C

RR/RD 5000/5000S
Access 1 2 3® Software Version 11

Instructor’s Guide

12 3
Access

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Crown Equipment Corporation ©2001

 Instructor's Guide
Education Center
New Bremen, Ohio 45869 USA
Phone: 419/629-2311
www.crown.com

The information in this guide is the latest available at the time of printing. Because Crown
is continually improving its products, the examples of Service Manual pages contained in
this guide are for reference only, and are subject to change without notice. Also, there may
be variations between pictorial representation in the guide or training lesson compared
with any particular truck in the field, due to product improvements, vendor changes, or
special options. Therefore, you should always consult the specific Service and Parts
Manual for the truck you are servicing.

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 Instructor's Guide

Contents

Instructor's Guide IV

Introduction, Objectives, and Topics 1

Types of Displays 4
Capacity Data Monitor (CDM) 7
Display Messages 13
The Access 2 and 3 control modules 24
Three Levels of Access 27
Analyzer Menu 36
Features Menu 47
Performance Menu 59
Hours Menu 69
Log Events Menu 72
Utilities Menu 74
Calibrate Menu 80
Troubleshooting 111
Summary/Closing 128

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 Instructor's Guide

RR/RD 5000/5000S Access 1 2 3â Training Lesson

This guide will assist you, the instructor, in scheduling, set-up, and presentation of the RR/RD
5000/5000S Access 1 2 3â Training Lesson.

Presentation Time (approx.): 5 - 8 hours

Audience: Service Technicians with an adequate knowledge and background in basic electricity,
basic hydraulics, and Crown's Service and Parts Manual layout.

Prerequisites: It is strongly recommended that each participant have a good working knowledge
of basic electricity, basic hydraulics, mechanical systems, and all applicable safety procedures,
and a familiarity with Crown's Service and Parts Manual layout.

Lesson Objectives: After completion of this lesson, the service technician should be able to:

1. Navigate through the Access 1 2 3â menus to extract log events/status codes.

2. Extract hour meter readings as well as program hour meter readings in the event a module or
motor is replaced.
3. Extract the module part numbers and software version.
4. Adjust the performance of the truck for a specific application/warehouse or experience/skill
level of the operator.
5. Set up the Features menu to match how the truck is equipped.
6. Calibrate the components of the truck to factory specifications.
7. Access the Analyzer menu to test switches, outputs, and other components.
8. Use the Access 1 2 3â control system to effectively diagnose truck malfunctions.

Recommended Materials:

1. RR/RD 5000 Service and Parts manual (PF11314-00C) - one per participant
2. Instructor's guide for the presentation
3. Access 1 2 3â software version -11 Training Lesson (CD-ROM)
4. Pencils, pens, highlighters, flip charts, and note paper
5. Copies of the Participant Workbook - one per participant
6. Props/components to pass around the class to reinforce learning
7. Copies of the Access 1 2 3â software version -11 test - one per participant
8. Instructor's answer guide to the Access 1 2 3â software version -11 test
9. Overheads of the following Service Manual pages:
M1.0-1450-050 through -065
DIA-1450-001 through -021
10. Supporting videos such as Basic Electricity, Basic Hydraulics, and Service and Parts Manual
11. Attendance sheets/records

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 Instructor's Guide

Lesson Plan: (slide orientation)

Description Slide(s) Elapsed Time Additional Material/Information

Introduction, Objectives, 1-3 2 - 4 minutes

and Topics

Types of Displays 4-6 3 - 6 minutes M4.3 - 1650 - 105 thru - 107

Capacity Data Monitor (CDM) 7 - 12 6 - 12 minutes M4.3 - 1450 - 200 thru - 202

Display Messages 13 - 23 7 - 14 minutes M4.3 - 1450 - 481

The Access 2 and 3 modules 24 - 26 2 - 4 minutes

Three Levels of Access 27 - 34 5 - 10 minutes M4.3 - 1650 - 108 thru - 109

Analyzer Menu 35 - 46 20 - 40 minutes M1.0 - 1450 - 050 thru - 065

M4.3 - 1650 - 110 thru - 113

Features Menu 47 - 58 30 - 60 minutes M4.3 - 1650 - 120 thru - 128

Performance Menu 59 - 68 30 - 60 minutes M4.3 - 1650 - 131 thru - 139

Hours Menu 69 - 71 5 - 15 minutes M4.3 - 1650 - 129

Log Events Menu 72 - 73 5 - 15 minutes M4.3 - 1650 - 130

M4.3 - 1450 - 480 thru - 550

Utilities Menu 74 - 79 5 - 15 minutes M4.3 - 1650 - 140

Calibrate Menu 80 - 110 30 - 60 minutes M4.3 - 1650 - 114 thru - 119

Troubleshooting 111 - 127 30 - 60 minutes M4.3 - 1450 - 480 thru - 550

DIA - 1450 - 001 thru - 021

Summary/Closing 128 5 - 10 minutes

Note: All training lessons should be given adequate time for completion, including additional time
for classroom discussion and written testing. Beyond the classroom, there is the need for
supervised hands-on instruction and practice. The size of the class will influence training time as
will the number of trucks involved.

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 Instructor's Guide

Suggested Procedures: (Before the start of the lesson)

1. Reserve a room dedicated to this class. The room needs to be large enough to comfortably
seat all participants with an unobstructed view of the audio-visual training aids.
2. Practice the use of the audio-visual equipment and check for a supply of spare bulbs.
3. Distribute Service Manuals, Participant Workbooks, pens, pencils, highlighters,
and note paper.
4. Review the Instructor's Guide, highlight areas of importance, and make notations that will help
you with your presentation.
5. Make copies of all handout materials that you intend to distribute during your presentation.
6. Reserve a truck(s) and a work area to perform the hands-on instruction and practice.

Suggested Procedures: (During the presentation)

1. Lead the participants through the Access 1 2 3â software version -11 training lesson and
Participant Workbook.
2. Lead the participants through a review of the Component Identification and Glossary sections
of the Service Manual.
3. Lead the participants through a review of the Status Code section in the Service Manual.
4. Lead the participants through a review of the Wiring Diagrams in the Service Manual.

Suggested Procedures: (After the presentation)

1. Take the participants out to the truck and allow each participant a chance to operate
all truck functions.
2. Review with the participants how to navigate through the level 1 menus.
3. Review with the participants how to gain access to the level 2 and 3 menus.
4. Review with the participants how to navigate through the various menus in level 2 and 3.
5. Review with the participants how to extract log events/status codes.
6. Review with the participants how to set up the features of the truck.
7. Review with the participants how to adjust the performance of the truck.
8. Review with the participants how to calibrate the truck.
9. Review with the participants how to check inputs, outputs, and components in the
analyzer menu.
10. Review with the participants the physical location of each component on the truck.
11. Review with the participants the various test points to measure and test components.

Enough time should be made available after each part of the lesson to allow for a question and
answer period. At this time, if the participants have no specific questions, the instructor should be
prepared to ask questions. These questions could take the form of a formal written exam, if the
instructor so desires.

It is recommended that each participant be given a "final exam" as a means of testing

comprehension. This could take the form of a participant "teach back" session, or a formal written
exam. Each participant will be evaluated and given a critique immediately following the
completion of the "final exam".

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 Instructor's Guide

Note: Every person has different capabilities, aptitudes for learning, and rates of retention.
Additional training may be required to help those individuals who need additional time to achieve a
thorough understanding of the Access 1 2 3â integrated control system used on the Crown RR/RD
5000/5000S series reach trucks.

The following list of pages and documents are separate PDF(Portable Document Format) files
located on the CD-ROM. We recommend that you print these pages and documents and combine
them with the Instructor's Guide pages to form the complete Instructor's Guide.

Access 1 2 3â test
Answers to the Access 1 2 3â test
M1.0-1450-050 through -065 Service Manual pages
M4.3-1450-200 through -202 Service Manual pages
M4.3-1450-480 through -550 Service Manual pages
M4.3-1650-105 through -140 Service Manual pages
DIA-1450-001 through -021 schematic wiring diagrams

We also recommend that you print the above listed service manual pages and combine them with
the Participant's Workbook pages to form the complete Participant Workbook. Refer to the
"Instructions on using this CD-ROM" for printing instructions.

The following documents are separate PDF(Portable Document Format) files located on the CD-
ROM that can be printed out and used as handouts for the lab exercises.

Blank Analyzer menu pages

Blank Features menu pages
Blank Performance menu pages
Blank Hours, Log Events, and Utilities menu pages
T.S.B. 426

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 Instructor's Guide

Access 1 2 3â Software version - 11

To prevent serious risk of death or injury to yourself and others, when working on the truck,
observe all safety precautions called out in the Service Manual.

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 Access 1 2 3®
Slide 1 © 2001
123
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Access 1 23 ®

RR/RD
5000/5000S series

Welcome to this lesson on the Access 1 2 3® integrated control system utilized on the RR/RD
5000/5000S series reach trucks.
Introduce yourself to the class. Have the participants introduce themselves to the rest of the
class. The reason for this lesson is to improve the participants performance in servicing and
troubleshooting the RR/RD 5000/5000S series reach trucks. The participants will benefit from
increased knowledge and skills which will increase their productivity on the job.
Navigation: Throughout this slide presentation you advance to the next slide/animation by
clicking the left mouse button, you can also use the Page Up, Page Down keys and the Arrow
keys on your keyboard as an alternate method of navigation.
Left “click” to advance to next slide.
Notes:

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Objective: Upon completion of this lesson, you

should be able to:
Extract log events/status codes
Extract hour meter readings
Extract module part numbers and software version
Adjust performance
Set up features
Calibrate components
Troubleshoot the various switches and components

Objective: Upon completion of this lesson, you should be able to navigate through the Access
1 2 3® menu to: extract log events/status codes, extract hour meter readings, extract module
part numbers and software version, adjust performance, set up features, calibrate components,
and troubleshoot the various switches and components utilized on the RR/RD 5000/5000S
series reach trucks.
Left “click” to advance to next slide.
Notes:

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• Identify Access 1 2 3® modules

• Three levels of access
• Menus
• Troubleshooting

In this lesson, we are going to identify the Access 1 2 3® control modules, the three levels of
access, all the menus including submenus, and finally troubleshooting. We will begin by
identifying the Access 1 2 3® control modules.
Encourage participants to take notes, ask questions about the material they don’t understand,
answer questions that may be asked of them, and provide feedback/input pertaining to the
information being covered.
Left “click” to advance to next slide.
Notes:

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Battery Discharge Indicator

Fork Height Indicator

Navigation Keys

Power “on”

Operator Improper Message

Sequence Error Display
Service Required

Reference Service Manual pages M4.3-1650-105 through -107 for display indicator
descriptions.
The Access 1 module, commonly referred to as the display module, is the interface between the
operator or service technician and the truck’s electronic system. There are three types of
display modules. Shown here is the Standard Display.
Left “click” to identify the various parts of the display one at a time.
Located on the right are the “up”, “down”, and “enter” buttons known as the Navigation Keys.
The Navigation Keys allow you to navigate through the various menus. In the upper middle part
of the display is the Battery Discharge Indicator. The Service Required light (wrench) will
illuminate when a status has been detected that requires attention; it will also be accompanied
by a status code. Just below the Battery Discharge Indicator is the Power “on” indicator light; it
illuminates when power is present to the display. The Operator Improper Sequence Error
indicator light will illuminate when the operator uses the incorrect sequence of truck operation.
The Fork Height Indicator light will illuminate when the forks are above free lift. It will flash and
an alarm will sound when the forks are above free lift and travel speed is greater than 1.5 mph
(2.4 km/h). The four-character Message Display presents information to the operator and
service technician. Because of the limited character Message Display, you will have to
reference the Service Manual to navigate through the service menus.
Left “click” to advance to next slide.

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Quick
Reference
Keys

Extended Message Display

Reference Service Manual page M4.3-1650-107 for display indicator descriptions.

Shown here is the Enhanced Display. In addition to all the features of the Standard Display, the
Enhanced Display has three additional buttons called the Quick Reference Keys.
Left “click” to identify the Quick Reference Keys.
The Quick Reference Keys can be used to go directly to the “Performance”, “Hours”, and “Log
Events” menus during normal truck operation.
Left “click” to identify the Extended Message Display.
The Enhanced Display has an Extended Message Display. It is a 16-character dot matrix
display with full alphanumeric capabilities. This provides for more comprehensive information to
the operator and service technician.
Left “click” to advance to next slide.
Notes:

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Capacity Data Monitor

Reference Service Manual pages M4.3-1450-200 through -202 for a description of the Capacity
Data Monitor (CDM) indicator lights and their functions.
Shown here is the Enhanced Display with Capacity Data Monitor (CDM).
Left “click” to identify the Capacity Data Monitor.
The Capacity Data Monitor (CDM) includes additional indicator lights that inform the operator of
the approximate lift height of the forks as well as the maximum recommended lift height of the
load that is on the forks.
Note: The Capacity Data Monitor (CDM) does not prevent the operator from lifting an over
capacity load above the maximum recommended lift height. The operators should always refer
to the capacity data plate for information on how much weight they can safely lift and to what
height. Reference the truck’s operator manual.
Left “click” to advance to next slide.
Notes:

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Maximum Recommended
Lift Height for Load
on the Forks

Fork Height

Corresponds to Data
Plate Icons

Reference Service Manual page M4.3-1450-200 for a description of the CDM indicator lights.
Now we will explain the various indicator lights associated with the Capacity Data Monitor
(CDM).
As the operator raises the forks, the fork icons will illuminate to indicate the approximate height
of the forks.
Left “click” to identify the zones/bars.
The zone/bar indicator lights provide a visual reference for the operator of the maximum
recommended lift height for the current load.
Left “click” to identify the data plate icons/circles.
The circles on the CDM correspond to the circle icons on the truck’s Capacity Data Plate. The
Capacity Data Plate lists the actual capacities, load centers, and lift heights of the truck.
Left “click” to advance to next slide.
Notes:

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TEST

Reference Service Manual page M4.3-1450-201.

In the example on the left, all indicator lights are illuminated and an alarm is sounded for
approximately 2 seconds during the truck’s power up self test.
Left “click” to display next illustration.
In the example on the right, the bottom fork icon is illuminated indicating that the forks are below
free lift. All of the zones/bars are illuminated indicating that the load on the forks can be safely
lifted to full height.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-201.

In the example on the left, the bottom fork icon is illuminated indicating that the forks are below
free lift. Only three of the zones/bars are illuminated indicating that the load on the forks can
only be safely lifted to the third zone/bar from the bottom.
Left “click” to display next illustration.
In the example on the right, the second fork icon from the bottom is illuminated and indicates
that the forks are above free lift, somewhere within the first zone/bar. The fork icon is not
flashing which indicates that travel speed is less than 1.5 mph (2.4 km/h). All of the zones/bars
are illuminated indicating that the load on the forks can be safely lifted to full height.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-201.

In the example on the left, the second fork icon from the bottom is illuminated indicating that the
forks are above free lift, somewhere within the first zone/bar from the bottom. The fork icon is
flashing, accompanied by the audible alarm, indicating that travel speed is greater than 1.5 mph
(2.4 km/h). All of the zones/bars are illuminated indicating that the load on the forks can be
safely lifted to full height.
Left “click” to display next illustration.
In the middle example, the second fork icon from the bottom is illuminated indicating that the
forks are above free lift, somewhere within the first zone/bar from the bottom. The fork icon is
not flashing, which indicates that travel speed is less than 1.5 mph (2.4 km/h). Only two of the
zones/bars are illuminated indicating that the load on the forks can only be safely lifted to the
second zone/bar from the bottom.
Left “click” to display next illustration.
In the example on the right, the second fork icon from the bottom is illuminated and indicates
that the forks are above free lift, somewhere within the first zone/bar from the bottom. The fork
icon is flashing, accompanied by the audible alarm, indicating that travel speed is greater than
1.5 mph (2.4 km/h). Only two of the zones/bars are illuminated indicating that the load on the
forks can only be safely lifted to the second zone/bar from the bottom.
Left “click” to advance to next slide.

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CHECK LOAD CHECK LOAD

Reference Service Manual page M4.3-1450-201.

In the example on the left, the bottom fork icon is illuminated indicating that the forks are below
free lift. None of the zones/bars are illuminated indicating that the load on the forks exceeds the
capacity of the truck [based upon a 24 inch (610 mm) load center]. The alarm is sounded, the
Operator Improper Sequence Error light is illuminated, and the message “CHECK LOAD” is
displayed to warn the operator that it is unsafe to lift the load.
Left “click” to display next illustration.
In the example on the right, the fourth fork icon from the bottom is illuminated indicating that the
forks are above free lift, somewhere within the third zone/bar from the bottom. The fork icon is
not flashing, which indicates that travel speed is less than 1.5 mph (2.4 km/h). Only two of the
zones/bars are illuminated indicating that the load on the forks can only be safely lifted to the
second zone/bar from the bottom. The alarm is sounded, the Operator Improper Sequence
Error light is illuminated, and the message “CHECK LOAD” is displayed to warn the operator
that he/she has lifted the load higher than the maximum recommended safe lift height/zone.
Left “click” to advance to next slide.
Notes:

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CHECK LOAD MONITOR DISABLED

Reference Service Manual page M4.3-1450-201 through -202.

In the example on the left, the fourth fork icon from the bottom is illuminated indicating that the
forks are above free lift, somewhere within the third zone/bar from the bottom. The fork icon is
flashing, accompanied by the audible alarm, indicating that travel speed is greater than 1.5 mph
(2.4 km/h). Only two of the zones/bars are illuminated indicating that the load on the forks can
only be safely lifted to the second zone/bar from the bottom. The alarm is sounded, the
Operator Improper Sequence Error light is illuminated, and the message “CHECK LOAD” is
displayed to warn the operator that he/she has lifted the load higher than the maximum
recommended safe lift height/zone.
Left “click” to display next illustration.
In the example on the right, all of the fork icons and zone/bar indicator lights are turned off. The
message “MONITOR DISABLED” is displayed to inform the operator that the forks are tilted to
their limits, thus disabling the Capacity Data Monitor (CDM). For the Capacity Data Monitor
(CDM) to function properly, the forks must be relatively level.
Left “click” to advance to next slide.
Notes:

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Test
Test

Reference Service Manual page M4.3-1450-481.

The following messages may occur during display operation and after truck power up/self test.
During truck power up/self test, “Test” will be displayed.
If a planned maintenance hour meter was programmed, and it counted down to zero, the
message “Ser<->due/Service Due” will be displayed to inform the operator to bring the truck in
for service.
The message “User Code Error” will be displayed if the operator entered the wrong user
code/PIN number and user codes/PIN numbers are enabled.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

If user codes/PIN numbers are enabled, after power up/selftest you will get four dashes on the
Standard Display or the message “User Code” on the Enhanced Display to prompt the operator
to enter a user code/PIN number.
The message “Stby/Please Stand By” will be displayed if the operator were to release and apply
the brakes five times in five seconds.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The message “Lo<->Batt/Low Battery” will be displayed when the battery charge is low. If this
message occurs frequently and at low state of battery charge, it may be an indication that the
BDI adjustment is set too low or the battery is in poor condition. Consider adjusting the P4 BDI
setting and having the battery tested/evaluated.
The message “Loc/Lockout Active” will be displayed when the service technician has enabled
the electronic lockout feature, in the “F21 Lockout” features menu, to inform the operator that
the truck is not available for operation.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The messages “Access 2/Access 3” and “Overtemp/Cold temp” will be displayed when the
temperature of the modules is above/below the limits for proper operation. Refer to the
appropriate status code for the necessary corrective actions to resolve the cause of the
overtemp/cold temp condition.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The message “Door/Battery Door” will be displayed when the battery retainer is not in place on
trucks equipped with the optional battery restraint switches.
The abbreviation Br1i/Brk1i represents the traction/drive brake inner coil. Br1o/Brk1o stands for
the traction/drive brake outer coil. Br2/Brk2 is the abbreviation for the caster brake, available
only on the “S” class trucks. The brake 1/brake 2 overtemp messages will be displayed when
the temperature/resistance of the brake coils is too high. Refer to the appropriate status code
for the necessary corrective actions to resolve the cause of the overtemp condition.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The message “Hand/Center Handle” will be displayed if the multi task handle is not in neutral
during selftest/power up. It may also be caused by a problem with one of the handle
potentiometers. Refer to the appropriate status code for the necessary corrective actions to
resolve the cause of the condition.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The message “Ctr/Center Pedal” will be displayed after selftest/power up, on “S” class trucks,
when the operator attempts to travel without cycling the center pedal which is brake switch three
(BRS3).
The message “Check Load” will be displayed, on trucks equipped with the Capacity Data
Monitor (CDM) option, when the load on the forks exceeds the capacity of the truck [based upon
a 24 inch (610 mm) load center] or the operator has lifted the load higher than the maximum
recommended safe lift height/zone.
The message “Ent/Entry Bar” will be displayed when attempting to travel with the entry bar
depressed.
The message “Foot/Left Foot” will be displayed when attempting to travel without the left pedal
depressed.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The message “Foot/Right Foot” will be displayed when attempting to travel without the right
pedal depressed.
The message “Lift 1/Lift 2 Motor” will be displayed when the brushes in the respective motors
have worn to the point where they require replacement, on trucks equipped with the optional
brush wear/motor temperature sensors. Refer to the appropriate status code for the necessary
corrective actions to resolve the cause of the condition.
The message “Lift Overtemp” will be displayed when the temperature of the Lift 1/Lift 2 motor(s)
is too high. Refer to the appropriate status code for the necessary corrective actions to resolve
the cause of the condition.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1450-481.

The message “Monitor Disabled” is displayed when the forks are tilted to their limits, on trucks
equipped with the Capacity Data Monitor (CDM) option.
The message “Rcut/Raise Cutout” will be displayed when the forks have reached a raise cutout
zone, on trucks that have been calibrated for a raise cutout.
The message “Travel Motor” will be displayed when the brushes in the traction/drive motor have
worn to the point where they require replacement, on trucks equipped with the optional brush
wear/motor temperature sensors. Refer to the appropriate status code for the necessary
corrective actions to resolve the cause of the condition.
Left “click” to advance to next slide.
Notes:

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Standard Display Review

> Navigation keys
> 4 - character information window
> User cannot choose performance level
> Elapsed timer not available
> Height and weight information not available

Left “click” to advance each topic one at a time.

The Standard Display incorporates three Navigation Keys/buttons. They are the “up arrow”,
“down arrow”, and “enter” keys/buttons.
The four-character message display has limited alphabet capabilities which means you will have
to reference the appropriate software menu in the Service Manual to be able to navigate
through the menus.
With the Standard Display, the user/operator cannot choose/select their performance level, the
elapsed timer feature is not available, and the height and weight information is not viewable
since the Capacity Data Monitor (CDM) option is not available with the Standard Display.
Left “click” to advance to next slide.
Notes:

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Enhanced Display Review

> Navigation keys
> Quick reference keys
> 16 - character information window
> *User can choose performance level
> *Elapsed timer
> *Height and weight information
> *Capacity Data Monitor
* If these features are programmed by the service technician

Left “click” to advance each topic one at a time.

The Enhanced Display incorporates the same three Navigation Keys/buttons as the Standard
Display.
In addition, the Enhanced Display includes three more keys/buttons called the Quick Reference
keys. They are the “Performance”, “Hour Meter”, and “Log Events” keys/buttons. These
keys/buttons can be used to allow you to go quickly and directly to the indicated operator
menus. While viewing one of these menus, pressing that menu’s Quick Reference key/button
will return the display to normal operation. In other words, pressing that menu’s Quick
Reference key/button will allow you to exit/escape out of that menu.
The Enhanced Display’s message display/window is extended to sixteen characters, versus four
characters on the Standard Display, and has full alphanumeric capabilities. This allows for
more comprehensive information to be presented to the operator and service technician.
With the Enhanced Display the user/operator can, choose/select their performance level if the
features “F19 User Perf” menu is enabled.
To view the height information, the truck must be equipped with a height encoder. To view the
weight information, the truck must be equipped with the Capacity Data Monitor (CDM). In order
for the user/operator to be able to view the elapsed timer, height and weight information, or
both, the appropriate submenu in the features “F18 Dashboard” must be enabled.
Left “click” to advance to next slide.

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RR/RD 5000 RR/RD 5000S

Access 2

The Access 2 control module is located on top of the power unit, just to the left of the multi task
control handle.
Access 2 controls the majority of the hydraulic functions/components and may be referred to as
the Hydraulic Control Module (HCM).
Left “click” to advance to next slide.
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RR/RD 5000 RR/RD 5000S

Access 3

The Access 3 control module is located on top of the power unit, just to the right of the Access 2
control module on the RR/RD 5010 and 5020 model trucks. On the RR/RD 5060 and 5080 “S”
class trucks, the Access 3 control module is located on the left front power unit wall.
Access 3 controls the majority of the traction functions/components and may be referred to as
the Traction Control Module (TCM).
Left “click” to advance to next slide.
Notes:

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Access 1 2 3® module review

How many different types of displays (Access 1) are there?

What are they?

Can you display lift height in inches on the Standard Display?

Does the CDM option prevent you from lifting an

over capacity load?

What do the rectangular bars on the CDM represent?

What does the CDM do if you lift an over capacity load?

Take this time to answer any questions the participants may have regarding the Access 1 2 3®
modules. If the participants do not have any questions, be prepared to ask them questions to
see if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
How many different types of displays (Access 1) are there? What are they?
Can you display lift height in inches on the Standard Display?
Does the CDM option prevent you from lifting an over capacity load?
What do the rectangular bars on the CDM represent?
What does the CDM do if you lift an over capacity load?
What does the CDM do if you travel faster than creep speed above free lift?
What does the CDM do if you lift the load above the maximum recommended lift height?
What does it mean if the message “Hand” is shown in the Standard Display?
Where is Access 3 located on a RD 5060?
Where is Access 3 located on a RR 5010?
Left “click” to advance to next slide.
Notes:

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• Identify Access 1 2 3® modules

• Three levels of access
• Menus
• Troubleshooting

Now we will discuss the three different levels of access to the Crown Integrated Control System.
Left “click” to advance to next slide.
Notes:

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Three levels of access

>Level 1
• Operator level
» Hour meters
» Log events
» *Performance
» *Elapsed timer
» *Height & weight
*Not available with Standard Display

Reference Service Manual page M4.3-1650-108.

Left “click” to advance each topic one at a time.
To access Level 1 menus, all you have to do is power up the truck. If user codes or PIN
numbers are active, then the operator must enter the correct PIN number to complete the power
up sequence.
On the Standard Display the operator will only have access to the “Hour Meters” and “Log
Events”. The “up”, “down”, and “enter” keys must be used to access the menus.
On the Enhanced Displays there can be up to five menus viewable by the operator depending
upon the features settings. On the Enhanced Displays there are Quick Reference keys to
quickly access the “Hour Meters”, “Log Events”, and “Performance” menus.
The “Elapsed timer” and “Height and Weight” menus must be set up in the features menu to
allow the operator to view.
All five menus can be accessed by using the “up”, “down”, and “enter” keys.
Left “click” to advance to next slide.
Notes:

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Three levels of access

>Level 2
• Service level (requires service code)
» Truck is fully operational
» Analyzer A1-A3
» Calibrate C1-C7
» Features F1-F23
» Hours H1-H6

Reference Service Manual page M4.3-1650-109.

Left “click” to advance each topic one at a time.
The Level 2 service menu is accessed by holding the “up arrow” key depressed during power up
of the truck. Then enter the service access code by using the “up”, “down”, and “enter” keys. In
Level 2, the truck is fully operational which allows the service technician the ability to operate or
drive the truck, without knowing or using user codes or PIN numbers, if they are active.
The “Analyzer” menu allows you to check inputs and outputs.
The “Calibration” menu allows you to calibrate the multi task handle potentiometers, the Load
Sense transducer (LS), the hydraulic proportional valves, and set raise cutouts.
The “Features” menu allows you to set up the truck to match how it is equipped.
The “Hours” menu allows you to view hour meter readings and program a planned maintenance
due reminder.
Note: in -09 and -10 software versions the “Hours” menu H1-H6 was called the “Hour reset”
menu and it allowed you to check and reset “Travel”, “Lift 1”, and “Lift 2” hour meters to zero
after the corresponding motor was replaced reference M4.3-1650-069.
Left “click” to advance to next slide.

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Three levels of access

>Level 2 continued

» Log events L1-L4

» Performance P1-14
» Utilities U1-U4

Reference Service Manual page M4.3-1650-109.

Left “click” to advance each topic one at a time.
The “Log Events” menu assists you in troubleshooting, by showing you the order in which the
events occurred, the hour meter reading when it occurred, the total number of times a particular
event occurred, and the ability to clear or erase the events.
The “Performance” menu allows you to customize the performance characteristics of the truck
for a specific application or warehouse or for different experience levels of operators.
The “Utilities” menu shows you software version and module part numbers and allows you the
ability to copy setups from one module to another if the need arises. In version 11 software we
have added “U3 Hour set” to the utilities menu. This submenu gives you the capability to enter
hour meter readings when Access 3 is replaced and to reset the “Travel”, “Lift 1”, or “Lift 2” hour
meter readings after corresponding motor replacement.
Left “click” to advance to next slide.
Notes:

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Three levels of access

>Level 3
• Service level (requires service code)
» Truck is inoperable
» Analyzer A1, A2, and A4
» Features F1-F23
» Log events L1-L4
» Utilities U1-U4

Reference Service Manual page M4.3-1650-109.

Left “click” to advance each topic one at a time.
The Level 3 service menus are accessed by holding both the “up” and “down” arrow keys
depressed during power up of the truck. Then you must enter the service access code by using
the “up”, “down”, and “enter” keys. In Level 3 you cannot operate the truck. In the “Analyzer”
menu we lose the “A3 Outputs” menu and gain the “A4 Test Outputs” menu. The “A4 Test
Outputs” menu gives you the ability to power the output components with full operational
voltage and current for testing or troubleshooting purposes.
The remaining “Features”, “Log Events”, and “Utilities” menus remain the same as previously
explained.
Left “click” to advance to next slide.
Notes:

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A Analyzer
C Calibrate
F Features
H Hours Level 3 Menus
L Log Events
P Performance
U Utilities

Reference Service Manual page M4.3-1650-109.

In Level 2 all the main menus are available.
Left “click” to highlight the Level 3 menus.
In Level 3 you get every other main menu “Analyzer”, “Features”, “Log Events”, and “Utilities”.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-109.

This is an example of the Service Manual page that describes what service menus are
available, and in what level.
Left “click” to advance to next slide.
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Three levels of access review

What level of access is for the operator?

What menus are available to the operator?

What level of access is the truck inoperable?

What level of access allows you to customize the

performance of the truck?

What submenu is not available in level 2?

Take this time to answer any questions the participants may have regarding the three levels of
access. If the participants do not have any questions, be prepared to ask them questions to
see if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
What level of access is for the operator?
What menus are available to the operator?
What level of access is the truck inoperable?
What level of access allows you to customize the performance of the truck?
What submenu is not available in Level 2?
Left “click” to advance to next slide.
Notes:

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• Identify Access 1 2 3® modules

• Three levels of access
• Menus
• Troubleshooting

Now we will explain, in detail, all the menus and submenus. This program is based upon
current production version -11 software. On 03/05/1999 we began a software upgrade to
replace software versions -03 through -07 to the then current -09 software. Software versions -
03 through -07 were installed in trucks built from 01/01/1998 through 10/15/1998. Trucks built
after 10/15/1998 were equipped with version -08 software and did not require the software
upgrade. -09 software was in production until 04/17/2000, at which time it was replaced with -
10 software. In the change from -09 to -10 software there was no change in the menus, only in
the software to first, limit the diagnostic check for status code 318 to only during selftest/power
up, and secondly, to lower the turn-on temperature for the motor compartment fans, so that they
will cool the motor compartment sooner. -11 software went into production on 08/28/2000 and
the following changes took place in the menus: the “Hour reset” menu was renamed “Hours”,
and the “U3 Hour set” submenu was added to the “Utilities” menu. The “U3 Hour set” menu
provides the capability to enter hour meter readings when Access 3 is replaced and to reset the
“Travel”, “Lift 1”, or “Lift 2” hour meters after the corresponding motor is replaced.
Left “click” to advance to next slide.
Notes:

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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

We will explain the menus in the following order, starting with the “Analyzer” menu on Service
Manual page M4.3-1650-110.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-110.

In the “A1 Status” menu the truck’s enabled configuration/status can be checked. In other
words, in the “A1 Status” menu you can view what functions are enabled or disabled based
upon the current status code.
After successfully entering the service code to gain access to Level 2, the first main menu to
appear is the “Analyzer” menu. Navigating through the menus is accomplished by using the
“up”, “down”, and “enter” buttons. If you want to view the submenus of the “Analyzer” menu,
press the “enter” button which will take you to the “A1 Status” submenu. If you want to view the
submenus of the “A1 Status” menu, press the “enter” button which will take you to the “A1.1
Steer” submenu. If you press the “down” button it will take you to the “A1.2 Accy” submenu. If
you had pressed the “up” button it would have taken you around to the “A1.9 Escape” submenu.
You can think of the submenus as a revolving barrel. For example, if you were at the “A1.8
Battery” submenu and wanted to go to the “A1.1 Steer” submenu you could press the “down”
button twice to quickly revolve around to the “A1.1 Steer” submenu, versus pressing the “up”
button seven times to get to the “A1.1 Steer” submenu.
Left “click” to highlight the “Analyzer” menu then left “click” to go to the enter key, then to
“A1 Status” and so on.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-111.

Left “click” to highlight each submenu one at a time.
The “A2 Inputs” menu allows you to check the inputs to the Access 2 and 3 control modules.
Some of the input menus are identified with a number, for example “A2.9 403-11”, rather than
an abbreviation. This number identifier refers to a wiring connection in the wiring diagrams. If
you were to reference DIA-1450-006 in the wiring diagrams, you will see that 403-11 is the
channel “B” input on trucks equipped with a height encoder ECR2.
The “A2.17 LMS” input is part of a special option called “Speed Cut”. This option can be
selected in the “F17” features menu. LMS is a special speed limit switch that would be wired
into CA403-16, reference DIA-1450-006. The special speed cut option in conjunction with the
LMS switch, mounted in the reach mechanism, is used to limit or reduce travel speed if the
reach mechanism is not fully retracted.
Reference the componentry pages in the M1.0 section of the Service Manual for a description of
the components.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-111.

Left “click” to highlight each submenu one at a time.
The “A2.20 HSS” input stands for High Speed Switch. HSS is located in the tilt cylinder on
trucks equipped with the productivity option. HSS is a pressure switch that will actuate when
there is more than a 500 pound (227 kg) load on the forks. The productivity option will allow
faster travel and lowering speeds when the forks are empty versus loaded.
The “A2.34 407-5” input is a spare input that is not used at this time,
reference DIA-1450-009.
The “A2.35 408-11” input is a spare (raise) input used for the special remote raise/lower option,
reference DIA-1450-010. Note the special option, remote raise/lower, requires special software
for it to function.
Reference the componentry pages in the M1.0 section of the Service Manual for a description
of the components.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-111.

Left “click” to highlight each submenu one at a time.
At the “A2.36” input, LS stands for Load Sense. LS is located in the tilt cylinder on trucks
equipped with the Capacity Data Monitor, CDM option. LS is a pressure transducer that
provides approximate weight measurement information on the forks for the Capacity Data
Monitor. The CDM option provides the same faster travel and lowering speeds when the forks
are empty as the productivity option, plus indicator lights for the operator to indicate if the load
on the forks can be safely lifted and to what height the load should be lifted, as well as the
approximate weight of the load on the forks.
The “A2.37 CA408-12” input is a spare (lower) input used for the special remote raise/lower
option, reference DIA-1450-010. Note the special option, remote raise/lower, requires special
software for it to function.
Reference the componentry pages in the M1.0 section of the Service Manual for a description
of the components.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-112.

Left “click” to highlight each submenu one at a time.
The “A3 Outputs” menu allows you to view the outputs of the Access 2 and 3 control modules.
SVA is the abbreviation for the accessory direction solenoid valve. It is energized for the
retract, tilt down, and sideshift left functions.
BRK1 is the drive brake; the “o” represents the outer coil and the “i” represents the inner coil.
Reference the componentry pages in the M1.0 section of the Service Manual for a description of
the components.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-112.

Left “click” to highlight each submenu one at a time.
The M1 motor is the traction motor; it is a separately excited type motor, which means that the
armature is controlled independently or separately from the field. The “A” in the abbreviation
M1-A represents the armature and the “F” in M1-F represents the field of the motor.
Reference the componentry pages in the M1.0 section of the Service Manual for a description
of the components.
Left “click” to advance to next slide.
Notes:

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Level 3 only

Reference Service Manual page M4.3-1650-113.

Left “click” to highlight each submenu one at a time.
The “A4 Test Outputs” menu allows you to test the outputs of the Access 2 and 3 control
modules.
The “A4 Test Outputs” submenu is available only in Level 3 which is accessed by pressing the
“up” and “down” arrow keys simultaneously during truck power up. The “A4 Test Outputs”
submenu allows the system to power the output components with full operational voltage and
current, without truck operation, for troubleshooting purposes.
To test/drive the components, you must scroll up or down to select the appropriate submenu,
then press and hold the “enter” button. After approximately 5 seconds, power will be removed
from the component being tested, and the system will return you to the “A4 Test Outputs” menu.
The proportional valves PVA and PVH are going to be driven/powered with a percentage of
battery volts as indicated above. If you do the math, 90% of 24 volts or 60% of 36 volts, both
equal approximately 20 volts. What this means is, regardless of truck voltage, 24 or 36, we
drive/power the proportional valves with approximately 20 volts when we perform the output test
on them.
Reference the componentry pages in the M1.0 section of the Service Manual for a description
of the components.
Left “click” to advance to next slide.

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Level 3 only

Reference Service Manual page M4.3-1650-113.

Left “click” to highlight each submenu one at a time.
At the “A4.18 M2” submenu, we will drive M2 with 50 amps on 36 volt trucks, or with 90 amps
on 24 volt trucks. M2 is the motor used to turn pump 1.
Reference the componentry pages in the M1.0 section of the Service Manual for a description
of the components.
Left “click” to advance to next slide.
Notes:

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Are there any questions?

What does the A1 status menu tell you?

What does LMS stand for?

What is the specific switch that A2.31 represents?

What does LS stand for?

What does SVA stand for?

Take this time to answer any questions the participants may have regarding the analyzer
menu. If the participants do not have any questions, be prepared to ask them questions to see
if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
What does the A1 status menu tell you?
What does LMS stand for?
What is the specific switch that A2.31 represents?
What does LS stand for?
What does SVA stand for?
What does BRK1o stand for?
What does M1-A stand for?
How do you escape/exit from the A2 Inputs submenu?
Lab exercise: Hand out the “blank” analyzer menu and have the participants go out in the
shop and fill in the analyzer menu using only the truck, no Service Manual. Tell the
participants to operate the truck and make notes on the voltage range of Pot 1, Pot 2, and Pot
3; when a particular switch input is 1 versus 0; when is SVP on, when is SVA on, etc.
Left “click” to advance to next slide.

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Analyzer menu review

What was displayed at “A2.9 403-11” when you
raised the forks above freelift? Why?

What was displayed at “A2.18 HGTS12” when you

raised the forks above freelift? Why?

What was displayed at “A2.19 ECR2” when you raised

the forks above freelift? What did you get when you lowered?

When is “A3.4 SVA” on?

When is “A3.6 SVP” on?

Left “click” to advance each question one at a time.

After the lab exercise have the participants explain their key learnings and review any
questions they may have regarding the analyzer menus. This could take the form of an open
discussion where each participant/group would verbally state their key learnings, or you could
have each participant/group write their key learnings on a flipchart.
Left “click” to advance to next slide.
Notes:

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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

Now we will go through the features menu. In the features menu, programming is performed to
set truck operation to match its hardware configuration.
Left “click” to advance to next slide.
Notes:

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1= Menu available on 36 volt trucks.

Reference Service Manual page M4.3-1650-120.

Left “click” to highlight each submenu one at a time.
The “F2 Pedals” menu will only be present in the Features menu if “F1 Voltage” is set to 36
volts.
The height encoder is standard on all trucks greater than 270” (6.9 m) lift heights. It is optional
on trucks with 270” (6.9 m) and less lift heights.
In the “F4 Truck Weight” menu, enter the truck weight as equipped with maximum battery,
which is indicated on the truck’s Capacity Data Plate.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-124.

Note: The fifth digit (zero) is hidden from view on the Standard Display. To enter a truck
weight of 8790 lbs (3987 kg), you would enter 0879. On the Enhanced Display the fifth digit
(zero) is permanent and unchangeable. To enter a truck weight of 13640 lbs (6187 kg), you
would enter 1364.
Note: Entering the wrong or improper truck weight can drastically effect plugging, regenerative
braking, as well as the stopping distance of the truck.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-120.

Left “click” to highlight each submenu one at a time.
At the “F5 Max Load” menu enter the maximum capacity load from the Capacity Data Plate. If
more than one capacity is listed, enter the heaviest weight listed on the Capacity Data Plate.
Note: “F5 Max Load” is combined with “F4 Truck Weight” to set up the parameters for plugging,
regenerative braking, and stopping distance. Entering the wrong or improper weight for “F5
Max Load” can effect the plugging, regenerative braking, as well as the stopping distance of the
truck.
Left “click” to advance to next slide.
Notes:

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1= Menu available on trucks with Enhanced Display and height sensor.

Reference Service Manual page M4.3-1650-120 through -121.

Left “click” to highlight each submenu one at a time.
The “F9 Capacity” menu is available on trucks with an Enhanced Display and height sensor. If
truck is equipped with a Capacity Data Monitor (CDM) the display should show “B”.
At the “F9.3 Zones” menu, enter the number of zones/spaces filled in on the capacity data plate.
At the “F9.4 Height 1” menu, enter the first (highest) height listed on the capacity data plate.
At the “F9.5 Weight 1” menu, enter the first (lowest) weight listed on the capacity data plate.
At the “F9.6 Height 2” menu, enter the second height listed on the capacity data plate.
At the “F9.7 Weight 2” menu, enter the second weight listed on the capacity data plate.
At the “F9.8 Height 3” menu, enter the third height listed on the capacity data plate.
At the “F9.9 Weight 3” menu, enter the third weight listed on the capacity data plate.
At the “F9.10 Height 4” menu, enter the fourth (lowest) height listed on the capacity data plate.
At the “F9.11 Weight 4” menu, enter the fourth (greatest) weight listed on the capacity data
plate.
Left “click” to advance to next slide.
Notes:

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2= 36 volt trucks with productivity

package/CDM.

Reference Service Manual page M4.3-1650-121.

Left “click” to highlight each submenu one at a time.
The productivity package and CDM options are only available on 36 volt trucks.
The menu “F10.2 b = Switch” should be chosen if the truck is equipped with the productivity
package and pressure switch (HSS) on the tilt cylinder.
The menu “F10.3 c = Capacity” should be chosen if the truck is equipped with the Capacity Data
Monitor option and pressure transducer (LS) on the tilt cylinder.
Left “click” to advance to next slide which explains the difference between productivity
package and the Capacity Data Monitor.
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• Productivity Package
– HSS (pressure switch) + FKS
– Faster travel and lowering speeds when empty

• Capacity Data Monitor (CDM)

– LS (pressure transducer) + FKS
– Faster travel and lowering speeds when empty
– Operator indicator lights, alarms, and warnings
– Approximate weight of load

Left “click” to display “HSS (Pressure switch) + FKS”. The productivity package consists of a
pressure switch abbreviated HSS and a forks tilted switch abbreviated FKS.
Left “click” to display “faster travel and lowering speeds when empty”. On trucks equipped
with the productivity package, you get faster travel and lowering speeds empty versus loaded.
However, when the forks are tilted all the way up or down, the FKS switch will open disabling
the productivity package.
Left “click” to display “Capacity Data Monitor (CDM)”.
Left “click” to display “LS (Pressure transducer) + FKS”. The Capacity Data Monitor consists
of a pressure transducer abbreviated LS, and a forks tilted switch abbreviated FKS.
Left “click” to display “faster travel and lowering speeds when empty”. On trucks equipped
with the CDM option, you get the same benefits of the productivity package, faster travel and
lowering speeds empty versus loaded. When the forks are tilted all the way up or down, it will
open the FKS switch disabling the CDM and cause the message “monitor disabled” to be
displayed.
Left “click” to display “operator indicator lights, alarms, and warnings”. The CDM option also
includes indicator lights for the operator to indicate if the load on the forks can safely be lifted,
and to what height the load should be lifted.
Left “click” to display “approximate weight of load”. The CDM option also allows you to
measure the approximate weight of the load on the forks.

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3= Available on 5000S only.

4= Menu available on trucks

with Enhanced Display.

1= Travel alarm.

Reference Service Manual page M4.3-1650-121 through -122.

Left “click” to highlight each submenu one at a time.
“F11 Hi Lift” is available only on the 5000 “S” class truck. If “F2 Pedals” is set to “b”, which
equals 2 pedals, the F11 submenu will not be viewable since “F11 Hi Lift” is not available on a
two pedal truck. “F11 Hi Lift” should only be set to “Yes” on 5000S trucks with the “E” battery
compartment box and equipped with the larger 7.5 inch (190 mm) diameter lift motors that
provide for high speed lift of 138 feet per minute (.70 m/s).
If the “F12 Metric” menu is set to “b = Yes” then a conversion of weight, height, and speed
measurements to metric will be present in messages on the display. The weight measurements
will be in kilograms (kg), the height measurements will be in meters (m), and speed will be in
kilometers per hour (km/h).
“F13 Brush/Temp” requires that the truck be equipped with the Enhanced Display since the
brush wear and motor temperature sensors wire into the display module, reference DIA-1450-
003 and -004.
Left “click” to advance to next slide.
Notes:

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2= Menu available on trucks with

Enhanced Display.

Reference Service Manual page M4.3-1650-122.

Left “click” to highlight each submenu one at a time.
The “F16 Fan” menu is used to enable the thermostatically controlled drive motor compartment
fan(s) on trucks equipped with the fan(s). Note: When enabled, the fan(s) will only operate
when the motor compartment reaches a predetermined temperature. The fan(s) are wired into
CA402-7, reference DIA-1450-006, and controlled by the Access 3 control module.
“F17 Speed Cut” is a special option that requires a special speed limit switch abbreviated LMS
which would be wired into CA403-16, reference DIA-1450-006. The special speed cut option in
conjunction with the LMS switch, which is mounted in the reach mechanism, is used to limit or
reduce travel speed if the reach mechanism is not fully retracted.
The “F18 Dashboard” menu is used to make additional information, such as a stopwatch type
timer, height, and weight, available on the operator menu (Level 1).
The “F19 User Perf” menu is used to enable/disable the user/operator the ability to choose their
performance level. Note: If “F19 User Perf” is set to “b = Yes” then any user/operator can
select any performance level (P1, P2, P3) regardless of whether or not user codes/PIN numbers
are used/enabled.
Left “click” to advance to next slide.

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1= Menu available with

Enhanced Display only.

Reference Service Manual page M4.3-1650-123.

Left “click” to highlight each submenu one at a time.
The “F20 User Codes” menu is used to enable and enter up to 25 different user codes or PIN
numbers. Each user code or PIN number can be assigned a specific performance level (P1,
P2, P3) based upon the operator’s skill level or driving experience. Note: If “F19” user
performance is enabled, then any user/operator can select any performance level regardless of
their assigned performance level associated with their user code/PIN number.
The “F21 Lockout” menu can be used by the service technician to electronically lockout/disable
the truck in the event it is being serviced. The message “Loc/Lockout Active” will be displayed
after power up/selftest, when the service technician has enabled the electronic lockout feature,
to inform the operator that the truck is not available for operation.
The “F22 Language” menu is not available on a Standard Display, and it only changes the
information displayed in Level 1, the operator level. Also note that Italian, Spanish, French, and
Dutch are not available yet and do not show up in the actual truck menu.
Left “click” to advance to next slide.
Notes:

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Are there any questions?

What model trucks have 5 pedals?

What trucks come standard with a height encoder?

Why is it important to enter the correct truck weight

in the F4 menu?

What size motors are required for F11 to function properly?

What does F19 do?

Take this time to answer any questions the participants may have regarding the features
menu. If the participants do not have any questions, be prepared to ask them questions to see
if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
What model trucks are 24 volt?
What model trucks have 5 pedals?
What trucks come standard with a height encoder?
Why is it important to enter the correct truck weight in the F4 menu?
What does F9 Capacity do?
What does F10 Productive do?
What size motors are required for F11 to function properly?
What does F19 do?
Lab exercise: Hand out the “blank” features menu and have the participants go out in the
shop and fill in the menu using only the truck, no Service Manual. Tell the participants to
change some of the feature settings such as voltage, pedals, height encoder, truck weight,
reach, high lift, speed cut, etc… to see what effect it has on the truck.
Left “click” to advance to next slide.

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Features menu review

What happens if you tell a truck equipped with
a height encoder that it doesn’t have a height encoder?

What happens if the wrong truck weight is entered

into the “F4 Trk Wt” menu?

What happens if you tell a single reach that it is a double?

Why?

What happens if you turn “F17 Speed Cut” on, on a truck that
doesn’t have the necessary hardware/software?

Left “click” to advance each question one at a time.

After the lab exercise have the participants explain their key learnings and review any
questions they may have regarding the features menu. This could take the form of an open
discussion where each participant/group would verbally state their key learnings or you could
have each participant/group write their key learnings on a flipchart.
Left “click” to advance to next slide.
Notes:

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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

Now we will go through the performance menu.

Note: The “Features” menu must be set prior to setting performance, since the “Features”
menu turns on and off certain performance menus.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-131.

Left “click” to highlight each submenu one at a time.
The factory settings (standards) for the P1 performance level are set to achieve the maximum
performance. Any adjustment under each performance level P1, P2, or P3, can be higher,
lower, or the same as the adjustments under any other performance level by customizing the
settings. For example, the P1 settings could be customized to be slower than or equal to the P3
settings.
The travel speeds displayed do not account for the boosted speed when equipped with the
productivity or CDM option. Therefore the maximum travel speed for all speed settings can be
up to .7 MPH (1.1 km/h) faster than displayed if the truck is equipped with these options and the
right conditions exist. Reference Service Manual page M4.3-1650-134.
The lowering speed displayed represents the lowering speed with a capacity load and the range
is 70 to 90 feet per minute (.35 to .45 m/s). On trucks equipped with the productivity or CDM
option, the fork empty lowering speed will be faster than what is displayed in the submenu.
Reference Service Manual page M4.3-1650-135.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-131.

Left “click” to highlight each submenu one at a time.
The factory settings (standards) for the P2 performance level are reduced from the maximum
level and are similar to the performance of the 3500 series reach trucks.
As we explained previously, the travel and lowering speeds displayed, in these submenus, do
not account for the boosted speed when equipped with the productivity or CDM option.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-132.

Left “click” to highlight each submenu one at a time.
The factory settings (standards) for the P3 performance level is the lowest performance settings
of the three levels.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-132 through -133.

Left “click” to highlight each submenu one at a time.
The “P4 BDI” menu is used to adjust the electronic system incorporated in Access 1 2 3® that
monitors the battery’s state of charge. Changing this setting will effect the battery discharge lift
lockout level, which disables the lift circuit when the battery is discharged. Decreasing the P4
setting will reduce the volts per cell monitor level allowing the battery to go into deeper
discharge prior to lift lockout. If the P4 setting is adjusted to a level that will permit battery
discharge that is too deep, fault code 832 will be registered. Increasing the P4 setting will
increase the volts per cell monitor level disabling the lift function earlier in the discharge cycle.
The “P5 Plug” menu adjusts the plugging force. Adjustment range for plugging is 1 to 9. A
setting of 9 will provide the shortest plugging (stopping) distance and 1 the longest.
The “P6 Drv Brake” menu affects the drive motor brake’s braking effort. A setting of 9 will
provide the most braking power and 1 the least. Reference M5.0-1450-001 in the Service
Manual for the necessary brake adjustment procedures prior to programming the P6 and P7
functions.
Left “click” to advance to next slide.
Notes:

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RR/RD 5000/5000S Brakes

• Two sources of braking
1. Electromagnetically released spring applied mechanical brake
– 5000S Electromagnetically applied caster brakes
2. Regenerative braking
• Braking effort determined by Access 3
– Truck weight with max battery
– Maximum load
– Max speed
• Regenerative portion made as large as possible
• Adjusted through the performance menu P6 and P7

Reference Service Manual page M5.0-1450-001.

Left “click” to bring up each item in the bulleted list one at a time.
There are two sources of drive wheel braking, a 3-step, spring applied, electromagnetically
released, friction disc brake, and dynamic motor braking, typically called regenerative braking.
The 5000S has additional braking in two, electromagnetically applied, friction disc brakes in the
caster wheels. The Access 3 microprocessor determines the amount of braking effort to be
applied based on the known truck weight (includes battery and maximum allowable fork load)
and the maximum allowable speed for the particular travel direction and fork height. The total
braking effort is shared between the drive tire and caster wheels (5000S) based on the known
weight distribution. The drive tire portion is further split between the motor regenerative braking
and the 3-step friction brake. The motor regenerative portion is made as large as practical in
order to reduce wear on the 3-step friction brake. The drive tire and caster tire brake effort can
be further electronically adjusted through the performance menu (P6 and P7) in order to
address tire slide for the particular floor condition in the application.
Left “click” to advance to next slide.
Notes:

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1= Available on 5000S only.

Reference Service Manual page M4.3-1650-132 through -133.

Left “click” to highlight each submenu one at a time.
The “P7 Cas Brake” menu, available on 5000S trucks only, affects the caster brake’s braking
effort. A setting of 9 will provide the most braking power and 1 the least. Note: Before making
changes in stopping distance, verify the actual truck stopping distance as listed in chart 1 on
page M5.0-1450-001 in the Service Manual.
The “P8 Accy > FLS” menu is used to adjust the speed of the accessory functions (reach, tilt,
and sideshift) when the forks are above freelift. A setting of 9 will provide the greatest speed
and 1 the least.
The “P9 Accy > 270” menu is used to adjust the speed of the accessory functions when the
forks are above 270 inches (6.9 m). A setting of 9 will provide the greatest speed and 1 the
least.
Left “click” to advance to next slide.
Notes:

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2= Cannot be set higher than the lowest forward and reverse speed setting in P1, P2,
and P3 setups.
3= Menu available on trucks equipped with height sensor only. Cannot be set higher
than the lowest forward and reverse speed setting in P1, P2, and P3 setups.

Reference Service Manual page M4.3-1650-133.

Left “click” to highlight each submenu one at a time.
The “P10 Trav > FLS” menu is used to adjust the traction speed when the forks are above
freelift.
The “P11 Trav > 270” menu is used to adjust the traction speed when the forks are above 270
inches (6.9 m).
The “P12 Coast” adjustment effects the coasting effort of the truck when the operator returns
the multi-task handle to neutral while the truck is in motion. A setting of 9 will provide the
longest coast distance and 1 the shortest.
The “P13 Acc Ramp” adjustment effects the ramp time of the accessory valve (PVA) and will
make the accessory functions more or less responsive to the operator commands. A setting of
1 will provide a smoother reaction (less responsive), while a setting of 9 will be more reactive
(responsive).
Left “click” to advance to next slide.
Notes:

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Are there any questions?

Can the truck travel faster than the forward and reverse
speed set in P1, P2, and P3? Why/How?

Can the truck lower faster than the lowering speed

set in P1, P2, and P3? Why/How?

What mechanical checks should be made before

adjusting “P6 Drive brake”?

What does “P12 Coast” do?

What does “P13 Acc Ramp” do?

Take this time to answer any questions the participants may have regarding the performance
menu. If the participants do not have any questions, be prepared to ask them questions to see
if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
Can the truck travel faster than the forward and reverse speed set in P1, P2, and P3?
Why/How?
Can the truck lower faster than the lowering speed set in P1, P2, and P3? Why/How?
What does “P4 BDI” stand for?
What mechanical checks should be made before adjusting “P6 Drive brake”?
What does “P12 Coast” do?
What does “P13 Acc Ramp” do?
Lab exercise: Hand out the “blank” performance menu and have the participants go out in the
shop and fill in the menu using only the truck, no Service Manual. Tell the participants to
write down what the min, max, and standard settings are. Tell the participants to customize
the various performance settings to see what effect it has on the truck.
Left “click” to advance to next slide.
Notes:

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Performance menu review

A setting of 1 at “P1.3 Accel”, is that fast acceleration or slow?

If you wanted the truck to plug in the shortest

distance possible, what would you set “P5 Plug” to?

If you wanted to slow down the speed of the accessory

functions above 270”, what would you set “P9 Accy > 270” to?

If you want the truck to coast a longer distance when the handle
is returned to neutral, what would you set “P12 Coast” to?

Left “click” to advance each question one at a time.

After the lab exercise have the participants explain their key learnings and review any
questions they may have regarding the performance menus. This could take the form of an
open discussion where each participant/group would verbally state their key learnings or you
could have each participant/group write their key learnings on a flipchart.
Left “click” to advance to next slide.
Notes:

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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

Now we will go through the “Hours” menu.

Left “click” to advance to next slide.
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Hours

Reference Service Manual page M4.3-1650-129.

Left “click” to highlight each submenu one at a time.
In -09 and -10 software this menu was called “Hour Reset” and it was used to reset “H2 Travel”,
“H3 Lift 1”, and “H4 Lift 2” hour meters after the corresponding motor was replaced.
In -11 software this menu is called “Hours” and is used to only view the H1 through H4 hour
meters.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-129.

Left “click” to highlight each submenu one at a time.
When programming the planned maintenance hour meter, you choose which one of the four
hour meters, “H1 Run”, “H2 Travel”, “H3 Lift 1”, or “H4 Lift 2”, that you want the planned
maintenance hour meter to monitor or be based upon.
If a PM hour meter is programmed/set, the PM hour meter will count down or decrease in hours
as the other truck hour meters count up or increase. When the PM hour meter counts down or
decreases to zero it will display the message “Service Due” in the display to prompt the operator
to bring the truck in for service.
Left “click” to advance to next slide.
Notes:

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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

Now we will go through the “Log Events” menu. In the “Log Events” menu you can view the last
16 status codes in the order in which they occurred as well as the accumulative count for each
code. In this menu you also have the ability to erase the codes.
Left “click” to advance to next slide.
Notes:

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331 3589

214 2971

826 1866

331 0003

826 0128

Reference Service Manual page M4.3-1650-130.

Left “click” to highlight each submenu one at a time.
The event codes are stored in two formats. The first is “History” which is the chronological order
in which the events occurred. The second is “Totals” which is the accumulative number of times
a specific event occurred.
There are two ways of erasing event codes. First you could erase the “History” which is the
chronological order in which the events occurred. Note that the accumulative history or “Totals”
will still be available for you to view. To erase all the chronological (History) and accumulative
(Totals) event codes you must perform an “Erase All”.
Left “click” to advance to next slide.
Notes:

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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

Now we will go through the “Utilities” menu.

Left “click” to advance to next slide.
Notes:

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121449

121611

121607-001

122676-001-11

Reference Service Manual page M4.3-1650-140.

Left “click” to highlight each submenu one at a time.
The “U1 Part Number” menu allows you to view the part numbers of the Access 1, Access 2,
and Access 3 modules as well as the software version number.
Note: The part number shown in the truck menu for Access 1 is incorrect; you should reference
the 4.8-1450-001 page in the parts section of the Service Manual for the correct part numbers
for Access 1.
The “U2 Copy Setups” menu provides the tool for copying setup values from one module to the
other.
“Setups” are all the Features and Performance settings as well as the Height, Weight, and
Valve calibration values. “Setups” do not include the handle calibrations.
Left “click” to advance to next slide.
Notes:

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Access 2 Access 3 Status code Action Taken
1. Blank Blank 835 Logs a status code indicating
invalid setups and disables all
truck functions.
2. Blank Valid data None Copies Access 3 setups to
Access 2 and continues power
up sequence.
3. Blank Invalid data 835 Logs a status code indicating
invalid setups and disables all
truck functions.
4. Invalid data Blank 835 Logs a status code indicating
invalid setups and disables all
truck functions.
5. Invalid data Valid data None Copies Access 3 setups to
Access 2 and continues power
up sequence.
6. Invalid data Invalid data 835 Logs a status code indicating
invalid setups and disables all
truck functions.

Left “click” to make the conditions appear, then the status code, then the action taken.
In the first example you will have to manually program/set all the features and performance
settings as well as perform a complete calibration of the truck.
In the second example, the system will automatically copy Access 3 setups into Access 2 and
continue the power up sequence. If this scenario occurs, it is recommended that you calibrate
the handle potentiometers.
In the third and fourth examples you will have to manually program/set all the features and
performance settings as well as perform a complete calibration of the truck.
In the fifth example, the system will automatically copy Access 3 setups into Access 2 and
continue the power up sequence. If this scenario occurs, it is recommended that you calibrate
the handle potentiometers.
In the sixth example you will have to manually program/set all the features and performance
settings as well as perform a complete calibration of the truck.
Left “click” to advance to next slide.
Notes:

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Access 2 Access 3 Status code Action Taken
7. Valid data Blank None Copies Access 2 setups to
Access 3 and continues power
up sequence.
8. Valid data Valid different data 834 Logs a status code indicating
setups mismatch and disables
all truck functions.
9. Valid data Invalid data None Copies Access 2 setups to
Access 3 and continues power
up sequence.

10. Valid data Valid identical data None Continue power up sequence.

Left “click” to make the conditions appear, then the status code, then the action taken.
In the seventh example, the system will automatically copy Access 2 setups into Access 3 and
continue the power up sequence. If this scenario occurs, it is recommended that you calibrate
the handle potentiometers.
In the eighth example you will have to enter the utilities menu and choose to copy setups from
the existing module to the replacement module and then calibrate the handle.
In the ninth example, the system will automatically copy Access 2 setups into Access 3 and
continue the power up sequence. If this scenario occurs, it is recommended that you calibrate
the handle potentiometers.
In the tenth example all you will have to do is calibrate the handle.
Left “click” to advance to next slide.
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U3.1 Run = 0 _ _ _

U3.2 Travel = 0 _ _ _

U3.3 Lift1 = 0 _ _ _

U3.4 Lift2 = 0 _ _ _

Reference Service Manual page M4.3-1650-140.

Left “click” to highlight each submenu one at a time.
In -09 and -10 software the “H2 Travel”, “H3 Lift 1”, and “H4 Lift 2” hour meters could be reset to
zero. This would be accomplished in the “Hour Reset” menu after the corresponding motor was
replaced. However, the “H1 Run” hour meter could not be reset to zero. In -11 software, the
“Utilities” “U3 Hour Set” menu, provides the capability to enter hour meter readings when
Access 3 is replaced and to reset the “Travel”, “Lift 1”, or “Lift 2” hour meters after the
corresponding motor is replaced. In other words, when Access 3 is replaced all the hour meter
readings will be zero in the new module. In -11 software you can set the hour meters to what
they were before the module was replaced. Note: The “Run” time hour meter cannot be reset
lower than what you originally set it for in the first place. For example, if the original Access 3
module had 6741 “Run” hours on it when it failed and you set/program the new replacement
Access 3 module to 6741 “Run” hours, you cannot go back in and set the “Run” hours to
anything less than what you originally set it to. In other words once you set the “Run” hours you
can only go back in and add to or increase the “Run” hours. By contrast, the “Travel”, “Lift 1”,
and “Lift 2” hour meters can be reset to zero, decreased in hours, or increased in hours by
going to the “Utilities” “U3 Hour Set” menu.
Left “click” to advance to next slide.
Notes:

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Log Events, Hours, and Utilities menu

review
What will happen when the PM hour meter counts
down to zero?

How many event codes can be logged in the order

in which they occurred?

What are the two formats in which event codes are stored?

What are setups?

When is it necessary to copy setups?

Take this time to answer any questions the participants may have regarding the log events,
hour reset, and utilities menus. If the participants do not have any questions, be prepared to
ask them questions to see if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
Which hour meter is not resettable to zero?
What will happen when the PM hour meter counts down to zero?
How many event codes can be logged in the order in which they occurred?
What are the two formats in which event codes are stored?
What are setups?
When is it necessary to copy setups?
Left “click” to advance to next slide.
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A Analyzer
F Features
P Performance
H Hours
L Log Events
U Utilities
C Calibrate

Now we will go through the “Calibration” menu. The “Calibration” menu allows you to
compensate for the mechanical tolerances in the electrical and hydraulic components.
Left “click” to advance to next slide.
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When to calibrate:
• Access 1 replaced will require the load sense transducer (LS) to
be calibrated.
• Access 2 or Access 3 replaced will require the potentiometers in
the multi task control to be calibrated.
• Any of the potentiometers or components used to mount or
position potentiometers in the multi task control replaced.
• The hydraulic manifold has been replaced without keeping the
existing electrical proportional valves (PVH, PVA).
• PVH replaced.
• PVA replaced.
• Load sense transducer (LS) replaced.
• Status code instructions recommends recalibration of a specific
component.

Reference Service Manual page M4.3-1650-116.

Left “click” to advance each item one at a time.
Shown above is a list of components, that if replaced, would require you to calibrate the truck.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-114.

Left “click” to highlight each submenu one at a time.
The “C1 Trav Handle” menu allows you to calibrate POT 1, the traction request potentiometer.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-117.

Shown above are the procedures for calibrating the traction request potentiometer.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-114.

Left “click” to highlight each submenu one at a time.
The “C2 R/L Handle” menu allows you to calibrate POT 2, the raise/lower request
potentiometer.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-117.

Shown above are the procedures for calibrating the raise/lower request potentiometer.
Left “click” to advance to next slide.
Notes:

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Reference Service Manual page M4.3-1650-114.

Left “click” to highlight each submenu one at a time.
The “C3 Accy Handle” menu allows you to calibrate POT 3, the accessory request
potentiometer.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-117.

Shown above are the procedures for calibrating the accessory request potentiometer.
Left “click” to advance to next slide.
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1= Available on trucks equipped with height sensor only.

Reference Service Manual page M4.3-1650-114.

Left “click” to highlight each submenu one at a time.
The “C4 Height” menu requires that the truck be equipped with a height encoder (ECR2) in
order to calibrate raise cutouts and maximum lift height. Note, if the “F3 Height” encoder
submenu is set to “No”, then the “C4 Height” submenu will not be present in the main
Calibration menu.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-117.

Shown above are the procedures for programming a raise cutout.
Note: If a second cutout is to be set, Raise Cutout 1 must be programmed for override versus
a stop.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-114.

Left “click” to highlight each submenu one at a time.
The “C4.3 Encoder” menu allows you to calibrate the height.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-118.

Shown above are the procedures for calibrating height.
Left “click” to advance to next slide.
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1= Menu available on trucks with Enhanced Display only. Capacity Data Monitor (CDM)
must be enabled (F9).

Reference Service Manual page M4.3-1650-115.

Left “click” to highlight each submenu one at a time.
The “C5 Weight” menu allows you to calibrate (LS) the pressure transducer which is part of the
Capacity Data Monitor (CDM) option.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-118.

Shown above are the procedures for calibrating weight.
Note, it takes approximately five seconds after you press the enter button in menu C5.1 for the
system to calibrate the “No Load” condition and change to the C5.2 menu, so do not press any
other display buttons or operate any truck controls during this process.
Note: For best accuracy, the weight lifted should be near the maximum rated load of the truck.
This information can be found on the truck’s Capacity Data Plate.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-115.

Left “click” to highlight each submenu one at a time.
The “C6 Valves” menu allows you to calibrate the proportional valve hoist (PVH) and
proportional valve accessory (PVA).
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-118.

Left “click” to underline PVA is termed “Accy”.
Left “click” to underline what “I” is.
“I” adjusts the point at which the spool in the valve is about to open and begin to port oil to the
function.
Left “click” to underline what “G” is.
“G” adjusts how far the spool in the valve will open or the maximum opening of the spool. The
farther the spool opens, the more oil will be ported to that function, the faster it will move.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-118.

Because of component tolerances, or in the event that PVH may have been replaced, you
should look for the value etched in the nut on the end of the valve as your first choice. If there is
no value etched into the PVH valve, look for a value etched into the manifold block.
Note: Some manifold blocks may have two values etched into the block, the lower of the two
values represents the “Main I” setting for PVH and the higher value represents the “Accy I”
setting for PVA. If there are no values etched into the nut on the valve or in the manifold block,
then enter a value of 145 as the default value.
Left “click” to advance to next slide.
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Note: Before adjusting Main

G make sure the truck is
operating in the P1
performance mode and that
the P1 settings have not
been customized.

Reference Service Manual page M4.3-1650-115.

Left “click” to highlight each submenu one at a time.
It is important to make sure that all the “Features” are set correctly and that when you begin to
calibrate the “Main G”, make sure you are operating in the P1 performance mode and none
of the P1 settings have been customized.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-118.

It is important to remember to get the hydraulic oil up to temperature before calibrating the
valves.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-118.

Shown above are the procedures for calibrating “Main G”.
Left “click” to underline the target time.
Left “click” to underline adding units to the target time.
Left “click” to underline subtracting units from the target time.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-115.

Left “click” to highlight each submenu one at a time.
The “C6.3 Accy I” menu allows you to calibrate minimum opening/offset of the PVA proportional
valve.
Left “click” to advance to next slide.
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Reference Service Manual pages M4.3-1650-118 through -119.

Because of component tolerances, or in the event that PVA may have been replaced, you
should look for the value etched in the nut on the end of the valve as your first choice. If there is
no value etched into the PVA valve, look for a value etched into the manifold block.
Note: Some manifold blocks may have two values etched into the block, the higher of the two
values represents the “Accy I” setting for PVA and the lower value represents the “Main I”
setting for PVH. If there are no values etched into the nut on the valve or in the manifold block,
then enter a value of 225 as the default value.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-119.

Shown above are the procedures for calibrating “Accy I”.
Note: When calibrating “Accy I” do not operate the lift or accessory functions; doing so will
cause the steering/lift motor (M2) to ramp up and operate at a higher amperage to supply the
additional amount of oil flow for the lift and accessory functions. After operating the lift or
accessory functions the steering/lift motor (M2) may not ramp down to normal steering idle
current levels. To reset the logic in the modules to allow the motor to operate at normal steering
idle current levels, momentarily step off of the pedals to allow the motor to stop.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-119.

Shown above is the steering idle current threshold chart.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-119.

The correct setting of “Accy I” will be accomplished when the pump motor current drops 10 -15
amps below the steer idle current threshold.
Left “click” to underline when you will know the setting is correct.
Note: An alternative procedure has been developed by Crown to simplify PVA (accessory
valve) calibration, refer to Technical Service Bulletin 426 for the new procedures. Handout
copies of T.S.B. 426 and review with participants. During the lab exercise be sure to
demonstrate the new procedures to the participants.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-115.

Left “click” to highlight each submenu one at a time.
The “C6.4 Accy G” menu allows you to calibrate maximum opening/gain of the PVA proportional
valve.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-119.

Shown above are the procedures for calibrating “Accy G”.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-119.

Shown above are the procedures for calculating how many units to add or subtract from the
gain setting to achieve the target time.
Left “click” to underline adding units to the target time.
Left “click” to underline subtracting units from the target time.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1650-119.

After adjusting the “Accy G” it may be necessary to readjust the “Accy I” if the steering/lift motor
does not idle down after approximately 5 - 10 seconds since the last steering command.
Note: Since calibrating “Accy G” required you to operate the reach function, the steering/lift
motor (M2) may not ramp down to normal steering idle current levels. To reset the logic in the
modules to allow the motor to operate at normal steering idle current levels, momentarily step
off of the pedals to allow the motor to stop.
Left “click” to bring up important note about air trapped in the circuit.
Left “click” to advance to next slide.
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Are there any questions?

When is it necessary to calibrate?

If a second cutout is to be programmed, what must raise

cutout 1 be set to?

Should “Max Height” be used for a third cutout? If not, why?

How much weight is required to calibrate “C5 Weight”?

What performance setting should be verified

before calibrating “Main G”?

Take this time to answer any questions the participants may have regarding the calibration
procedures. If the participants do not have any questions, be prepared to ask them questions
to see if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
When is it necessary to calibrate?
If a second cutout is to be programmed, what must raise cutout 1 be set to?
Should “Max Height” be used for a third cutout? If not, why?
How much weight is required to calibrate “C5 Weight”?
What should the load center be for the test weight used to calibrate “C5 Weight”?
What is the minimum amount of weight required to calibrate “C6 Valves”?
Why is it important to get the hydraulic oil up to temperature when calibrating the valves?
What is the correct setting for “Accy I”?
What performance setting should be verified before calibrating “Main G”?
Lab exercise: Have the participants go out in the shop and perform a complete calibration of
the truck. For this exercise the participants should use their Service Manuals.
Left “click” to advance to next slide.
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Calibrate menu review

Why is it important to get the hydraulic oil up to temperature
when calibrating “Main G”?

Why is it important to have the test weight at the proper load

center when calibrating “Weight”?

When calibrating “Accy G” where must the forks be positioned?

Why?

When “Accy I” is correctly calibrated, what should the

final setting be?

Left “click” to advance each question one at a time.

After the lab exercise have the participants explain their key learnings and review any
questions they may have regarding how to calibrate the truck. This could take the form of an
open discussion where each participant/group would verbally state their key learnings or you
could have each participant/group write their key learnings on a flipchart.
Left “click” to advance to next slide.
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• Types of Displays
• Three levels of access
• Menus
• Troubleshooting

Now we will explain how to troubleshoot the RR/RD 5000/5000S series reach trucks.
Left “click” to advance to next slide.
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Software Version 122676-001-11

Reference Service Manual page M4.3-1450-480.

Statistically, the majority of malfunctions occur in or at output components such as solenoid
valves, contactors and motors.
Left “click” to underline the most error prone components.
The next most error prone components are connectors, wiring and input devices such as
switches, potentiometers or encoders.
Left “click” to underline the least likely components.
The least likely to fail are the electronic Access 2 and Access 3 control modules.
Left “click” to underline that you should start troubleshooting at the outputs.
In all cases, begin troubleshooting at the output device, proceed to input devices, then, and only
then, move on to the electronic module to which these devices attach.
Left “click” to advance to next slide.
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• Electrical ????

• Hydraulic ????

• Mechanical ????

• Status code ????

Other things to consider when troubleshooting is that the cause of the problem may not be
electrical, it could be a hydraulic problem or even something mechanical. Be aware that most
electrical problems will register a status code, but hydraulic and mechanical problems may not
register status codes.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1450-487.

If a status code is registered, then follow the procedures associated with the status code.
Left “click” to show step 1.
Left “click” to show step 2.
Left “click” to show “If: Battery volts”.
Left “click” to show “If: 0 volts”.
Left “click” to show “If: 20 volts”.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1450-487.

The majority of status codes will include a schematic which represents the circuit associated
with that particular status code.
“Click” on “PLAY” to begin animation of the positive and negative sides of the circuit.
The lines highlighted in red are the ones you would check if you were missing battery positive to
the component. The ones highlighted in green are the ones you would check if you were
missing the negative to the component.
“Click” on the “NEXT” button to advance to next slide.
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When truck does not operate and

there is not a code
1. The power up circuit has malfunctioned.

Reference Service Manual page M4.3-1450-480.

There are four circumstances that will not register a code. The first one we will discuss is when
the power up circuit malfunctions.
Left “click” to advance to next slide.
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Access 2
Software Version 122676-001-11

Reference Service Manual page DIA-1450-003.

“Click” on “PLAY” to begin the animation from battery positive to the keyswitch (KYS) then to
the modules precharge connections.
The power up circuit functions as shown. When the battery is plugged in, battery positive
potential is supplied to the keyswitch (KYS) and to both precharge inputs to Access 2 and
Access 3 control modules. This will precharge the capacitor banks in both modules to battery
potential.
“Click” on “PLAY” to connect the keyswitch (KYS) to the start position and advance to next
slide.
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Access 2
Software Version 122676-001-11

When the keyswitch (KYS) is cycled to the start position battery positive is supplied to the
module power inputs of Access 1,3,and 2. This will signal the modules to begin system selftest.
“Click” on “PLAY” to show current flow through the emergency disconnect switch (EDS), test
point five (TP5), to the K1 relay coil and advance to next slide.
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At the same time, battery positive will flow through the emergency disconnect switch (EDS), test
point five (TP5), to the coil of the K1 relay. Current will continue to flow to the T common
connection at CA402-13, of the Access 3 module, which is internally connected to the “B-”
terminal, which is connected to battery negative. This will complete the circuit to the K1 coil
which will close the K1 relay tips. The keyswitch (KYS) is a “make before break” type of switch,
which means that it will make the ignition or on position before breaking or disconnecting the
start position.
“Click” on “PLAY” to connect the ignition or on position.
When the ignition or on position is made, battery positive will flow through test point seven
(TP7), the closed K1 relay tips, test point six (TP6), the emergency disconnect switch (EDS),
test point five (TP5), to the K1 relay. This sets up a latch circuit to keep the K1 relay coil
energized, as well as maintaining power to the modules, so that when the keyswitch (KYS)
breaks the start position the circuit remains latched on.
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With the circuit latched on, power will be maintained at the modules as well as the K1 relay coil
until the keyswitch (KYS) is turned off.
“Click” on the “NEXT” button to advance to next slide.
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When truck does not operate and

there is not a code
1. The power up circuit has malfunctioned.

2. The malfunction is not electrical.

®
3. The Access 1 2 3 system detects a condition requiring
system shutdown. (Truck does not function)

Reference Service Manual page M4.3-1450-480.

The second condition in which you would not get a code is if the malfunction is not electrical in
nature. For example, if the pump motor splines were to wear out, the motor would run but the
pump would not generate any flow for the hydraulic circuits to operate.
Left “click” to display the third condition.
The third condition in which you would not get a code is if a system shutdown occurs.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1450-480.

There are circumstances which cause the Access 1 2 3® system to go into system shut down.
In this condition the truck will not power up. The shutdown is required to protect the Access 1 2
3® electronic system when it detects conditions which could be destructive to its internal
electronic system. These types of faults could be the direct result of shorted or open circuits
which are primary to the system’s power source.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1450-480.

During normal operation when a fault does occur, Access 3 will flash the status code that
corresponds to the cause of the malfunction. In the event Access 3 cannot flash the status
code, then Access 2 will flash the status code. In other words, only one module will flash a
status code during normal operation.
But when a system shut down sequence has occurred, Access 2 will flash once followed by four
flashes, then it will repeat.
Left “click” to underline that Access 3 will flash a 1 followed by 3-2-8.
Access 3 will flash once (to get your attention) followed by three flashes, then two flashes, then
eight flashes, then it will pause before repeating.
During a system shutdown sequence, the 3-2-8 that Access 3 is flashing is not the status code
associated with the malfunction, it is only a code that indicates that a system shutdown
sequence has occurred. Do not troubleshoot a code 328 !!!!!!!
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1450-480.

During a system shutdown sequence, to extract the correct status code you must enter the two
button level (Level 3) and select log events.
Left “click” to advance to next slide.
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When truck does not operate and

there is not a code
1. The power up circuit has malfunctioned.

2. The malfunction is not electrical.

®
3. The Access 1 2 3 system detects a condition requiring
system shutdown. (Truck does not function)

4. Truck powers up but malfunctions.

Reference Service Manual page M4.3-1450-480.

The fourth condition is where the truck powers up but no status code is registered.
Left “click” to advance to next slide.
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Reference Service Manual page M4.3-1450-480.

This could be caused by the following list of unmonitored inputs. What we mean by
unmonitored is that they are not associated with a status code. You can still monitor these
switches (inputs) by going to the Analyzer A2 Inputs menu.
Left “click” to advance to next slide.
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Troubleshooting review
If the truck does not operate and there is not a status code,
what could cause this?

During a system shutdown sequence, what will Access 2 do?

During a system shutdown sequence, what will Access 3 do?

Why does a system shutdown sequence occur?

What status code should you troubleshoot when a system

shutdown sequence occurs?

Take this time to answer any questions the participants may have regarding the
troubleshooting procedures. If the participants do not have any questions, be prepared to ask
them questions to see if they are learning the information.
Questions participants should be able to answer at this point:
Left “click” to advance each question one at a time.
Statistically what components cause the majority of malfunctions?
Statistically what are the next most error prone components?
Statistically what components are the least likely to fail?
If the truck does not operate and there is not a status code, what could cause this?
During a system shutdown sequence, what will Access 2 do?
During a system shutdown sequence, what will Access 3 do?
Why does a system shutdown sequence occur?
What status code should you troubleshoot when a system shutdown sequence occurs?
How do you extract the status code when a system shutdown sequence occurs?
What are some of the inputs not associated with a status code?
Left “click” to advance to next slide.
Notes:

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 Access 1 2 3®
Slide 128 © 2001 Summary 123
Access
®

Software Version 122676-001-11

• Identify Access 1 2 3® modules

• Three levels of access
• Menus
• Troubleshooting

In summary, we have identified the modules that make up the Access 1 2 3® control system.
Access 1 is your display and interface into the system, while Access 2 controls the majority of
the hydraulic components, and Access 3 controls the majority of the traction components.
We’ve explained the three different ways the system can be accessed. We’ve explained each
menu starting with the “Analyzer” menu which assists you in troubleshooting inputs and outputs.
The “Calibrate” menu compensates for the mechanical tolerances in the electrical and hydraulic
components. The “Features” menu allows you to set up the truck to match how it is equipped.
The “Hours” menu allows you to view hour meters and program a planned maintenance due
reminder. The “Log Events” menu assists you in troubleshooting, by showing you the order in
which the events occurred, the hour meter reading when it occurred, the total number of times a
particular event occurred, as well as the ability to clear or erase the events. We’ve shown you
that in the “Performance” menu you can customize the performance characteristics of the truck,
for a specific application or warehouse, and for different experience levels of operators. The
“Utilities” menu shows you software version and module part numbers as well as allowing you
the ability to copy setups from one module to another if the need arises. The “Utilities” menu
also allows you to enter hour meter readings when Access 3 and or a motor is replaced. We’ve
explained to you how to troubleshoot utilizing the features of the Access 1 2 3® integrated
control system. We feel that the information covered in this lesson has given you the necessary
knowledge and skills to improve your ability to troubleshoot and service the RR/RD 5000/5000S
series reach trucks.

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 Access 1 2 3®
Slide 129 © 2001 The End 123
Access
®

Software Version 122676-001-11

Thank you for participating in

this lesson on Access 1 2 3
®

Notes:

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