
Step 2: Use Analyzer Menu A3.6 to check for exces-
sive current in M1 due to a mechanical condi-
tion of the drive motor, drive unit or brakes.
Refer to Control of Hazardous Energy in the
Service and Parts Manual to lift and block the
truck frame so the drive tire is off the ground.
Apply full throttle in walkie speed mode (not
high speed).
Discharge the Access 3™ capacitors. Check
for loose, corroded or damaged terminal con-
nections on Access 3™. Check +BV, + and
BNEG terminals.
• If:Connections are loose.
– Then tighten to a torque of 15 Nm (11 ± 1.5 ft lb).
• If:Connection terminals are bad.
– Then replace cables as necessary.
• If:Terminals are OK.
– Then proceed to Step 4.
Step 4: Check the U, V and W M1 power cables for ex-
cess wear.
• If:Any cable shows signs of abrasion or excess
wear.
– Then replace the cable as necessary.
• If:The power cables are OK.
– Then proceed to Step 5.
Step 5: Check for loose connections and broken wires
at motor connector CA405-1 and CA405-2.
Check for loose connections and broken wires
at Access 3™ CA201-4 and CA201-16. Visu-
ally inspect CA201 and CA405 to ensure pins
are fully seated.
• If:A bad connection or broken wires are found.

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– Then replace the wire harness.
• If:No bad connections or broken wires are found.
– Then proceed to Step 6.
Step 6: Disconnect CA201. Use a DVOM to check the
resistance of TS1 between Access 3™
CA201-4 and CA201-16 on the wire harness.
• If:Resistance is more than 330 ohm.
– Then proceed to Step 7.
• If:Resistance is less than 330 ohm.
– Then skip to Step 8.
Fig. 11 (14994-01)
Step 7: Determine if the truck is under a heavy-duty
cycle or high ambient temperatures.
• If:The truck is overheating due to these conditions
and performance is degraded.
– Then allow the truck to cool down.
• If:The truck is not overheating due to the above
conditions.
– Then proceed to Step 8.
Step 8: Replace the M1. Monitor the event.
• If:Event code continues and performance is de-
graded.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Event Code 332
Open Output Circuit - Current High
One of the following Access 3™ outputs exceeded 1.5
amps continuous or three amps peak: BRK (CA201-2),
Pump Contactor (P) solenoid (CA201-18), Line
Contactor (L) coil (CA201-21) or Steer Solenoid
(CA201-22). Access 3™ disables all truck functions.
Likely causes are a defective contactor coil or a short
to +BV. The short could be internal or external to
Access 3™.
Crown 2007 PF15787-11 Rev. 8/11
ELECTRICAL SYSTEM
Event Code 332
Step 1: Turn the truck OFF. Remove wire 5904 from
the line contactor coil. Turn the truck ON. Use
Access 1 to clear all events. Press the brake
pedal.
• If:Event Code 332 logs again.
– Then turn the truck OFF. Reconnect wire 5904.
Proceed to Step 2.
• If:Event code 332 does not log again.
– Then turn the truck OFF. Replace the line contac-
tor (L). Connect wire 5904 to the new line contac-
tor.
Step 2: Use the lower switch (LOS1) to lower the forks
to a maximum height of 76 mm (3 in). Turn the
truck OFF. Remove wire 5901 from the raise
solenoid (P). Turn the truck ON. Use Access 1
to clear all events. Press the raise switch.
• If:Event Code 332 logs again.
– Then turn the truck OFF. Reconnect wire 5901.
Proceed to Step 3.
• If:Event Code 332 does not log again.
– Then replace the raise solenoid (P). Connect
wire 5901 to the new raise solenoid.
Step 3: Turn the truck OFF. Disconnect CA404 Elec-
tric Brake connector. Turn the truck ON. Use
Access 1 to clear all events. Turn the truck
ON. Cycle BRS and DMS.
• If:Event Code 332 logs again.
– Then turn the truck OFF. Reconnect CA404. Pro-
ceed to Step 4.
• If:Event Code does not log again.
– Then replace BRK1. Connect CA404.
Step 4: Turn the truck OFF. Remove wire 5902 from
the steer solenoid (S). Turn the truck ON. Use
Access 1 to clear all events. Cycle BRS and
DMS.
• If:Event Code 332 logs again.
– Then turn the truck OFF. Reconnect wire 5902.
Proceed to Step 5.
• If:Event Code 332 does not log again.
– Then replace the steer solenoid (S). Connect
wire 5902 to the new steer solenoid.
Step 5: Turn the truck OFF. Inspect the wire harness
connectors for a short circuit across the termi-
nals of the connectors. Remove any debris
that may have accumulated on the connec-
M4.8-6745-011
01 Rev. 8/11
11
ELECTRICAL SYSTEM
Event Code 333
tors. Turn the truck ON. Use Access 1 to clear
all events.
• If:Event Code 332 logs again.
– Then proceed to Step 6.
Step 6: Turn the truck OFF. Replace the main wire
harness. Turn the truck ON. Use Access 1 to
clear all events.
• If:Event Code 332 logs again or becomes intermit-
tent.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2. Use Access 1 to
clear all events and verify the event code does
not reappear.
Fig. 12 (17421-01)
Event Code 333
Line Contactor (L) Tips Welded or Driver is Shorted
The line contactor (L) is not opening, either due to a
bad Access 3™ driver or welded contactor tips.
Step 1: Turn the truck OFF. Check the line contactor
(L) tip condition.
• If:Tips are welded.
– Then replace the tips or the line contactor (L).
• If:Tips are not welded.
– Then proceed to Step 2.
Step 2: Turn the truck ON. With the BRK Foot Pedal
up (BRS open), use a DVOM to check the line
contactor coil voltage. Test with the positive
DVOM probe at the line contactor coil terminal
connected to wire 5904 and the negative
probe at Access 3™ B-.
M4.8-6745-012
01 Rev. 8/11
12
• If:Voltage is less than 21 V.
– Then check the wire harness for a shorted wire to
BNEG or a short of wire 5904 to the truck frame.
• If:The a wire is shorted.
– Then replace or repair as necessary.
• If:Wires are OK.
– Then proceed to Step 3.
CAUTION
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
1. Move truck to a secure non traffic maintenance area
with a level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller for
15 or more seconds.
Step 3: Turn the truck OFF. Disconnect the battery.
Discharge the Access 3™ capacitors. Use a
DVOM to check the resistance across the line
contactor terminals (cable lugs) to make sure
it is not stuck shut.
• If:Resistance is infinite (open).
– Then replace Access 3™ (configure new
Access 3™ in Analyzer Menu U2).
• If:There is measurable resistance, but it is not infi-
nite (open).
– Then repair or replace the line contactor (L).
Fig. 13 (15006-01)
Event Code 334
Access 3™ Brake Driver Open Circuit Detected
An Access 3™ diagnostic tool prevents driving with the
parking brake (BRK1) engaged. Access 3™ monitors
Crown 2007 PF15787-12 Rev. 8/11

CA201-2 for an open load. Upon release of BRK1, 24 V
is applied to the BRK1 coil for 1 second, and then
reduced to 12 V. If Access 3™ does not detect the
proper current during this time, Event Code 334 logs
and traction is inhibited. Likely causes are open wiring
between Access 3™, KYS and BRK1, an open BRK1
coil or shorted wiring between the BRK1 coil and
BNEG.
Step 1: Turn the truck OFF. Disconnect CA404. Use a
DVOM to check BRK1 coil resistance. Deter-
mine the part number printed on BRK1. If the
part number is 5678-05, then the coil resis-
tance should be approximately 17.1 ohms. If
the part number is 5678-31, then the coil resis-
tance should be approximately 8.3 ohms.
• If:The BRK1 coil resistance is not as specified.
– Then replace BRK1.
• If:The BRK1 coil resistance is OK.
– Then proceed to Step 2.
Step 2: Check the continuity of wire 2912 between
CA404-1 and KYS.
• If:Wire 2912 is open.
– Then repair or replace the wire as necessary.
• If:Wire 2912 is OK.
– Then proceed to Step 3.
Step 3: Check for a short between CA404-2 and
BNEG.
• If:A short exists.
– Then repair or replace the wire as necessary.
• If:No short exists and the event continues.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 14 (17421-01)
Crown 2007 PF15787-13 Rev. 8/11
ELECTRICAL SYSTEM
Event Code 336
Event Code 336
Throttle Voltage Outside Limits.
Throttle voltage from ACCEL POT1 is more than 4.0 V
when either FS or RS is activated. Event Code 336 is
also logged if the ACCEL POT1 output is more than
11.0 V. Corrective action includes verifying the issue,
centering ACCEL POT1 or readjusting RS and FS.
Step 1: Turn the truck ON. Use Access 1 A5.9 to view
the ACCEL POT1 voltage at rest.
• If:Voltage is more than 0.5 V and less than 11.0 V.
– Then center ACCEL POT1 using the adjustment
procedure in the Control Pod section of the Ser-
vice and Parts Manual.
• If:Voltage is 11.0 V or more.
– Then skip to Step 5.
• If:Voltage is less than 0.5 V.
– Then proceed to Step 2.
Step 2: Check the operation of FS and RS. Inspect the
switches for mechanical sticking or incorrect
adjustment.
• If:The switches are sticking.
– Then replace the switch and linkage as neces-
sary.
• If:Thread locking adhesive on switch arms is dis-
turbed or the switch linkage has been adjusted pre-
viously.
– Then readjust switch actuation so that the switch
actuates (goes to zero ohm or audible click) be-
fore the ACCEL POT1 reaches 4.0 V (or with the
battery disconnected, before it reaches 1.5 k ohm
between the brown and blue wires of ACCEL
POT1).
Step 3: Turn the truck OFF. Use a DVOM to measure
the resistance of the FS and RS switch termi-
nals.
• If:Switch resistance does not reach less than 5 ohm
while twisting the handle.
– Then replace switch.
Step 4: Use a DVOM to check the wiring from FS and
RS to Access 3™ for cuts or shorts to the
frame.
• If:Shorts or cuts are found.
– Then repair or replace the wires as necessary.
M4.8-6745-013
01 Rev. 8/11
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ELECTRICAL SYSTEM
Event Code 343
Step 5: Use a DVOM to check the wiring from ACCEL
POT1 to ACCES 3 for cuts or shorts to the
frame. Check wires 102, 303 and 512 from
Access 3™ to CA402. Check each wire for
shorts to the frame and shorts to each of the
other wires.
• If:Shorts or cuts found.
– Then repair or replace the harness as necessary.
Step 6: Check the Access 3™ terminal connections
and all connections to FS and RS.
• If:Loose or unseated connections are found.
– Then repair or replace as necessary.
Step 7: Make sure ACCEL POT1 is secured tightly to
the mounting bracket and the potentiometer
body does not rotate with normal operation.
• If:The ACCEL POT1 body is incorrectly adjusted.
– Then properly adjust ACCEL POT1.
• If:The ACCEL POT1 body is loose.
– Then tighten the mounting screw using blue
thread locking adhesive to secure.
Step 8: Monitor the event.
• If:The event code continues.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 15 (17422)
M4.8-6745-014
01 Rev. 8/11
14
Event Code 343
FS and RS switches detected simultaneously
Access 3™ sees both FS and RS simultaneously.
Likely causes are incorrect adjustment of FS or RS or
a wiring short circuit.
Step 1: Determine if FS and RS are incorrectly adjust-
ed so both are closed simultaneously.
• If:Switches are incorrectly adjusted.
– Then readjust the switch. Refer to the Control
Pod section in the Service and Parts Manual for
direction switch adjustment.
• If:Switches are not incorrectly adjusted.
– Then make sure the switches are in good working
order.
• If:Switches are worn or damaged.
– Then replace the switches.
• If:Switches are OK.
– Then proceed to Step 2.
Step 2: Turn the truck OFF. Determine if the FS or RS
wires are shorted. Use a DVOM to check the
resistance between wires 2916 and 2917.
• If:Resistance is measurable, but not infinite (open).
– Then the wires are shorted to one switch. Repair
or replace the harness as necessary.
• If:Resistance is infinite (open).
– Then proceed to Step 3.
Step 3: Turn the truck ON. Use a DVOM to determine
if the FS or RS wires are shorted to +BV. Con-
nect the negative meter lead to the Access 3™
BNEG terminal as a negative reference.
Check the voltages at wires 2916 and 2917,
one at a time, with the positive meter lead.
• If:Voltage is more than 1.0 V.
– Then the switch wiring is shorted to a positive
voltage source (typically another wire). Repair or
replace the harness as necessary.
Crown 2007 PF15787-14 Rev. 8/11

Fig. 16 (17423)
Event Code 346
DC Bus Charging Timeout
Occurs during start-up when Access 3™ detects the
DC Supply voltage (as measured at the + and BNEG
terminals) is too low to ensure reliable operation. Event
Code 346 logs if the voltage is less than 23 V. DC Bus
is normally pre-charged through the KYS input
(CA201-1). After turning truck ON, DC Bus must be
pre-charged to full voltage within three seconds. TR1
across the line contactor contacts helps to pre-charge
the DC Bus.
Step 1: Turn the truck OFF. Disconnect the battery.
Use a DVOM to measure continuity across the
pump contactor (P) power terminals.
• If:Resistance measured is less than 10 ohm.
– Then replace the pump contactor (P).
• If:Resistance measured is more than 10 ohm.
– Then proceed to Step 2.
Step 2: Connect the battery. Turn the truck ON. Use a
DVOM to check the pump contactor coil driver
voltage. Connect the positive DVOM lead to
Access 3™ CA201-18 and the negative lead
to Access 3™ BNEG.
• If:Voltage is less than 5 V without a raise (RAS)
command input on CA201-10.
– Then check for pinched or shorted wires. Repair
as necessary.
• If:Wires are OK.
– Then proceed to Step 7.
• If:Voltage is more than 5 V but less than 20 V.
– Then check wires for a short to the truck frame.
Repair as necessary.
Crown 2007 PF15787-15 Rev. 8/11
ELECTRICAL SYSTEM
Event Code 346
• If:Wires are OK.
– Then proceed to Step 7.
• If:Voltage is more than 20 V and M2 continues to
run.
– Then look for a short to frame or incorrect wiring.
Repair as necessary.
• If:Wires are OK.
– Then proceed to Step 3.
Step 3: Turn the truck OFF. Disconnect the battery.
Use a DVOM to check the battery voltage at
the battery terminals.
• If:The voltage is less than 23 V.
– Then recharge or replace battery.
• If:The the voltage is more than23 V.
– Then proceed to Step 4.
Step 4: Check the condition of the terminals on each
end of the battery connector.
• If:The connections are loose or corroded.
– Then tighten or replace the terminals.
• If:The connections OK.
– Then proceed to Step 5.
Step 5: Check the power connections of the line con-
tactor (L), FU1 and Access 3™ (+BV, + and
BNEG terminals). Make sure the terminals are
tightened to the proper torque specification
and the threads are in good condition.
• If:The connections are loose or corroded.
– Then tighten or replace the terminals as needed.
• If:Connections OK.
– Then proceed to Step 6.
Step 6: Check the voltage loss of FU1. Connect the
battery. Turn the truck ON. Measure the DC
voltage between the Access 3™ +BV and
BNEG terminals. Record the measurement.
Measure the DC voltage between the
Access 3™ + and BNEG terminals. Record
the measurement. Calculate the voltage differ-
ence between the two measurements.
• If:FU1 voltage loss is 0.5 V or more.
– Then replace FU1.
Step 7: Use a DVOM to measure voltage between the
Access 3™ BNEG and + terminals.
• If:The voltage is more than 23 V.
M4.8-6745-015
01 Rev. 8/11
15
ELECTRICAL SYSTEM
Event Code 362
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
• If:The voltage is less than 23 V.
– Then proceed to Step 8.
Step 8: Remove TR1 from the line contactor (L). Allow
TR1 to cool to room temperature. Use a
DVOM to check the resistance of TR1.
• If:Resistance is not 39.5 ohm.
– Then replace TR1.
• If:Resistance is 39.5 ohm.
– Then proceed to Step 9.
Step 9: Inspect the line contactor terminal threads for
excess wear. Replace the contactor if neces-
sary. Install TR1 and the power cables back on
the line contactor (L). Torque the line contactor
(L) bolts to the specified torque. Do not over
tighten. Turn the truck on and monitor the
event code.
• If:Event code continues.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 17 (17424)
M4.8-6745-016
01 Rev. 8/11
16
Event Code 362
AC Current - Current Short
Short circuit in M1 or Access 3™ power stage or wiring.
CAUTION
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
1. Move truck to a secure non traffic maintenance area
with a level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller for
15 or more seconds.
Step 1: Turn truck OFF. Disconnect the battery. Dis-
charge the Access 3™ capacitors as de-
scribed in the beginning of this section.
Step 2: Check the U, V and W M1 power cables for
loose connections or incorrect wiring at M1
and Access 3™.
• If:There are any loose or incorrectly wired connec-
tions.
– Then tighten or make corrections as necessary.
Step 3: Check the U, V and W M1 power cables for
shorts, abrasion or excess wear.
• If:Any of the above conditions are found.
– Then replace the cable(s) as necessary.
• If:The power cables are OK.
– Then proceed to Step 4.
Step 4: Disconnect the U, V and W power cables from
M1. Use a DVOM to check the resistance be-
tween each M1 terminal and the M1 frame.
• If:Resistance is infinite (open).
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
• If:Resistance is measurable, but not infinite (open).
– Then replace M1.
Crown 2007 PF15787-16 Rev. 8/11

Fig. 18 (14993-01)
Event Code 372
CAN Timeout
Access 3™ did not receive an expected CAN message
from Access 1 within the allotted time.
Step 1: Check the Access 3™ status LED.
• If:The light is flashing.
– Then proceed to Step 2.
• If:The light is solid.
– Then skip to Step 5.
CAUTION
Due to capacitance voltage present in the traction mo-
tor controller, whenever performing maintenance
which may permit contact with the bus bars and asso-
ciated power cables, discharge the capacitors.
1. Move truck to a secure non traffic maintenance area
with a level floor.
2. Lockout/Tagout truck as described in Battery - Lock-
out/Tagout in this section.
3. Place a minimum 100 ohm, 10 watt resistor between
the positive and negative terminals of the controller for
15 or more seconds.
Step 2: Turn the truck OFF. Disconnect the battery.
Discharge the Access 3™ capacitors as de-
scribed in the beginning of the Event Codes
section. Disconnect Access 1 CA401 and
Access 3™ CA201. Visually inspect the CAN
HI and CAN LO terminals to ensure they are
fully inserted in harness connectors. CAN HI =
Access 3™ CA201-23 & Access 1 CA401-8.
CAN LO = Access 3™ CA201-15 & Access 1
CA401-9.
Crown 2007 PF15787-17 Rev. 8/11
ELECTRICAL SYSTEM
Event Code 372
Step 3: Check the resistance between CAN HI and
CAN LO terminals. Connect CA401 to
Access 1. Disconnect Access 3™ CA201.
Check the resistance between CA201-15 and
CA201-23 on the harness plug. Make sure
Access 1 CA401 is still connected and fully
seated. Resistance should be 60 ± 1 ohm.
• If:Resistance is not 60 ± 1 ohm.
– Then disconnect Access 1 CA401 and check the
resistance between CA401-8 and CA401-9 on
the harness connector. Resistance at this point
(with both CA201 and CA401 disconnected)
should be 120 ± 1 ohm.
• If:Resistance is not 120 ±1 ohm.
– Then replace the main wire harness.
• If:Resistance is 120 ± 1 ohm.
– Then replace Access 1.
Step 4: Connect CA201 and CA401. Connect the bat-
tery. Turn the truck ON. Monitor the event
code.
• If:Event Code continues.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 19 (14988)
Event Code 399
Access 3™ Internal Issue
Step 1: Use Access 1 Utilities Menu U2 to reconfigure
Access 3™. Turn the truck OFF, then back
ON. Monitor the event code.
• If:Event code continues.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
M4.8-6745-017
01 Rev. 8/11
17
ELECTRICAL SYSTEM
Event Code No Indication
Event Code No Indication
Forks will not raise or truck will not travel
(Access 1 displays Left Pedal SRO)
Step 1: Open the power unit door and check the status
LED on Access 3™.
• If:A green LED is flashing.
– Then proceed to Step 2.
• If:LED is solid green (not flashing).
– Then proceed to Step 3.
Step 2: Stand on the floorboard with both feet posi-
tioned properly on the DMS and BRS pedals.
Use the control pod to command a travel direc-
tion.
• If:Access 1 displays “LEFT PEDAL” and there is an
audible sound.
– Then check line contactor (L) for welded tips. Re-
pair or replace the line contactor as necessary.
• If:Access 1 displays “LEFT PEDAL” and there is no
audible sound.
– Then check the pump contactor (P) for welded
tips. Repair or replace the pump contactor as
necessary.
Step 3: Issue is not related to the line or pump contac-
tors. Check other No Event Codes in this
Quick Reference Guide for “Lift does not en-
gage,” or “Truck will not travel”.
Event Code No Indication
Truck does not function
Step 1: Open the power unit door and check the status
LED on Access 3™.
• If:Status LED is not on.
– Then check FU2. Turn the truck OFF. Remove
FU2. Use a DVOM to check FU2 continuity.
• If:FU2 is open.
– Then replace FU2. Turn the truck ON.
• If:FU2 blows again.
– Then check harness for shorts or pinched wires.
• If:FU2 is OK.
– Then proceed to Step 2.
• If:Status LED is continuously on and not flashing.
– Then turn the truck OFF, then back ON.
M4.8-6745-018
01 Rev. 8/11
18
• If:LED is still continuously on and not flashing with
no truck functions.
– Then proceed to Step 2.
• If:Status LED is blinking rapidly.
– Then check the Access 1 Event Log and proceed
to that Event Code diagnostic in this Quick Refer-
ence Guide. If Access 1 is not ON, then count the
LED flash sequence to determine the Event
Code number and use that Event Code to trou-
bleshoot the issue.
• If:No event code is present, either on Access 1 or
by counting the flash sequence.
– Then update Access 1 and Access 3™ with the
latest revision software.
• If:Issue still exists.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Step 2: Use a DVOM to check the voltage from the
Access 3™ + terminal and the Access 3™ B-
terminal.
• If:Voltage is more than 17 V.
– Then proceed to Step 3.
• If:Voltage is less than 17 V.
– Then check the battery condition and connector,
power cables and line contactor (L).
Step 3: Check condition of the KYS terminals and wir-
ing.
• If:Wiring or terminal crimps show corrosion or loose
connection.
– Then replace/repair as necessary.
• If:The terminals and wiring are OK.
– Then proceed to Step 4.
Step 4: Check KYS for a high resistance connection.
With the truck ON, check voltages. Connect
the positive DVOM lead to the supply terminal
of KYS (red wire 201) and the negative DVOM
lead to Access 3™ BNEG. Then check the
voltage with the positive DVOM lead connect-
ed to the wire 2925 terminal of KYS and the
negative DVOM lead to Access 3™ BNEG.
• If:Voltage on FU2 side of KYS is less than 17 V.
– Then check FU2 and the FU2 wiring for shorts or
pinched wiring.
• If:Voltage on FU2 side of KYS is more than 17 V
and the 2925 terminal is less than 17 V.
– Then replace KYS.
Crown 2007 PF15787-18 Rev. 8/11
 ELECTRICAL SYSTEM
Event Code No Indication

• If:Voltage is more than 17 V on both sides of KYS.

– Then proceed to Step 5.
Step 5: Make sure that BRS is properly adjusted and
being activated by the brake pedal. Turn the
truck OFF. Disconnect CA601. Use a DVOM
to measure resistance between JC601-1 and
JC601-2. Press the brake pedal. Resistance
should go from near-zero ohm (less than 5
ohm) with the pedal depressed to an open cir-
cuit with the pedal not depressed.
• If:BRS resistance is not as expected at JC601
when the brake pedal is pressed.
– Then check BRS wiring from CA601 to BRS. Re-
pair or replace wires as necessary.
• If:Wires are OK.
– Then adjust or replace BRS as necessary.
• If:BRS resistance is as expected at JC601 when
the brake pedal is pressed.
– Then proceed to Step 6.
Step 6: Turn the truck OFF. Use a DVOM to check the
continuity of the BRS wiring from PC601 to
KYS (wire 2926) and to Access 3™ (wire
2909) on the main harness. Check the con-
nections at Access 3™ CA201 to make sure
all terminals are fully seated and wiring is free
of cuts or abrasion.
• If:Shorts or open connections are found.
– Then repair or replace the harness as necessary.
• If:Wires and connections are OK.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 20 (15029-01)
Event Code No Indication
0% BDI on Access 1
Caused by lack of CAN communication between
Access 3™ and Access 1. Follow troubleshooting
steps for Event Code 110.
Event Code No Indication
Lift engages without RAS1 activation
Step 1: Turn the truck ON. Use the Access 1 Analyzer
Menu A2.6 to determine if the RAS1 switch is
stuck. LMS must be closed for RAS1 to toggle
the A2.6 input.
• If:A2.6 status is “0” and toggles to “1” when the
RAS1 switch is activated.
– Then proceed to Step 2.
• If:A2.6 status is “1” without activating RAS1.
– Then check RAS1 to make the switch is mechan-
ically stuck.
• If:RAS1 is stuck.
– Then replace or readjust RAS1.
• If:RAS1 is OK.
– Then check RAS1 wiring for shorted or pinched
wires to CA403 then to CA401.
Step 2: Turn the truck OFF. Disconnect the battery.
Measure continuity across the pump contactor
(P) power terminals.
• If:Resistance is less than 10 ohm.
– Then replace the pump contactor (P).
• If:Resistance is more than 10 ohm.
– Then proceed to Step 3.
Step 3: Connect the battery. Turn the truck ON. Use
the Access 1 Analyzer Menu A3.3 to check the
pump contactor (P) coil driver. Do not request
raise.
• If:A3.3 indicates the pump contactor (P) coil driver
is ON.
– Then proceed to Step 4.
• If:A3.3 indicates the pump contactor (P) coil driver
is OFF.
– Then proceed to Step 5.
Step 4: Check pump contactor (P) wiring for pinched
or shorted wires.

Crown 2007 PF15787-19 Rev. 8/11 M4.8-6745-019

01 Rev. 8/11
19
ELECTRICAL SYSTEM
Event Code No Indication

• If:Wires are pinched or shorted. • If:Horn does not operate.

– Then repair or replace wires. – Then check the wires from RAS1 back to FU2.
• If:Wires are OK. Check FU2 for an open fuse.
– Then replace Access 3™. Configure new Step 4: Listen for the pump contactor (P) to close con-
Access 3™ in Utilities Menu U2. tacts when RAS1 is activated.
Step 5: Check wires for shorts to frame. • If:Contactor does not close.
• If:Wires are shorted to frame. – Then proceed to Step 5.
– Then repair or replace harness. • If:Contactor closes.
• If:Wires are not shorted to frame. – Then measure the voltage across pump contac-
– Then replace Access 3™. Configure new tor (P) power terminals with battery connected
Access 3™ in Utilities Menu U2. and RAS1 engaged.
• If:Voltage is more than 1 V.
– Then replace P.
Event Code No Indication • If:Voltage is less than 1 V.
Lift does not engage – Then check pump motor (M2) for proper voltage
across motor terminals.
Step 1: Turn the truck ON. Use Access 1 Analyzer
Menu A2.14 to check the BDI Reading. • If:Voltage at M2 is +BV.
– Then repair or replace M2.
• If:BDI is less than 20% state of charge.
• If:Voltage at M2 is not +BV.
– Then recharge or replace battery.
– Then check FU1 and M2 power cables for good
• If:BDI is greater than 20% state of charge.
connections. Repair or replace as necessary.
– Then proceed to Step 2.
Step 5: Use Access 1 Analyzer Menu A3.3 to check
Step 2: Use Access 1 Analyzer Menu A2.6 to deter- the lift contactor (P) coil driver. Activate RAS1
mine if RAS1 or LMS is stuck open. to request raise.
• If:A2.6 status is “0” and toggles to “1” when the • If:A3.3 status is OFF.
RAS1 switch is activated.
– Then check wire 5901 for open and good connec-
– Then proceed to Step 4. tions. Repair or replace wire as necessary.
• If:A2.6 status does not change when RAS1 is acti- • If:Wires are OK.
vated.
– Then replace the pump contactor (P).
– Then proceed to Step 3.
• If:A3.3 status is ON.
Step 3: Make sure RAS1 and LMS are being mechan-
– Then replace Access 3™. Configure new
ically activated as expected. RAS1 is activated
Access 3™ in Utilities Menu U2.
by pushing the switch on the control pod. LMS
is held closed and opens when the forks reach
the lift limit. LMS should be in the closed posi-
tion to complete the circuit and allow RAS1 to
toggle the A2.6.
• If:Switches are not being activated.
– Then adjust, repair or replace switches as neces-
sary.
• If:Switches are being activated.
– Then check to see if horn operates (horn uses the
same positive feed as the raise switches).
• If:Horn operates.
– Then check the wires from RAS1 to Access 3™
including LMS.

M4.8-6745-020 Crown 2007 PF15787-20 Rev. 8/11

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Fig. 21 (17425)
Event Code No Indication
BDI does not reset
Step 1: Check the control parameters in the Perfor-
mance Menu. Set P4 - Battery Empty to 9. Set
P5 -Battery Full to 2. Set P6 -Battery Reset to
80%.
Step 2: Turn the truck OFF. Disconnect the battery.
Check the battery voltage at the battery termi-
nals.
• If:Voltage is less than 24.7 V.
– Then the battery is not fully charged. Place bat-
tery back onto charger and set for a full charge. It
is also recommended to perform an equalize
charge whenever possible.
• If:Battery does not read full voltage after being on
charger.
– Then check condition of battery and charger.
• If:Battery condition is poor.
– Then lower the battery reset value as low as 60%
in Performance Menu P6. The deteriorated bat-
tery will not allow a long battery cycle.
Crown 2007 PF15787-21 Rev. 8/11
ELECTRICAL SYSTEM
Event Code No Indication
• If:Voltage is greater than 24.7 V and all Perfor-
mance Menu settings are correct.
– Then proceed to Step 3.
Step 3: Check voltage loss of FU1. Connect the bat-
tery. Turn the truck ON. Measure the DC volt-
age between the Access 3™ +BV and BNEG
terminals. Record the measurement. Measure
the DC voltage between the Access 3™ + and
BNEG terminals. Record the measurement.
Calculate the voltage difference between the
two measurements.
• If:FU1 voltage loss is 0.5 V or more.
– Then replace FU1.
• If:FU1 voltage loss is 0.5 V or less.
– Then try a different fully charged battery. Turn the
truck OFF, then back ON.
• If:BDI then resets.
– Then check condition of the original battery.
• If:BDI does not reset.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 22 (14992-01)
Event Code No Indication
Truck will not travel
Step 1: Check that Battery Restraint (BRES) switches
(where equipped) are adjusted properly and
battery gates are fully seated. If the truck is not
equipped with BRES proceed to Step 2. View
BRES in Analyzer Menu A2.4 (F7 must be EN-
ABLED).
• If:BRES switches are not adjusted or operating
properly.
– Then adjust or repair as necessary.
• If:BRES switches are OK.
– Then proceed to Step 2.
M4.8-6745-021
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ELECTRICAL SYSTEM
Event Code No Indication
Step 2: Check connection CA204 for connectivity. If
BRES option is present, PC204 and JC204
fast-tabs should be connected to the battery
restraint cable. If BRES option is not present,
PC204 and JC204 should be connected to
each other (near the CA204 connection). En-
sure these connections are secure and wiring
is not damaged in this area.
• If:Fast-on tabs are disconnected or damaged.
– Then replace or repair as necessary.
• If:CA204 connection is OK.
– Then proceed to Step 3.
Step 3: Use Access 1 Analyzer Menu A2.1 to check
BRS. Cycle BRS.
• If:A2.1 changes state as expected.
– Then proceed to Step 5.
• If:A2.1 does not change state.
– Then check the wiring to BRS.
• If:BRS and wires are OK.
– Then proceed to Step 4.
Step 4: Turn the truck OFF. Lift and block the truck so
that the drive tire is off the ground. Refer to
Control of Hazardous Energy in the Service
and Parts Manual. Check BRS adjustment for
proper range of motion.
• If:Switch contacting arm does not activate BRS.
– Then adjust to contact BRS during typical operat-
ing range.
• If:Switch contacting arm activates BRS as ex-
pected.
– Then proceed to Step 5.
Step 5: Open the power unit door and check the status
LED on Access 3™.
• If:Status LED is not on.
– Then check FU2. Turn the truck OFF. Remove
FU2. Use a DVOM to check FU2 continuity.
• If:FU2 is open.
– Then replace FU2. Turn the truck ON.
• If:FU2 blows again.
– Then check harness for shorts or pinched wires.
• If:FU2 is OK.
– Then proceed to Step 6.
• If:Status LED is continuously on and not flashing.
– Then turn the truck OFF, then back ON.
M4.8-6745-022
01 Rev. 8/11
22
• If:LED is still continuously on and not flashing with
no truck functions.
– Then proceed to Step 6.
• If:Status LED is blinking rapidly.
– Then check the Access 1 Event Log and proceed
to that Event Code diagnostic in this Quick Refer-
ence Guide. If Access 1 is not ON, then count the
LED flash sequence to determine the Event
Code number and use that Event Code to trou-
bleshoot the issue.
• If:No event code is present, either on Access 1 or
by counting the flash sequence.
– Then update Access 1 and Access 3™ with the
latest revision software. Turn the truck OFF, then
back ON.
• If:Issue still exists.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
• If:Status LED is blinking slowly.
– Then update Access 3™ with the latest revision
software. Turn the truck OFF, then back ON.
Step 6: Use a DVOM to measure the voltage from
Access 3™ + to Access 3™ BNEG.
• If:Voltage is more than 17 V.
– Then proceed to Step 7.
• If:Voltage is less than 17 V.
– Then check the battery, power cables and line
contactor (L) for a high resistance connection.
Step 7: Turn the truck ON. Check KYS for a voltage
drop. Connect the positive DVOM lead to the
supply terminal of KYS (red wire 201) and the
negative DVOM lead to Access 3™ BNEG.
Then check the voltage with the positive
DVOM lead connected to the wire 2925 termi-
nal of KYS and the negative DVOM lead to
Access 3™ BNEG.
• If:Voltage on FU2 side of KYS is less than 17 V.
– Then check FU2 and the FU2 wiring for shorts or
pinched wiring.
• If:Voltage on FU2 side of KYS is more than 17 V
and the 2925 terminal is less than 17 V.
– Then replace KYS.
Step 8: Check condition of KYS wiring and terminals.
• If:Wiring or terminal crimps show corrosion or loose
connection.
– Then repair or replace as necessary.
Crown 2007 PF15787-22 Rev. 8/11

Step 9: Turn the truck OFF. Disconnect the battery.
Disconnect CA201. Connect the battery. Turn
the truck ON. Connect the positive DVOM lead
to CA201-1 and the negative lead to
Access 3™ BNEG.
• If:Voltage is less than 17 V.
– Then check the wiring between CA201-1, raise
solenoid + connection and the KYS B+ connec-
tion.
• If:There is a loose connection or damaged wire.
– Then repair or replace the harness.
• If:Voltage is more than 17 V.
– Then replace Access 3™. Configure new
Access 3™ in Utilities Menu U2.
Fig. 23 (17426)
Event Code No Indication
Access 1 is not lit
Step 1: Turn the truck OFF. Disconnect CA401 con-
nector on the back of Access 1. Make sure
that all pins are fully seated in the connector.
Connect CA401 back onto Access 1. Turn the
truck ON.
• If:Connector is secure and Access 1 still does not
light.
– Then proceed to Step 2.
Step 2: Turn truck OFF. Disconnect CA401. Use a
DVOM to check the resistance between the
Access 3™ BNEG terminal and CA401-4.
• If:Resistance is more than 5 ohm.
Crown 2007 PF15787-23 Rev. 8/11
ELECTRICAL SYSTEM
Event Code No Indication
– Then check the wire between CA401-4 and the
Access 3™ BNEG terminal. Repair or replace
the harness as necessary.
• If:Resistance is less than 5 ohm.
– Then proceed to Step 3.
Step 3: With CA401 still disconnected, turn the truck
ON. Connect the positive DVOM lead to
CA401-3 on the wire harness and the negative
lead on the Access 3™ BNEG terminal. Mea-
sure the voltage.
• If:Voltage is less than 24 V.
– Then proceed to Step 4.
• If:Voltage is greater than 24 V.
– Then reprogram Access 1.
• If:Issue continues.
– Then replace Access 1.
Step 4: Check the voltage drops for each component
in the +BV supply line. Connect the negative
lead of the DVOM to the Access 3™ BNEG
terminal. One at a time, connect the positive
DVOM lead to check voltages at the line con-
tactor (L) terminal, each side of FU2 and each
side of KYS.
• If:The voltage drop from the line contactor (L) to
FU2 is more than 0.3 V.
– Then repair or replace wire 202 of the wire har-
ness. Make sure the FU2 terminals are secure.
• If:The voltage drop from FU2 (+BV side) to FU2 (+
side) is more than 0.3 V.
– Then replace FU2. Make sure the FU2 terminals
are secure.
• If:The voltage drop from FU2 to KYS is more than
0.3 V.
– Then repair or replace wire 201 of the wire har-
ness. Make sure the FU2 terminals are secure.
• If:The voltage drop between the KYS terminals
(with KYS turned on) is more than 0.3 V.
– Then repair or replace KYS. Make sure the wire
terminals are secure.
• If:The voltage drop from KYS to CA401-3 (with KYS
turned on) is more than 0.3 V.
– Then repair or replace wire 2913 of the wire har-
ness. Make sure the wire terminals are secure.
Step 5: Use the DVOM to check the voltages at
Access 3™ CA401-3 (+BV) and CA401-4
(BNEG).
M4.8-6745-023
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ELECTRICAL SYSTEM
Event Code No Indication

• If:Access 1 power loss is intermittent.
– Then replace the wire harness.
• If:All voltages are normal and fault is not intermit-
tent.
– Then replace Access 1.
the acceleration). Reference the front of Info-
Point Quick Reference Guide or
Access 1 2 3® in the Service and Parts Manu-
al for menu structures.
• If:Increased acceleration parameters do not im-
prove acceleration rate.
– Then proceed to Step 3.
Step 3: Check PT1 for proper operation. Lower the
forks completely to the ground. Use Access 1
Analyzer Menu A2.11 to check the value of the
load sensor counts.

Correct PT1 Counts

(View in A2.11)

Load on Forks Counts

kg lb ± 50
0 0 150
Fig. 24 (17427)
455 1000 200
910 2000 250
Event Code No Indication
1360 3000 300
Slow acceleration rate
1815 4000 350
Check the load sensor (PT1), Access 1 and
Performance Menu settings (P1, P2, P3). 2270 5000 400
Step 1: Determine if acceleration rate changes with re- 2720 6000 450
spect to load.
3175 7000 500
• If:Slow acceleration is noticed with a load on the
forks, but acceleration is increased when forks are 3630 8000 550
empty.
• If:PT1 counts are 50-75.
– Then proceed to Step 2.
– Then the PT1 offset is correct. Proceed to Step 4.
• If:Acceleration rate does not change, regardless of
weight on forks. • If:PT1 counts are less than 50 or greater than 250.
– Then skip to Step 3. – Then proceed to Step 5.
Step 2: Use Access 1 to check the performance set- • If:PT1 counts are between 75 and 250.
tings. Enter into Service Level 2 or 3. If Fea- – Then the hydraulic pressure is incorrect. Lower
tures Menu F4- User Performance is forks completely to ground. Read value at Ana-
lyzer Menu A2.11.
ENABLED, select and verify the Performance
Menu P1, P2, and P3 settings. If F4 - User Per- • If:Hydraulic pressure remains the same.
formance is DISABLED, the truck will operate – Then perform hydraulic and mechanical trouble-
shooting as outlined in the Service and Parts
in P1 mode. In the Features Menu, make sure
Manual. There is hydraulic pressure residing in
that F3 - Productivity is ENABLED. Enter the the system.
Performance Menu P1, P2, and P3 setups. In-
Step 4: With no load on the forks, raise the forks 50-
crease acceleration rates by incrementing the
76 mm (2-3 in) above the ground. Check the
1-9 counter (the higher the number, the faster
PT1 value in Analyzer Menu A2.11.

M4.8-6745-024 Crown 2007 PF15787-24 Rev. 8/11

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 ELECTRICAL SYSTEM
Event Code No Indication

• If:PT1 counts are between 130 and 220.

– Then the hydraulic pressure is correct. Repro-
gram Access 1 and Access 3™. If issue contin-
ues, replace Access 1.
• If:PT1 counts are less than 130 or more than 220.
– Then the hydraulic pressure is incorrect. Perform
hydraulic and mechanical troubleshooting as out-
lined in Service and Parts Manual. There is hy-
draulic pressure or mechanical friction residing in
the system.
Fig. 25 (15152)
Step 5: Turn the truck OFF. Disconnect CA615. Turn
the truck ON. Use a DVOM to measure volt-
age between CA615-1 and CA615-2 on the Event Code No Indication
harness side of connector.
Power steering pump does not run
• If:Voltage is 10 ± 0.5 V.
Step 1: Check that Battery Restraint (BRES) switches
– Then proceed to Step 6.
(where equipped) are adjusted properly and
• If:Voltage is outside of that range.
battery gates are fully seated. If the truck is not
– Then check the harness for shorted or open wir-
equipped with BRES proceed to Step 2. View
ing. Repair or replace the harness as necessary.
BRES in Analyzer Menu A2.4 (F7 must be EN-
Step 6: Turn the truck OFF. Disconnect the battery.
ABLED).
Disconnect Access 1 CA401 and PT1 CA615.
Check the connection of PT1 wire 103. Use a • If:BRES switches are not adjusted or operating
properly.
DVOM to measure the resistance between
CA401-13 and CA615-4. – Then adjust or repair as necessary.
• If:BRES switches are OK.
• If:Resistance is less than 1 ohm.
– Then proceed to Step 2.
– Then replace Access 1.
Step 2: Check connection CA204 for connectivity. If
Step 7: Check the M1 connections to verify M1 opera-
BRES option is present, PC204 and JC204
tion. Disconnect the M1 U, V, and W terminals.
fast-tabs should be connected to the battery
Move the cables out of the way to test M1. Use
restraint cable. If BRES option is not present,
a DVOM to check the resistance between
PC204 and JC204 should be connected to
each terminal and the truck frame (best truck
each other (near the CA204 connection). En-
frame connection is often motor endhead).
sure these connections are secure and wiring
• If:Any nominal resistance (anything other than a is not damaged in this area.
complete “open”) is read between a motor terminal
and the truck frame. • If:Fast-on tabs are disconnected or damaged.
– Then M1 has a short to frame and is causing the – Then replace or repair as necessary.
loss of acceleration. Replace or repair M1. • If:CA204 connection is OK.
– Then proceed to Step 3.
Step 3: Use Analyzer Menu A2.2 to check DMS oper-
ation.
• If:DMS input does not toggle as expected with DMS
activation.
– Then check input and wiring from DMS to
Access 3™. Repair or replace DMS and wiring as
necessary.

Crown 2007 PF15787-25 Rev. 8/11 M4.8-6745-025

01 Rev. 8/11
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ELECTRICAL SYSTEM
Event Code No Indication

• If:DMS input is OK.

– Then proceed to Step 4.
Step 4: Check Analyzer Menu A3.4 to check the
Access 3™ steer contactor driver.
• If:A3.4 output is as expected.
– Then use a DVOM to check +BV to the solenoid.
• If:+BV is not present.
– Then check the wires from CA201-22 to the steer
pump contactor (S).
• If:A3.4 output is not as expected, but inputs are OK.
– Then replace Access 3™.

M4.8-6745-026 Crown 2007 PF15787-26 Rev. 8/11

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26